Demm Engineering & Manufacturing Magazine October 2012 by Adrenalin Publishing Ltd

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

LET’S GET TOGETHER

SKF National Maintenance Engineering Conference

Energy efficiency More power to you

Thermal imaging How to see what can’t be seen

Industrial coatings Care and protect

Filtration

Solutions for cleaner air and water

www.demm.co.nz

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Ed Says

At some point in time, an editor woke up one morning (always a good sign) and penned an introduction to their magazine. Thereafter, everyone else followed suit. I’m not convinced anyone reads the introduction to a magazine. It’s like reading the user manual of any piece of equipment you have ever bought. All you really want to do is use it. My guess is you’d prefer to just turn the page because I offer no great insights in this column. However, before you do so, I need to remind you of one of the year’s big events – The SKF National Maintenance Engineering Conference and Exhibition in Rotorua. This magazine is the conference’s official media sponsor and all of us on the team are proud to be associated with it. As you will read on page 31, the November event has gone from strength to strength since it started in 2002 – and such is the popularity of the annual exhibition – it is already outgrowing its present venue.

Contents 2

News

a chance to show and tell, they are about networking, meeting

Product watch

people, sharing ideas and discovering new ways of working.

Energy efficiency

Thermal imaging

Events such as these are not just about providing companies

The conference is not to be missed. Being the new boy on the block I am duty bound to change something – it’s the law. So from this edition onward we have a

20 Industrial coating

news section at the front of the magazine.

24 Filtration

This gives us a chance to share information that doesn’t naturally fit under the wide range of sections in the magazine – I hope you find it of value. As usual there’s plenty inside, thanks for reading and have a great month.

27 Maintenance matters 31

National conference

36 Electrical technology 37 Test and measurement

Steve Hart Editor

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.

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

Adrenalin Publishing Ltd. 14c Vega Place, Mairangi Bay. P.O. Box 65 092 Mairangi Bay, Auckland, 0754.

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Phone: 64-9-478 4771 Facsimile: 64-9-478 4779 Printing: GEON ISSN 1172-4536 (Print) ISSN 2253-279X (Online) Circulation: 12,754

NEWS

Call for engineering scholarship applications The Competenz Scholarship for 2013 is now open for applications and there is $1000 each for 10 ambitious engineers. The scholarships are designed to advance the careers of those working in the engineering and manufacturing sector. Connor Farrell, who is studying toward a National Certificate in Mechanical Engineering (Level 5) in Engineering Fabrication, was awarded a scholarship earlier this year. “I applied for this scholarship because I have a young family and have very little extra money,” says Farrell. “Receiving this scholarship meant a lot to me because if I didn’t receive it I most likely wouldn’t have been able to sit the qualification.”

Competenz Scholarships are for those enrolling in a Level 5 Certificate and Level 6 Diploma or a Level 4 Assessment of Prior Learning. To be eligible, candidates must have completed, or be due to complete, a Level 4 National Certificate in fabrication, refrigeration and air conditioning, locksmithing or fire protection, or Level 4 or 5 in mechanical engineering. Candidates will also be considered if they were enrolled in an eligible course from 1 August 2012. Receiving a scholarship benefits both the employee and the employer. Those wishing to apply for a 2013 Competenz Scholarship must be enrolled in their chosen course by 1 March 2013 – the deadline for applications. Application forms are

The deadline to apply to Competenz for one of its $1000 scholarships is 1 March 2013.

available at competenz.org.nz

Kiwi firms targeted by trademark crooks

Invert Robotic’s James Robertson with his wall-climbing robot.

Going up the wall Christchurch business Invert Robotics has beaten more than 750 businesses from across New Zealand to take the top prizes in the 2012 ANZ Flying Start Business Plan Competition. Invert Robotics, which builds remotely-operated climbing robots that inspect industrial equipment in the dairy industry, won the ANZ Flying Start Business Plan Supreme Award for the best overall business plan. The award comes with a prize worth $56,000 to further grow their business.

• Go to www.demm.co.nz/enquiry quote: 2

October 2012

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Businesses are being warned of overseas scammers that are targeting local firms with unsolicited trademark and domain name services. Intellectual property expert, Theodore Doucas of Zone IP and Zone Law, an intellectual property consultancy and law firm in Wellington, says over the last few months his firm has received triple the usual amount of calls and emails from businesses on the receiving end of the scammers. “I’m not sure why there has been an increase in unsolicited activity from a number of scammers – particular out of China and Hungary – but it may be because not enough is being done to warn local businesses about these scams. “The Australian Trade Mark Registry (IP Australia)

publishes a list of scammers, but Intellectual Property Office of New Zealand (IPONZ) does not. So it may be that lack of education makes us easier targets.” Common scams include an email from a Chinese company claiming somebody else is applying for the same trademark or domain name in China, under pretence of having links with the New Zealand company. The company then offers to represent the New Zealand company or buy the domain name on behalf of the New Zealand company for a fee.

NEWS

SPIIND opens in Auckland SPIIND, the Northland-based, engineering and contracting services company, is opening an office in Auckland in a bid to tap the growing food industry and opportunities with Taranaki Oil. Its general manager, Paul Hebberd, says the company will open its doors in East Tamaki, on 1 October, with a staff of 12. The company, which has been an engineering king-pin in Whangerei for 35 years, has changed its name and logo – SPI is out and SPIIND is in. A change made so its trademark and website domain are consistent. In addition to servicing the Refining NZ’s Marsden Refinery, other blue chip companies operating in Northland, such as Fonterra and Carter Holt Harvey, are long-term customers of the firm.

Free software for students Siemens PLM Software is offering a free student edition of its plant simulation package in the Tecnomatix portfolio. Students at any academic level can download the manufacturing application and develop real-world skills that are sought after in the global manufacturing industry. Plant Simulation is a 3D visualisation and discrete event simulation software. The student edition can be installed on computers running Microsoft Windows

OS to quickly and easily create digital logistics models through the use of builtin object libraries to optimise material flow, resource utilisation and operations. The digital model enables students to run experiments and ‘what-if’ scenarios, while having access to extensive analysis tools, statistical models and charts to evaluate different manufacturing situations. To download the free student edition, go here: http://goo.gl/cQSXW

Spark blast A company owned by Air New Zealand has been fined more than AU$57,000 over a fuel tank explosion at Adelaide Airport that injured a worker. Mark Meehan was repairing the wing on a twin-engined Cessna 401 in March at the premises operated by TAE Aviation, a wholly-owned subsidiary of Air New Zealand. He had begun using a cutting tool to remove a corroded panel when a spark ignited residual fuel vapours in the plane’s fuel tank. The blast smashed Meehan’s left arm, burned both hands and burnt and lacerated his face. TAE pleaded guilty to breaching workplace safety laws by not ensuring the fuel tank was free of fuel or fuel vapours and by not warning Meehan of the risk of an explosion. TAE Aviation was fined $56,000 and ordered to pay other court costs after receiving a discounted penalty because of its early guilty plea and contrition.

NEWS

Solid option for waste treatment Pump Systems, an authorised distributor for Vaughan Rotamix, designs and supplies large-volume tank mixing systems for the New Zealand and Australian wastewater sectors. The Rotamix System is designed for critical high capacity processes, such as in municipal anaerobic digesters and sludge blending tanks. The success of Rotamix is built on more than 50 years experience in the wastewater and solids pumping industry, and through smart integration of the Vaughan Chopper Pump. Development of the local market of Rotamix by Pump Systems has called for a requirement to adapt the system to fulfil needs at the lower end – for smaller volume containment (typically 750 cubic metres or less) – as well

as for processes that regularly empty and refill tanks. As a result, Pump Systems now offers a tailored, costeffective pump and nozzle mixing system that will meet these lower-end demands. Each small tank mixing system is custom designed by Pump Systems to meet individual requirements around the customer’s process, installation, and fluid type. Systems are designed to thoroughly mix a tank at all levels, with zero stratification or “layering”. Mixing energy from the Vaughan pump is targeted across the central tank floor to re-suspend and distribute solids to the outer areas of the tank, where the high-velocity mixing nozzles rotate the movement upwards. Being a recirculation-based system, each subsequent pass through the externally-

Mechanical Engineers! Advance your career with the Competenz Scholarship

mounted Vaughan mixing chopper pump means that any solids such as rag, fibrous material, and plastics, are continuously broken down and preconditioned, further producing a homogenous slurry. The firm says ragging and clogging problems are not only eliminated from within the tank itself, but any downstream mechanical equipment such as valves, pumps and heat exchangers are also better protected from stringy fibres and clumps. Pump Systems offer a range of standard mixing system configurations to suit most cylindrical tanks from as small as 3m up to around 12m in diameter. Nozzle stacks are available in single or twin barrel

configurations, with special low profile and up-aimed nozzle options. All nozzle stack componentry including nozzle barrels, tips, fasteners and clamps are made from 316 stainless steel, and are all individually replaceable. There are no moving or rotating parts within the process itself, therefore no requirement for platforms and hoists, as would be required with most traditional mixing apparatus. As for the Vaughan mixing chopper pump, all main components are supplied as standard in heat-treated cast ductile iron and cast steel materials offering a long wear life with excellent impact and abrasion resistance.

Quake skills to be shared

This is the perfect opportunity for anyone with a Level 4 or 5 qualification wanting to up-skill to Level 5 or 6.

Apply now! Call 0800 526 1800 or visit competenz.org.nz to complete an application online.

October 2012

Five seismic engineers from the Christchurch office of global engineering firm Aurecon left for Lisbon on 20 September to benchmark their knowledge and skills at the 15th World Conference on Earthquake Engineering. One of those attending the five-day event is Aurecon’s technical director Stephen Hogg. He says the world’s seismic engineering gurus will be present and that it was the perfect place to ensure that “here in Christchurch we are at the absolute forefront of earthquake engineering. “We might have a massive ‘working laboratory’ at our backdoor, but are we really as good as we think? That is what we want to find out,” says Hogg.

PRODUCT WATCH

All change 3M’s Photochromic light sensitive safety glasses do all the changing – automatically. Its lenses are UV reactive so they respond to the amount of Ultraviolet (UV) light, lightening or darkening as needed. The spectacles change from dark to clear in 35 seconds and go from clear to dark in eight seconds.

Go to www.demm.co.nz/ •enquiry quote: D121005

CadSoft V6 now out

Breathe anywhere

CadSoft Computer, a part of element14 (formerly Farnell), has released version six of its Eagle PCB software for board design. Awarded Product of the Year – Engineer Software 2012 by German magazine Elektronik, CadSoft Eagle helps users save time by optimising and integrating new features such as BGA escape routing, differential pair routing, automatic meanders and undo/redo logs. Additionally, this latest version provides easy layout dimensioning, assembly variants, cut-out polygons, and the design reuse feature to merge board/schematic pairs using the paste function.

BOC has launched what it says is the smallest and lightest powered respirator currently on the market. Its PAFtec CleanSpace is a motorised facemask for use in professional, industrial and urban environments. The respirator is a low profile passive mask that has applications in the welding, smelting and pharmaceutical sectors as well as mineral exploration, food manufacturing, construction,

•

Go to www.demm.co.nz/enquiry quote: D121005B

woodworking, emergency services, heavy industry, open-cut mining and agriculture. Designed without hoses or cables, the mask fits with existing safety equipment. It also incorporates patented responsive flow control software that responds to airflow demand breath by breath.

PRODUCT OF THE MONTH

Go to www.demm. •co.nz/enquiry quote: D121005C

AADEMM20110415

save your energy...

Efﬁcient, Compact, Maintenance Free, Aurora make us part of your process www.aurora-nz.com

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sales@aurora-nz.com

PRODUCT WATCH

Air pressure safety Christchurch-based Allied Air Compressors is stocking the Protect-Air range of safety valves. The German-made products include the HoseGuard airfuse, a device for compressed air lines that automatically cuts off the supply when the air flow exceeds a pre-set rate, such as in the event of a sudden rupture in a compressed system, pipe or hose. It is also stocking the

SaveAir product, a pre-set inline energy-saving membrane regulator used to supply a constant and exact outlet pressure – regardless of input pressure. Allied Air Compressors say the Protect-Air range meets new European and American directives governing the safety of workers.

Go to www.demm.co.nz/ •enquiry quote: D121006

Light duties Narva’s new hand-held LED light fits in the palm of the hand and has a handy foldaway hook/ stand – making it ideal for a multitude of uses. The Palm Light is designed to be tough, compact and weatherresistant, with a lens that is made from virtually unbreakable polycarbonate. The lamp produces a wide-angle light output from 15 high intensity

Dormer on iTunes A mobile app for Dormer Tools’ publications is available from the iTunes store. Created to support the launch of the firm’s 2012 catalogue, the free app will become a virtual Dormer library, featuring not only digital formats of all product literature, but also useful reference material. The 2012 catalogue is the first to be added to the D.Library, and gives users the option to select the relevant section, flip through the content page by page, zoom in and display

October 2012

images or dimensional tables quickly and easily. Direct links to contact information for Dormer Tools’ worldwide offices and a wide range of product machining videos on the company’s YouTube channel can also be accessed directly from the app. Future developments include launching a version for android devices, a text search function and additional language versions.

Go to www.demm.co.nz/ •enquiry quote: D121006D

LEDs and its lithium-ion battery provides four hours of continuous use before recharging. Included in the pack are 240V and 12/24V charging units. Narva says another of the design features is the soft rubberised housing that sits comfortably in the hand and provides a non-slip textured surface for safer handling.

Go to www.demm.co.nz/ •enquiry quote: D121006C

PRODUCT WATCH

Free and easy Rittal Rittal’s SE 8 free-standing enclosure system offers full compatibility with its TS 8 top enclosure system, to provide the widest variety of configurations and cost advantages in one single solution. Typical applications are in compact machinery and equipment and their power distribution and automation components, which can be accommodated in a single enclosure. For such cases, Rittal has expanded its TS 8 system platform by adding the new system enclosure SE 8. Unlike baying suites with frames and removable side panels, the body of the SE 8 – consisting of two side panels and a roof – is

BUILD IT Exactingly right – Every time –

made from one piece of sheet steel. The rear panel of the enclosure is screwed on for easy access. Cable entry solutions can be employed on the integrated base frame, as in the TS 8 bayed system. The doors and the base/ plinth of the SE 8 have also been taken over from the TS 8 program. There are also benefits for CAD designers. Since the interior of the SE 8 and TS 8 are identical, planning can be started immediately. You only need to determine afterwards whether a free-standing or a bayed enclosure is needed.

Go to www.demm. •co.nz/enquiry quote: D121007

• 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

Pumped up and ready to flow

Leak tester in colour Bestech Australia has released the next generation of its furness leak detector for in-line production leak testing. Like the FCO750 before it, the FC0770 can be used to test automotive components, pharmaceutical products, safety pressure devices, plumbing fittings, gas appliances and medical equipment. The prime feature of the detector is its full colour touch screen. It has automatic storage of test graphs and other data and

test recipes, or preset test sequences, for up to 300 different products as standard. The user can program the unit via its front panel, with a laptop or PC via its RS232, RS485, USB or Ethernet interface. Common with all other furness leak testers, the FCO770 can be set up by the user to test with vacuum or positive pressure as standard.

Go to www.demm.co.nz/enquiry •quote: D121008

ANOTHER WORLD FIRST H6032 - DN50 - 420 BAR 400mm BEND RADIUS 1,000,000 IMPULSE

The latest addition to Danfoss’s range of high-pressure pumps has come to market. The APP 11-13 completes its range of pumps for all small and medium-sized RO plants. With its capacity of 11-13 m3/h, the APP 11-13 is ideal for RO systems that produce between 100 and 125 m3/day. And if APP 11-13 is installed with iSave, Danfoss’s energy recovery device, it can even handle up to 250 – 300 m3/ day. The axial piston design results in constant flow regardless of pressure variations, as well as fewer moving parts for improved reliability and reduced maintenance costs. Belt drivers and pulsation dampers are both things of the past with the APP series, and no oil lubrication is needed, as the pumped medium itself lubricates moving parts.

Go to www.demm.co.nz/enquiry •quote: D121008B

FEATURES

R TIGHT BEND RADIUS R 420 BAR / 6100 PSI R AVENGER™, DIEHARD™ & SLIDER™ COVERS

R AVAILABLE IN SIZES UP TO 2”

NEW ZEALAND 24 Sylvia Park Road Mt Wellington, Auckland 1130 New Zealand 800mm

October 2012

Tel Service Fax Email

9573 2680 0800 111 247 9573 0255 sales@ryconz.co.nz

PRODUCT WATCH

New drive saves space chain replaces the individual power and feedback cables needed for panel-mounted servo drives.” Pipe says fewer cables help to reduce assembly time, the potential for wiring errors, and the time it takes to troubleshoot and repair a machine. Terminating servo motor power and feedback cables at panel-mounted servo drives can take about 20 minutes per axis. The Kinetix 6000M integrated drive-motor system allows machine builders to do this in approximately 30 seconds, helping to dramatically reduce installation time. “Machine builders for motor-intensive applications need the flexibility to modify machine axes as easily as possible to meet future demands,” says Himanshu Shah, senior analyst with ARC Advisory Group. “With the Kinetix 6000M integrated drive-motor system, axes can easily be added or removed from the integrated drive-motor daisy chain without modifying components and wiring in the control enclosure.” The new drive-motor is available in three different frame sizes, offering optional holding breaks and SIL2/PLd safe torque-off functionality.

Go to www.demm.co.nz/ •enquiry quote:

I’m a Total Fan

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

Engineering - Total Robert Neal, Seafarer Marine customer since 2001

ATTN12TOT92

Machine builders can reduce control system enclosure size, cut wiring time and simplify cabling when using the new Allen-Bradley Kinetix 6000M integrated drive-motor system from Rockwell Automation. The Kinetix 6000M drivemotor combines the highperformance Allen-Bradley MP-Series food-grade servo motor and Kinetix 6000 multiaxis servo drive technologies into a single, compact, on-machine package. “Machine builders face a variety of challenges,” says Paul Sipe, marketing manager, motion business, Rockwell Automation. “They need to balance the goals of increasing machine flexibility by using more servo axes, while reducing machine size and assembly labour costs. Now, integrated drive-motor technology can help them achieve these goals.” Moving servo drives out of the control enclosure and onto the machine delivers significant space savings, while reducing cabling. “For example, replacing panel-mounted drives with the Kinetix 6000M integrated drive-motor system can reduce panel space required by up to 60 percent for a typical eightaxis system,” says Sipe. “Additionally, the number of cables exiting the control enclosure is reduced by as much as 75 percent because a hybrid/network cable daisy

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

D121009

PRODUCT WATCH

Fast starting gas tester Eurotec has launched the Testo 310 flue gas analyser into the New Zealand market. With four measurement menus for flue gas, draught, ambient CO and pressure, the analyser covers all the basic measurements on a heating system. Features such as easy handling, clear menu structures, backlit display and fast sensor zeroing distinguish the Testo 310 in daily use. The instrument is ready to use 30 seconds after being switched on. With a printer specially developed for the 310, hard copy read-outs can be created.

Go to www.demm.co.nz/enquiry •quote: D121010

TurboNest 2012 now out Hypertherm, a US-based manufacturer of cutting systems, has released its TurboNest 2012 and NestMaster 2012 nesting software. Major enhancements include 2D CAD design capability with everything needed to create or edit a detailed CAD drawing.

The part list panel has been redesigned for greater flexibility and control over parts from the main software window; and DXF output was added as a standard feature. “The software enhancements make the nesting process even more efficient and easier for our customers,” says

LabView upgraged National Instruments has introduced NI LabView 2012, the latest version of the industry-leading system design software for engineers and scientists. Users get ready-to-run starting points for a breadth of LabView applications and access to new training options that help improve the quality of their systems. These new features, says the firm, demonstrate its ongoing commitment to provide a platform that accelerates the success of any measurement or control system. “Building a system fast is

important, but it’s equally important to build it right – that means using solid architectures and proven development practices,” says Dr James Truchard, NI president, CEO and cofounder. “New features and resources in LabView 2012 promote training and drive development practices to help our customers deliver highperformance and high-quality systems in less time, thereby minimising development and maintenance costs.”

Go to www.demm.co.nz/ •enquiry quote:

October 2012

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Derek Weston, product marketing manager for Hypertherm’s software team. “ProNest is a component of Hypertherm’s integrated cutting solutions, providing support for true hole and rapid part technologies.”

Go to www.demm.co.nz/enquiry •quote: D121010B

PRODUCT WATCH

Low flow accuracy Yokogawa Electric has released the Rotamass LR, the world’s smallest dual bent tube Coriolis mass flowmeter for gas and liquid flow measurement. The effective turndown is no less than 2,000:1 for liquids and 5,000:1 for gases, and the mass flow measurement range spans from 10.5 g/h up to 40 kg/h, achieving a measurement accuracy of ±0.15 percent of reading for liquids and ±0.5 percent for gases. The company says market research has identified increasing demand for smaller devices with a two-inch bore diameter or less. It also says there is rising demand

for low flow measurement solutions that achieve high accuracy and stability. John Hewitt, managing director of Yokogawa Australia and New Zealand, says the majority of small Coriolis flowmeters on the market currently use single tube detectors, which have been shown to be less accurate and stable under conditions that include vibration and changes in the ambient or fluid temperature. “To meet the market’s need for accurate and stable measurement of fluids at low flow rates, Yokogawa has developed this low flow Coriolis flowmeter based on its

proven dual bent tube detector design,” says Hewitt. “By measuring and controlling very low flow rates with a high level of precision, Yokogawa is helping its customers realise the VigilantPlant concept.”

Go to www.demm.co.nz/enquiry •quote: D121011

Valve for hazardous media NOSHOK’s 3070 series double block and bleed valve has redundant isolation valves and a dedicated vent valve to ensure additional safety in hazardous media applications. The valve can have a 700 Bar hard seat pressure rating at 95°C. The block valve isolates the downstream process fluids, while the bleed valve exhausts upstream

fluids enabling instruments to be removed without disturbing the permanent piping installation on the bottom. The quarter-inch NPT vent plug is located ninty degrees to the left and may be removed and replaced with exhaust piping to direct the fluids or gases to a safe location.

• Go to www.demm.co.nz/enquiry quote: D121011B

How to get wound up at work Graewe (Xtras for Extrusion) has a range of fully automatic winding machines for low to high-speed extrusion lines. They are designed for the precise coiling of pipes, hoses and profiles and offer a range of strapping units using PP band with a choice of 2/3/4/6 straps or stretch film wrapping, or a combination of the two. The machine can coil pipe with a maximum diameter of 180mm into coils of 1600mm diameter and widths of 1200mm. The coil diameter and width can be changed quickly by a centralised adjustment. The coils can weigh up to 1500kg and the winding machines have a speed of up to 150m/minute. Their compact design allows for easy placement of the machines into existing production lines. A coil unloading and palletising system are available, along with a labelling system. The winding machines use a force ventilated AC winder motor, which can be regulated by a dancer control or tractive force.

The traverse is synchronised with the coil revolution and can be adjusted with little effort. There is automatic changeover from one winding turret to the other without buffer storage and without the slowing down of the extrusion line.

•

Go to www.demm.co.nz/enquiry quote: D121011C

Miniature accelerometer The Dytran model 3122C is a miniature charge mode accelerometer designed for use in high temperature general-purpose vibration applications. Designed for reliable performance in temperatures up to +191°C, the Dytran model 3122C is available with a sensitivity of 50 pC/g. These charge mode accelerometers feature a hermetically sealed, all stainless steel design with the sensor operating in compression mode. Total weight is 25 grams, and the height is 1.3cm, making it ideal for environments where high temperature and low mass are required. Units feature a 10-32 radial connector and 10-32 tapped mounting hole.

•

Go to www.demm.co.nz/enquiry quote: D121011D

PRODUCT WATCH

Spiral of success From the drilling rig to the wind farm, equipment failure means operations stop. When you need to make hydraulic assemblies on the spot, six GlobalSpiral ferrules from Gates will do the job of 143 wire-braid couplings. It is a flexible solution that is compatible with a broad range of wire-braid hydraulic hose. GlobalSpiral ferrules are a moneysaving solution for those who crimp their own assemblies in the field or in the shop and – due to remoteness of location and cost-associated inventory limitations – may not have access to a full range of couplings for both wire-braid and spiralwire hoses. This line of couplings will allow those who crimp assemblies with the ability to assemble them not only with Gates spiralwire line of hoses, but with their full line of wire braided hoses as well. These durable, two-piece couplings have been designed and validated with Gates’ production hoses to offer the optimal hose/coupling interface across all sizes and hose/coupling types. Rigorous and thorough validation testing

Hydraulic failure in the field can be quickly fixed with GlobalSpiral ferrules.

assures superior performance – even in the most demanding of applications. All testing of the product was conducted in accordance with SAE J517 specifications and requirements. The release of the single stem/ferrule solution for hydraulic hoses offers the benefits of less floor space and a no-skive solution for fast, secure assemblies tested

to 6000 PSI WP capability across all sizes. “Bite the wire” crimp design improves coupling retention and blow-off prevention and the machined full-torque nut technology eliminates damaged couplings and leaks due to over-torquing.

Go to www.demm.co.nz/enquiry •quote: D121012

Belts to boost your machine productivity

You can rely on Habasit to help you achieve maximum performance from your equipment. Habasit plastic modular and fabric belts can be tailored to any application, and are backed with on-call technical support.

For further technical and sales information please call 0800 000 070.

DEMMAM053325

October 2012

Habasit - Solutions in motion

Energy Efficiency

Tune up your old boiler Businesses could reduce boiler running costs by up to 25 percent with help from an Energy Efficiency Conservation Authority (EECA) programme. The EECA Boiler Tuning Programme can help users of large steam and hot water boilers, such as factories and hospitals, to optimise the fuel use of their boilers. Funding of up to 40 percent of the cost of six-monthly boiler tunings for two years is available to companies in the scheme. EECA Business project manager Pramesh Maharaj says: “One industrial site we worked with made cost savings of $45,000 a year from a boiler tuning. It took only a couple of hours to complete and started delivering to their bottom line immediately.” Research carried out by EECA shows the long-term business benefits of regular boiler tuning are not well understood. “Typically boilers are tuned only when there is a disruption to the steam or hot water supply. For optimal performance boilers should be tuned once every six months,” says Maharaj. “The aim of the programme is to raise awareness of the business benefits of boiler tuning and encourage businesses to put in place a regular programme for boiler tuning services.” The boiler tunings are being done by firms such as RCR Energy, Energy Plant Solutions, Gas and Oil Combustion Services, and Advanced Boiler Services. A spokesman for Advanced Boiler Services says that on a steam boiler, an economiser can improve its efficiency by 6ºC or more, depending on the exhaust gas temperature and size of the boiler. “These are normally

only fitted to boilers with modulating feed water control valves to ensure water flow through the economizer, but on smaller boilers a closed system can be used circulating into the feed tank,” he says. Another option is to preheat the water, using steam injection to heat the tank of feed water. “A heat exchanger is a very energy efficient way to heat the feed water but is dependant on the condensate return rates,” says the spokesman. “A rise of 6ºC in boiler water temperature by condensate return can produce a fuel saving of 1 percent.” He also says that any leaks in process equipment and pipe work is lost energy, requiring the replacement of water, more energy to heat that water and chemicals to maintain a balanced water system. “Leaking valves and glands is a very common cause for the loss of steam and easily remedied by servicing valves regularly and replacing gland packing to ensure valve spindles are not damaged through erosion,” he says. “Exposed pipe work and equipment can reduce the temperature of the heating medium and therefore more energy is required to prevent heat losses required to operate equipment. It is a good idea to insulating pipe work. “Also, by ensuring that all condensate traps within the process are well serviced and operating correctly will ensure that steam is not lost returning back to the feed tank or going to drain. “Most condensate traps can be checked with an instrument without removing the traps from the system and this should be done at periodic intervals.”

•

Go to www.demm.co.nz/ enquiry quote: D121013

ISN S

PHERICAL ROLLER BEARINGS with patented DODGE IMPERIAL™ adaptor mount system for damage free shafting and easy 15 minute mounting.

30 to 140mm

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Polymer or Stainless Steel FDA/ USDA Approved Bearings ¾" to 2" and 20 to 50mm.

PARA-FLEX™ SHAFT COUPLINGS

Fast and easy installation with patented GRIP-TIGHT™ shaft mounting, high misalignment and vibration tolerance plus a 5 year element warranty

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Energy Efficiency

All steamed up Planning ahead when installing new plant machinery has helped a meat processing firm save $100,000 a year. Investment in a steam system review coupled with an energy recovery exercise at meat processing firm Affco Wairoa has paid for itself in just over a year. The firm built a rendering plant to avoid trucking meat off-site, and – with energy conservation in mind – set out to ensure condensate was recycled to the boiler house. The site’s 11.3MW coal-fired boiler had capacity to supply the new rendering process equipment – the majority used for two rotary driers to produce chicken feed and dog biscuits. When reviewing the condensate return system, at differential pressures higher than four bar (between steam use in process and the backpressure of the condensate), a conventional condensate pump return system is not very effective, wreaking > 6 percent flash steam energy in the condensate lines and often boiling the boiler feedtank water.

nZ_deMM_201209_orange.indd 1

October 2012

A three-port secondary side control on the heat exchangers give rapid response to the variable hot water demands.

Affco NZ’s plant engineer, Paul Sullivan says: “I worked with another operation where we couldn’t control the flash steam, it just went to waste. In this case, we worked with Spirax Sarco to ensure we had minimal wasted energy in the steam and condensate loop.” After review and several site visits,

Spirax Sarco proposed: •S plit condensate into low and high pressure systems. •U se energy from dryer condensate at high pressure by installing a flash vessel. •F lash steam energy is recovered and used for new “on-demand” hot water system comprising of two heat exchangers in series utilising low pressure condensate for pre-heating and high pressure flash steam (ideal as existing hot water system was budgeted for an upgrade). •E xcess flash steam beyond hot water demand is used to heat the make-up water storage tank. •R eturn all spent condensate to vented receiver and pump back to boiler. Sullivan says: “Dropping the pressure and temperature of the condensate to 80°C was ideal. All the flash steam is run through the main heat exchanger and serves almost the entire wash-down hot water requirements. “The only time we use direct boiler steam for hot water is at start-up from 6am

3/08/2012 10:30:49 AM

Energy Efficiency

to 9am, and it is minimal as the storage tank is pre-heated to about 65°C from the previous day – from excess flash steam.” The new hot water and flash steam recovery system uses closed-loop feedback control to ensure that the hot water production is fast and responsive, with the heating mediums (flash steam and low pressure condensate) already coming from other processes. This demand can be variable, therefore three-way control valves were installed on the hot water (process) outlet of each heat exchanger with a bypass loop, to cater for the wide operating range of the system. By controlling the

condensate return temperature at 80°C (sub-cooling) it ensures maximum energy recovery. All spent condensate is then returned to the condensate receiver and pumped to the boiler feedtank, enabling a reduction in boiler chemicals and make-up water required. The Spirax solution combined the need for condensate return and a hot water system upgrade into a large energy savings project. Sullivan says: “The installation has met all our requirements plus more; we are not wasting energy, we are saving in the order of $100,000 a year.”

•

Go to www.demm.co.nz/ enquiry quote: D1210115

testo 330 LL visualizes measurement data

graphically:

Understand ﬂue gas analysis at a glance!

1.10

12.0 AG to s tes e ga F lu

How to save $2 billion Fletcher Building is partnering with the Energy Efficiency and Conservation Authority (EECA) to reduce its energy usage and environmental footprint. Fletcher Building’s CEO Jonathan Ling and EECA GM Ian Niven signed a formal energy management agreement on 5 September during a visit to Tasman Insulation’s Auckland manufacturing facility. Under the agreement with EECA, Fletcher Building will introduce an energy management programme across its New Zealand businesses, beginning with independent energy audits and assessments of its work sites. The results of those audits will be used by the company to design and implement commercially viable energy saving initiatives. Ling says the company was already making great progress in reducing its energy use and greenhouse gas emissions. The company is targeting electricity savings of at least 17.5 GWh annually by 2014.

We measure it.

ons

Valu

Sta

Opti

This is equivalent to the amount of electricity used by 2,200 houses in a year and is worth approximately $2 million a year in avoided electricity supply costs. “In total, New Zealand businesses could save around $2 billion in energy costs every year – savings that would go straight to their bottom line,” says Niven. “EECA is working with businesses of all sizes and across all sectors to promote a culture of good energy management as a way to improve overall business performance.” EECA Business will provide some funding towards the programme, which will be made up of several projects, to a maximum of $300,000 over two years. Fletcher Building has engaged Energy NZ and Stewardship Solutions to assist with identifying and implementing opportunities that will improve energy efficiency across its business divisions.

Go to www.demm.co.nz/ •enquiry quote:

Flue gas analyzer testo 330 LL How you beneﬁt: • High resolution colour display supports your analysis of the heating system with graphic presentation of the measurement procedures • Easy symbols and graphics show you the measurement data of your heating system optically • Many new measurement menu procedures for professional installation and commissioning

4 years’ warranty on instrument and probes

optionally with

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

D121015B

Energy Efficiency

Slip sliding away Companies in nearly every industrial sector are seeking new ways to improve energy efficiency. Lubrication may be part of the answer. Management is constantly under pressure to increase productivity while reducing maintenance costs. On the plant floor, staff are being asked to implement energy saving and continuous improvement initiatives, to help save maintenance costs while, at the same time, increasing productivity. Mobil says one of the most cost-effective ways for industrial companies to improve equipment performance, maximise productivity and increase energy efficiency, is with the right lubricant. Mobil claims its DTE 10 Excel series – a category of hydraulic oils from the team behind Mobil Industrial Lubricants – is “improving hydraulic efficiency and generating consistent energy savings”. According to a case study report by Mobil, its DTE 10 Excel product, which was released to market in 2009, was tested in a hydraulic system containing a standard vane pump. The temperature of the pump using DTE 10 was measured to be 6°C to 7°C less than competitive products run under identical conditions. Mobil says equipment running at reduced temperatures demonstrates higher hydraulic efficiency and that can mean lower energy consumption to help reduce energy costs. To demonstrate its potential to help lower energy costs in the plastic industry, DTE 10 was tested in an injection machine. The hydraulic system consisted of two electric motors, operating at 100 HP and 75 HP with one variable volume axial piston

pump and four fixed volume vane pumps. The fluid reservoir volume was 1,250 litres. Mobil says the DTE 10 showed an average energy saving of 2.2 percent compared to Mobil DTE 25, though energy savings of 4.1 percent and 3.6 percent were recorded in certain parts of the system cycle. Mobil has also demonstrated fuel savings linked to the use of DTE 10. In a controlled field demonstration with a commercially available excavator, up to a six percent reduction in fuel consumption per work cycle was documented, as well as a significant reduction in cycle time versus a standard ExxonMobil SAE 10W hydraulic fluid. Mobil DTE 10 Excel also demonstrated in the test the value of its high viscosity index and stability by operating successfully in temperatures as low as – 34°C and by maintaining ISO VG class. Mobil says its DTE 10 Excel series represents the “pinnacle in hydraulic system lubrication for modern manufacturing processes that helps boost productivity”. It claims DTE 10 can last up to four times longer than the Mobil DTE 20 series in proprietary laboratory tests due to its “outstanding thermal and oxidative stability”. That means, says the firm, fewer oil changes, lower equipment failure and increased operational efficiencies.

Go to www.demm.co.nz/enquiry •quote: D121016

How to save on energy bills Nu-Way Energy is able to look at your power processes and suggest the most efficient and cost effective ways to reduce your energy bill. The company’s combustion systems can be sized and designed to suit the specific requirements of an application, offering a purpose-built solution to a problem – whether it involves making steel or heating ladles, melting aluminium or heating your tanks. Valve trains and control panels are designed and built in-house by the firm, which it says “ensures compliance with the relevant local codes”. Having extensive knowledge of the many control options available and the various benefits they offer to particular applications, the Nu-Way Energy can select the best burner and control package for an application to ensure that optimum energy efficiency is achieved without compromising reliability. The company says it is in a strong position to help companies that need to reduce emissions and energy used for process heating, while increasing productivity at an energy-intensive plant. It can also select a combustion system that will suit the particular requirements of an application and help firms that want to reduce the impact of the carbon tax on their business.

Go to www.demm.co.nz/enquiry •quote: D121016B

Hot issue solved with liquid coolers In some cases, simple fan-and-filter units are not enough to dissipate high heat loads from enclosures. Alongside modern compressor cooling units, which also cool with air, liquid-based cooling systems can offer advantages, depending on the application. To increase the energy efficiency of an entire cooling system, Rittal has improved its current air/water heat exchangers. New and intelligent Eco Mode controls are now used with Comfort units with cooling outputs of 500W to 5000W. They turn the fan off or on as needed, depending

October 2012

on the temperature in the enclosure. In order to measure the effective internal temperature of the enclosure, the control system switches on the fans for 30 seconds every 10 minutes, ensuring the circulation of air. The new units also offer assembly benefits. They can be mounted to the enclosure in less than two minutes. The heat exchangers are held in place by simply snap-fitting them to pre-mounted fixtures. Only two screws are needed to fasten the devices securely. Assembly is performed entirely from

outside, without the fitter having to fasten the air/water heat exchanger from within. Rittal has also improved the water connections. Alongside standard connections with flexible hose and plug-in joints and couplings, other types of joint are available such as internal threads, quick-release fasteners, direct hose ports or Ermeto quick-release systems. Such simplifications in handling can lead to savings in time during commissioning and operation and cut costs.

• Go to www.demm.co.nz/enquiry quote: D121016C

Thermal Imaging We measure it.

Thermal imaging finds hot spots There is one easy-to-use gadget that can help identify electrical danger areas in almost any situation.

NEW SEE MORE : THE NEW THERMAL IMAGERS FROM TESTO

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

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

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

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

When buildings burn and people suffer, the inevitable questions follow thick and fast. How did it happen? What was the cause? And the big one; how can we stop it from happening again? More often than not, it’s the insurance underwriters who probe the cause of the blaze and ask searching questions, looking for any negligence or ways the incident could have been avoided. As a preventative measure, business owners are being required by some insurance firms to provide thermal switchboard survey reports as part of their commercial premises fire risk assessment. Thermal survey reports have become a valuable business document that can lower insurance premiums and help businesses save money as well as identify danger zones. Faults that can be detected with a thermal imaging camera are indicated by elevated heat coming from the problem area. The causes of these faults can range from a loose connection on a circuit

breaker, an over-current problem on a circuit or simply a loose screw – faults that are typically hard to see with the naked eye. The commercial sector is valuing infrared technology as it calculates the cost savings associated with reduced breakdown maintenance and lost production downtime. The use of thermal imaging identifies faults at an early stage, enabling remedial work to be planned around business operations. Also, as faults are found early, the cost of remedial works is far less than if left to the point where equipment fails and disaster follows. Thermal imaging surveys include both infrared and visual images to provide those without electrical knowledge, a better understanding of the problem and its implications. The annual switchboard and electrical distribution system thermography surveys provides facility managers a vastly improved picture of the condition of their assets, leading to better asset-related business decisions. And as thermography surveys can be completed with no interruption to business operations, it presents as a valuable and cost-effective package to many businesses. It’s a similar story in domestic situations. If you’ve noticed your power dropping out, electrical appliances not working or the household lighting playing up, then it could be a fault in your switchboard that can easily be identified with a thermal imaging survey.

Go to www.demm.co.nz/ •enquiry quote: D121018

October 2012

Thermal Imaging

Thermal imagers cut power bills Because Flir thermal imaging cameras measure heat, the infrared technology can be used to measure the temperature differences in your building – and show you ways to cut your power bills. Measuring heat is the easiest and quickest nondestructive method of detecting energy waste, moisture intrusion and electrical issues. “Once the issues are identified, such as faulty insulation or ill-fitting windows, most can be quickly remedied and consumers will immediately see the benefit with reduced power bills,” says Flir Systems’ managing director Roger Christiansz. Infrared cameras can be used on the inside and outside of a building and will highlight differences in surface temperature, prompting further investigation. Pioneers in infrared technology, Flir Systems designs, manufactures, and supports thermal imaging systems and subsystems for industrial, scientific, government, commercial, and firefighting applications.

• Go to www.demm.co.nz/enquiry quote: D121019

Leadership has a class of its own

FLIR E-Series: Picture Perfect A new generation of FLIR hand-held ‘point & shoot’ thermal imagers is here. Packed with class leading features, the E-Series is designed for applications including electrical, industrial, mechanical, HVAC and building. Take your pick of three pixel resolutions – all with 60Hz frame rate and a 3.0 Meg visual camera built in.

The new FLIR E-Series. It’s all class. Get Connected! Connect to iPhone or iPad via Wi-Fi to use the FLIR ViewerApp for processing and sharing results.

◊ Mobile Device Wi-Fi Connectivity ◊ Large Bright Touchscreen ◊ Built-in Digital Camera & Laser Pointer ◊ Groundbreaking Performance & Affordability ◊ Superior Point & Shoot Thermal Imagery

Want to know more? Freecall New Zealand 0800 785492 or www.flir.com

ISO No. FLIR20837

Industrial coatings

Coatings faster than the speed of sound Page Macrae in Mount Maunganui has established a specialist coating operation to offer physical vapour deposition coating services Page Macrae Engineering’s coatings facility has been operational since April 2011. Its PVD process offers a micrometer thickness range ceramic coating technology applied by the cathode arc evaporation technique. This uses a large vacuum chamber, metal targets (product) as the sources of the base metal ions, high current-low voltage DC arcs to provide the energy, ionised process gases / plasma to conduct these to the surface and controlled chamber and process temperatures to support the chemical reactions. It also features measured mass flows of reactive gases at controlled partial pressures to control the chemical reactions. The metal ions are evaporated from the surface of the target product by the arcs that also partially ionise the reactive gas to form a conductive plasma cloud in the chamber. The metal ions accelerate to the surface of the work at velocities on the order of 10km a second, under a high DC electrical bias, and then combine with the reactive gases at the surface to grow a ceramic or inter-metallic compound – atom by atom on the surface of the substrate material. The current range of PVD coatings offered by the company is: •T itanium – Titanium Nitride (TiN) and Titanium Carbo-Nitride (TiCN). •C hromium – CrN and CrCN. •Z irconium – ZrN and ZrCN.

• Titanium-Aluminium – TiAlN. • TiAlCN. Most of the above coatings are well known to machinists and toolmakers as functional coatings seen on various high speed steel (HSS) and tungsten carbide (WC) cutting tools, inserts and holders – most of which are PVD coated today. Extended life Simple TiN PVD coating can extend the life between sharpening for typical HSS cutting tools between two to five times depending on tool application/ feeds/ speeds etc. Additionally, these same coatings can be applied for decorative purposes such as tap ware, sporting goods, door handles or architectural features to provide good facsimiles of white gold, rose gold, brass or antique brass. They wear much better than gold or brass surfaces and never need polishing to remove tarnishing. Plastics feedstock, soils, foodstuffs or other organic matter will not stick to TiN – a feature that makes it especially useful for plastic injection moulding hardware where easy clean-up is important to limit down-time. Page Macrae Engineering’s coatings division has experience with functional TiN PVD coatings that to date include D2, Calmax, H13, P20, Stavax/ 420, S600 and Sleipner tool steels. AISI 4140, 4340 and 8650 and various forms of high cobalt HSS and simple PCS.

Applications Work has included various plastic moulding hardware such as nozzles, push pins, push pin sockets and complete extrusion die sets (single and multi-segment). TiN coating of austenitic stainless steels is also ongoing – 304, 316 and 316L parts typically for industrial process machinery end applications for foodstuffs, water recirculation units, marine and plastics mould cooling parts. Titanium, tungsten carbide and nitinol substrate material parts are also PVD coated for a variety of customers today. Hardness of a basic TiN PVD coating is of the order of 10 times that of austenitic stainless steel at between 1,800 – 2,200 Hv depending on the specific measurement equipment employed. This is moot as most substrates are nowhere near hard enough to support this. Typical PVD coating thickness is approx one to two microns although most coatings are at the one micron end of the spectrum. Between two to five diameters of coating throw can be achieved into a through hole and up to 7D in some cases but for larger bores of approx 35mm and up. Certain hole diameter to depth ratios can create electrical “hollow cathode” effects which lead to less predictable coating behaviour inside the hole. Work must be electrically conductive to support DC bias voltage and also needs to be fixture – we can hook, peg or wire most parts, there will be a witness mark where the work rests on or is supported by the

Before and after shots show how products look after being coated at the facilities owned and run by Page Macrae Engineering.

October 2012

Industrial coatings

fixture. The parts must rotate and revolve in the chamber so a good form of restraint is necessary. Parts as large as one metre long x 30mm wide x 300mm deep can be accommodated in the chamber although jig manipulators are weight limited to a 250kg total load. There are six rotating and revolving hangars so about 125kg is about a practical maximum piece size if two parts of the same size are placed on opposite sides of the manipulator (to balance the vacuum rotary gland seal in the chamber roof) Typical coating temperature are in the 150 – 300˚C range, typical coating pressures are thousandths of a Pascal for cleaning, hundredths of a Pascal for etch cleaning the surface in an Argon inerted environment and the actual coating which occurs in the tenths of Pascal range with reactive gas bled in under mass flow control. Clean Due to the high vacuums involved, poor quality castings or weld inclusions

can out-gas and/or cause speckling on the surface of the work. Parts must be scrupulously clean ahead of coating and contaminants such as rust/ oxidation, grease/ oil, silicone/ RTVs or Loctite type products need to be cleaned completely off the parts before chamber processing. This can take more time than the actual coating operation. Assembled parts such as hinges or press fitted pins will generally bleed trapped lubricating or cutting oil residues from the joint under vacuum processing conditions, and should not be assembled before attempting coating as a rule. Cleaning ahead of coating will generally be best effected by ultrasonic cleaning. Page Macrae Coatings has a large capacity aqueous ultrasonic cleaning line and a smaller capacity solvent ultrasonic cleaner. Various electric ovens are used for drying off moisture/ hydrogen ahead of coating and to pre-heat large section parts to speed up the pump-down in the vacuum chamber. Nitrile or cotton gloves are used at all times when handling customers’ work.

Costs Costs are best determined from examining part drawings or ideally test running actual parts as the required fixturing can limit the number of parts that can be physically loaded into the chamber for one run – some part geometry issues create shadowing or masking effects that can influence coating colour density. As a batch process, more parts per run equates to a Iower piece cost to the end customer. However, smaller lots can often be combined from various customers wanting the same process recipe (especially for the most common Functional TiN PVD coatings on tool steel or WC). Other coating technologies currently being developed at the Page Macrae Coatings facility include the millimetre scale Atmospheric and Low Pressure Plasma Spray (APS/ LPS) coatings and nanometre scale Ion Beam surface modification and deposition.

Go to www.demm.co.nz/enquiry •quote: D121021

PVD Technology for all your decorative and functional surface coating needs

Take a closer inspection New inspection kits from DeFelsko Instruments allow for the inspection and control of all aspects of the coating process. One electronic gauge accepts a variety of attachable probes and easily converts from a coating thickness gauge to a dew point/humidity/surface temp gauge, surface profile gauge or an ultra sonic wall thickness gauge. Kits are supplied in a heavy-duty plastic case and are available in a variety of models. The gauge is supplied in a standard or advanced model with the advanced model being able to connect via WiFi to tablets, smart phones and computers. This allows users to store measurements, browse stored measurements, charts, statistics and notes.

• Go to www.demm.co.nz/enquiry quote:

D121021B

Some key benefits of PVD Coating: • Wear Resistance • Corrision Resistance • Durable Cutting Edges • Decorative Finish • Large Production Runs

EMAIL: enquiries@page-macrae.co.nz WEB: www.page-macrae.co.nz

Industrial coatings

Stress-free factory floor coating Regis Coatings uses state-of-theart manufacturing technology to ensure its products are developed for NZ conditions and ideal for the wear and tear of normal operations in factories, hangars, workshops, and food and beverage facilities. The firm provides a tough, reliable and easily maintained coatings and epoxy fillers. Its Cretex and Epotread Epoxy systems are manufactured in Christchurch and used to repair worn, cracked and eroded concrete floors. Its epoxy systems resist attack

and if a coating of Epotread 1000 is applied after the repair, the surface will become easier to clean and keep clean. In addition to the epoxy systems, Regis Industrial imports the Shell Flintkote range of bitumen-based coatings, these are marketed under the Duromastic brand. These emulsion (water-based) and solvent-based products are used for damp proofing and metal protection.

Go to www.demm.co.nz/enquiry •quote: D121022

‘Holy grail’ coating system Researchers at the Advanced Energy and Materials Systems Lab at the University of Canterbury have demonstrated a technology, described as a “holy grail” of modern industry. For the first time applying a uniform, robust and adherent ceramic coating to a complex shaped metal part has become possible, opening the door to the development of a fully fledged industrial process. The enabling technology for this breakthrough is called Pulsed-Pressure Metal-organic Chemical Vapour Deposition (PP-MOCVD), and was invented by associate professor Susan Krumdieck (mechanical engineering) during her PhD

thesis research in 1999. It has since been developed into a platform technology with potential applications in industries such as dairy, industrial manufacturing, medical and mining. NASA and international companies such as Teledyne, have already expressed interest in the product by contacting Krumdieck following her announcement in May this year. “Aerospace applications are quite exciting but it’s really the ability to add value and extend the utility of everyday products that is a true sign of success,” she says. “This is something industry has always dreamed about. Metal is of course the ideal material to make machines out of,

but then the surface is susceptible to corrosion and wear. It’s like the holy grail of modern industry.” Krumdieck says 15 years ago her supervisor gave her the “nearly impossible” research project of coming up with a lowcost process for depositing-depositing, or “growing” oxide ceramic coatings on metal parts. She says the secret to the PP-MOCVD process is that it eliminates the “carrier gas” that had always been used in conventional chemical vapour deposition and meant only flat objects could be coated.

Go to www.demm.co.nz/enquiry •quote: D121022B

Carbothane® 134 HG is a high gloss, excellent weathering, acrylic-urethane finish coat. It far out performs an SSPC Level 3 urethane specification for colour and gloss retention. Used extensively in virtually all industrial markets, Carbothane® 134 HG provides a smooth, durable finish that has superior resistance to corrosion, abrasion and chemical exposure. Features excellent flow, low VOCs and indefinite recoatability. Talk to your local Carboline rep today.

October 2012

Industrial coatings

Coating for the future Specifying the right coating for the job is key to managing maintenance and costs In the oil & gas and petrochemical industries the investment in bulk storage assets is a major capital item. Outside of processing facilities, the maintenance of storage facilities and tank farms in general requires a large portion of the maintenance engineer’s budget. Specifying the correct coatings systems for both the interior lining and exterior coating of petrochemical tanks is crucial in ensuring longevity of service, predictable maintenance requirements and suitability for a particular environment. If the vessel is an insulated tank, it adds another layer of complexity demanding a comprehensive specification, particularly with the potential for corrosion under insulation (CUI) scenario developing. Polymer Group recently undertook a contract to provide a complete solution for Shell Todd Oil Services at its Paritutu tank farm facility, providing not only such

a comprehensive specification but also undertaking the project management of the rigid polyurethane foam insulation and the protective membrane coating. To protect the tank shell from corrosion under the insulation, the external area of the tank was initially coated with a globally proven phenolic epoxy followed by 50mm of rigid polyurethane spray foam, and then 400 microns of protective membrane topcoat. Polymer Group is an experienced

• Go to www.demm.co.nz/enquiry quote: D121023

Epotread

™

Tough coating with corrosion protection Dulux Powder & Industrial Coating’s Kulorthene series of Abcite thermoplastic coatings have been developed specifically to offer long-term corrosion protection, flexibility, and impact strength, according to the company’s literature. It says the coating has “excellent resistance” to abrasion, chemicals, UV and exterior weathering for environments that are harsh or aggressive. The firm says its Abcite powder coatings are suitable for a wide range of end uses, such as water pipes and valves, marine fittings and fixtures, internal and external cable trays, motorway guard rails, balustrades, railings and fencing, farm and agricultural equipment, bus shelters as well as street and garden furniture.

protective coatings and specialty insulation manufacturer with its own project management and contract application division. The company services clients such as Shell Todd, Genesis Energy, Fonterra, Contact Energy and Trust Power, providing sole responsibility supply and apply contracts.

PREMIUM EPOXY FLOOR COATING

Dulux says the corrosion resistance of Abcite has been independently tested in Germany to ISO 12944-6. The product also meets standards C5-M and Im3. Its anti-corrosion properties are due to the product’s “unique chemical structure”, which provides “excellent adhesion to suitably prepared substrates” in a single coat without a primer. Abcite powder-coated surfaces meet the cathodic disbondment and “effect on water quality” (AS/NZS 4020:2005 for use in contact with drinking water) and meets the requirements of AS/NZS 4158:2003 (for valves and fittings used in the water industry).

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

HEAVY DUTY • PROVEN PERFORMANCE

Specially formulated for concrete floors, Epotread™ is the perfect solution for factories, warehouses, showrooms, and anywhere there is heavy indoor traffic. Not only is Epotread™ easy to apply, it’s long lasting surface will provide a safe, clean work environment for your business.

Freephone

0800 542 542 email sales@regiscoatings.co.nz

www.regiscoatings.co.nz

D121023B

Filtration

Conquering dust in Avondale “Veni, vidi, vici” is a famous quote from Julius Caesar and the name of a fabrication firm in Auckland. Perhaps better known to its clients as V3, exhibition stand maker Veni, Vidi, Vici (I came, I saw, I conquered) has won its battle with the MDF, wood and plastic dusts generated at its facility in Avondale thanks to a filter system from NZ Duct & Flex. “Exhibition stands absolutely have to be ready by the opening time of the show,” says V3’s MD Trevor Thomson. “A day later is not an option. Production delays simply cannot occur.” To increase its speed of operation, V3 invested in a large CNC router for producing stand graphics and modules. However, the firm needed an extraction system that matched the investment being made. Excellent filtration and reliability were also a priority. NZ Duct & Flex recommended a six module filter and fan, both sourced from Danish firm JKF Industri. Geoff Ebdon of NZ Duct & Flex says companies often invest significant sums of money in the ‘latest’ machinery, but the dust extraction system that’s required is the last thing they think of. “It’s a common problem,” says Ebdon. “But dust extraction is just something you have to spend money on.”

V3’s 84 bag modular filter system supplied by NZ Duct & Flex.

CNC installation instructions feature a minimum air extraction velocity recommended by the manufacturer. “Accountants may drop their togas, but as a rough guide, we would expect that if you spend $100,000 or more on a CNC, you need to add $30,000 for the extraction

system,” says Ebdon. “Smaller units are available that will be adequate for a short time before they clog up and the dust extraction from the CNC heads drops off. Then you start to encounter reduced performance and increases in wear on the machine tools.” For V3, the system features 84 dust bags and makes it easier to get the dust out of the factory so exhibition displays can be painted or stained without having to clean them down. “NZ Duct & Flex share the JKF design engineer’s belief in low pressure, low maintenance design,” says Ebdon. “Bigger filters with more surface area for the same amount of money as some of the smaller filters you see around. “Modular systems are one of the most cost effective dust extraction systems in the industry and it’s good to see production at V3 in such great shape with plenty of capacity in the filter and fan for future expansion. “Our filter unit is designed with three large inspection doors, so in fact there are only 28 bags in each segment. If a bag does get holed, maintenance is easy for the staff – even the furthermost bag is easily accessible.”

• Go to www.demm.co.nz/enquiry quote: D121024

Right filter for the job The most successful method of extracting any dust or fume is at the point of creation, says Cameron Prestidge from Egmont Air. “It sounds simple, but the challenge is a design that achieves this without interfering or restricting the process of work in operation,” he says. Egmont Air, specialists in dust and fume extraction, design systems to improve the manufacturing process by removing toxic or nuisance pollutants before they reach the operators’ breathing zone. Health and safety is critical where industrial processes expose employees to dust, powders, smoke or fumes, and it is important the correct airflows and capture designs are specified. In this way, pollutants are removed before affecting people and spreading throughout the working environment.

October 2012

“Capturing toxic particles ‘at source’ also offers other benefits in terms of workshop cleanliness, clean-air compliance and employee well-being, to create a workplace that provides a more productive environment,” says Prestidge. Egmont Air provides devices such as articulating arms, fume cupboards, down-draught benches, air-cleaners, centralised vacuum systems, specialised hoods and other proprietary equipment, so that an extraction solution can be specified for each application. Filtration and dust collectors can be specified so the correct type of dust collector can be matched to each pollutant. High-efficiency filtration provides clean-air discharge to exceed environmental regulations, in some cases allowing purified air to be returned to the working environment.

“Automatic cleaning by a reverse-pulse of compressed air maintains the filters in optimum working condition and reduces the level of maintenance and monitoring required, compared to other types of cleaning,” says Prestidge.

• Go to www.demm.co.nz/enquiry quote: D121024B

Filtration

Absolutely anything you need for Dust and Fume Extraction

Breathe easy Nu-Way Energy has added Weather-Rite to its range of HVAC products with what the firm says is one of the most versatile indirect-fired heating systems. With three fuel options, three control options, nine discharge choices, horizontal or upright installation, plus a complete line of air handling and filtering accessories, the latest addition to Nu-Way’s IDF-Series is designed to last “for years”. Among the key features of the system include discharge air free of combustion byproducts, high efficiency due to three or four pass heat exchanger design, longer part longevity as motors, belts and bearings are placed out of the airstream. In addition, unit cabinets are supported by a welded steel frame, the outer casing is coated to help protect

New Zealand

DUCT & FLEX against corrosion and its modular design allows for custom configurations to meet customers’ needs.

•

Go to www.demm.co.nz/ enquiry quote: D121025

Flex

In-stock for overnight delivery

Modular Duct

Aquaheat to grow under new owner Engineering and contracting business Aquaheat New Zealand has been bought back from Australian owners and is now a fully-owned subsidiary of New Zealand Stock Exchange-listed Horizon Energy Distribution. General manager Paul De Bernardo says Aquaheat is well positioned to provide fully integrated offerings of specialist building and mechanical services for commercial, industrial and infrastructure clients across the country. “We have a total staff of 220 people with specialist skills in HVAC and mechanical services, medical gas services, plumbing and gasfitting, fire protection and roofing and cladding,” says De Bernardo. “Our current workload with major construction

companies is strong, and while we have a well-recognised and enviable track record in the construction of commercial developments, hospitals and civic facilities, we are looking to grow our relationships with industrial and infrastructure clients, an area where we have not been so active recently.” In addition to the company’s contracting and maintenance activities, Aquaheat is also the New Zealand licensee for Colt International, a provider of smoke and fire control systems, natural ventilation, car park ventilation and solar shading. De Bernardo says the development of new products in Europe enables Colt Products and Systems to offer the “very best energy efficient and technically advanced solutions to the market”.

Widest Range Baghouse Filters

Dust Storm Filters

Fans

European Quality Fume Arms

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

www.nzduct.co.nz 25

Filtration

Concrete air solution Wam’s Silotop is a cylindrically-shaped dust collector for venting pneumatically filled silos. Its stainless steel body contains vertically-mounted polypleat filter elements with an air jet cleaning system that’s integrated into the hinged weather protection cover. Ideal for the concrete industry, the latest incarnation of the Silotop features stainless steel plates. The unit is low level for the ease of maintenance and servicing, is 800mm in diameter with a bottom flange and 24.5m sq (264 sq ft) filter surface. With almost 29,000 units working worldwide since first going into production in 1998, Silotop has become the world’s favourite solution for bin or silo venting. However, after 10 years, the firm decided it was time for a makeover. The unit is now fitted with 304 stainless steel seal plates. In addition, the lid is now a lightweight, heavy-duty PVC curved for weather protection and watershed. Gas struts have been fitted to the lid for ease of use while adding extra protection when servicing the unit. A lockable snap hook ensures the lid remains sealed, providing added protection from the elements. Originally designed for cement and similar materials, Silotop can be used with any dust-generating material as long

The redesigned Wam Silotop R03.

as it is dry and does not pack under pressure.

•

Go to www.demm.co.nz/enquiry quote: D121026

The lid of the new Silotop in its upright position showing the gas strut to ease its opening and closing, and the new stainless steel plate housing the removable filters.

Krauss Maffei release small laboratory extruder Krauss Maffei Extrusion of Munich, Germany, has released the KMD 35-26/L parallel counter-rotating twin-screw extruder for laboratory purposes. It is Krauss Maffei’s smallest extruder of this type and can be used by raw material manufacturers and processors to reduce their material costs. The concept can simulate scaled-down process engineering with extremely low material consumption. Formulations can be mixed in small quantities and optimised in subsequent test series before large material quantities are used in a production machine. It is suitable for all commercially-available hard and soft PVC mixtures. The twin-screw extruder is equipped with a powerful gearbox that has a

October 2012

comparatively high torque in spite of a small axial distance. It has been designed with internal screw tempering and barrel air cooling. Several transducers are mounted on the barrel for this purpose. Different screw geometries are available for pipe, profile and sheet extrusion. Output for profile production is 15–40kg/h and 30–70kg/h for pipe production. The laboratory extruder can be used in production companies for quality control tasks. “Processors benefit from enormous cost savings when they test the formulation on a small scale, and can therefore offer customers a premium quality end product without producing large numbers of rejects,” says Peter Oswald, head of profile & sheet extrusion at Krauss Maffei.

“This model is also a lucrative investment in ecological terms because valuable raw materials can be used sparingly.”

• Go to www.demm.co.nz/enquiry quote: D121026B

MAINTENANCE MATTERS

Hydraulics keeps the pressure on Difficult tasks can be performed with relative ease using hydraulic lifts, but users are cautioned to always put safety first. The very simplicity of hydraulic tools can often lead to their abuse. It is often difficult to comprehend the tremendous forces that are generated with a minimum of input from the user. However, where the proper rules and disciples are observed, hydraulic power is also one of the safest methods of applying force – and some of the most common mistakes are the simplest to rectify, says global high-force hydraulics leader Enerpac. For the safety of the operators, of people in the vicinity of the job and the longer life and efficient functioning of the equipment, the company suggests these simple guidelines.

Dress right Wear safety glasses, hard hat, gloves, safety shoes or boots and protective clothing relevant to the particular site conditions. Get into the safety habit before you lay a hand on the hydraulic tools.

Check your set-up. Most problems encountered in a hydraulic system are the result of improper assembly or operation. Read all instructions carefully and, before you use any hydraulic equipment, be sure you know what its function is and how it works. Position the load on firm, flat ground and if possible, use a jacking base. This prevents the load from “kicking out” or the reaction force punching a hole in the floor – another rather embarrassing situation. The two greatest enemies of hydraulics are heat and dirt. Keep oil connections clean, and use dust caps to keep dirt out. Heat above 65°C will soften packings and weaken hoses. If it is necessary to use heat, shield the cylinder with a blanket or a piece of sheet metal to deflect the heat.

Using a saddle will help prevent the plunger from mushrooming.

Use a jacking base to prevent the load from “kicking out”.

Make sure you use a saddle, otherwise the plunger will mushroom. When fitting a saddle into the end of the plunger,

ensure the face of the saddle is hard up against the face of the plunger. Cylinder mounting threads should always be fitted with thread protectors, otherwise damage to the thread will weaken it and reduce its capacity to withstand the reactive force of the cylinder.

Full pressure Never attempt to lift a load that exceeds the capacity of your system. Overloading damages cylinders, blows seals and bends plungers. As a general rule of thumb, estimate the load and then double it. If 10 tonnes is estimated and a 10 tonne ram used, “you” are working to generate the pressure. Use a 20 tonne ram and let the “area” do the work. Use a gauge to indicate safe operating loads and pressure levels. Before advancing or retracting a cylinder, make sure the area is clear. Using products to their maximum, repeatedly, will lead to premature failure. Just as you don’t drive your car to its maximum speed, build some safety into your hydraulics and follow the 80 percent rule. Leaving 20 percent of the plunger inside the base will give greater stability and using at 80 percent of rated load capacity means that pumping is not as difficult. Do not use an extension on the pump handle. The use of an extension could tip the pump forward and jam and damage your knuckles. It can also make the pump

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MAINTENANCE MATTERS

become unstable or pressurised beyond its safe limits.

functioning over the long term.

Hose Management Maintenance Hydraulic systems are designed to use hydraulic oil only. Follow the manufacturer’s recommendations, as the incorrect oil will damage the system and make it unsafe to use. Just like a car, it needs to be changed in order to ensure the oil is in good condition. When you are finished, release the pressure gently. Releasing the pressure in a system suddenly will cause the needle to snap back – throwing the gauge out of calibration. Use a snubber valve to prevent this happening, this will also dampen out any pressure fluctuations, giving a more accurate, easy-to-read pressure or force indication. Before storing hydraulic equipment, make sure it has been properly cleaned and lubricated where necessary. This will ensure its longevity and efficient

The hose is one of the most delicate parts of a hydraulic pump, yet it is essential for it to work correctly. Always leave some slack in the hose. As hoses pressurise, they shorten and if there is no slack, the hose will pull out of the end fittings. Never place the hose directly below your load, and make sure it is well clear of other objects. Dropping heavy objects on it will lead to hose failure.

Avoid sharp bends in the hose as this will damage the internal wire braids. Always carry equipment by the cylinder and the pump, never by the hose. This would strain the hose and excessive strain will cause the braids to fracture or pull out of the crimp, causing leaks.

Best advice The selection of the correct size cylinder, the right pump to operate it, the right choice of accessory equipment, together with the following some simple safety rules, will add the value of safety to the power and convenience of high pressure tools. Enerpac has offices in New Zealand and produces thousands of high-pressure hydraulic products that are distributed worldwide.

Avoid sharp bends in the hose as this will damage the internal wire braids.

• Go to www.demm.co.nz/enquiry quote: D121028

Safety fit for all Noting that every dollar spent on safety sends $4 to $6 to the bottom line, a report by 3M recommends that companies invest in risk evaluations to identify on-site hazards, and put the best processes. The processes can include personal protection equipment (PPE), says the authors of 3M’s Safety Outlook and Trends report. The report says employers can increase worker comfort and compliance by providing respirators, hard hats and other equipment that work well together and fit each unique

face and head shape. The report reveals cutting-edge advancements in PPE manufacturing and fit-test systems for hearing and respiratory protection that allow health and safety managers to confirm that the PPE is suitable for each user. “The safety and health professional must demonstrate to his or her employer that safety is not just compliance or regulation driven,” says Terrie Norris, president of the American Society of Safety Engineers.

“He or she must demonstrate the financial benefits.” The Safety Outlook and Trends Report was compiled based on a survey of safety and health professionals, 3M scientific research, and data from industry associations – including the National Institute for Occupational Safety and Health, World Health Organisation, Occupational Safety & Health Administration, Home Improvement Research Institute, Home Safety Council, and Health & Safety Middle East.

SKF Reliability Systems Excellence in Reliability Solutions Asset Management Services

Some of SKF’s AMS processes and tools include:

If you are looking for assistance on plant improvements, efficiencies and effectiveness, SKF can assist. SKF Asset Management Service is a solution that is provided locally in New Zealand. SKF can design and deliver a program that will help you achieve your maintenance and business goals.

• RCA - Root Cause Analysis • LCC - Life Cycle Costing • CMMS – Implementation • Assessments and benchmarking • Maintenance strategy review • Reliability Centred Maintenance • Training and Change Management

Key Outcomes: The Maintenance strategy and Program optimisation process is designed to: • Significantly enhance the effectiveness of your Maintenance effort • Improve plant performance (availability/ efficiency/OEE) • Reduce your maintenance effort leading to reduced maintenance cost.

www.skf.co.nz

October 2012

Other SKF Services available:

• Reliability Training Solutions • Maintenance Strategy Design • Proactive Reliability Maintenance For further information contact your local SKF Authorised Distributor or email marketing.skfnz@skf.com

• SKF SRCM process • Job Plans • Criticality analysis • Maintenance strategy development • Failure Modes and Effects Analysis • Spares and inventory management • Reliability, Availability and Maintainability • Diagnostic Centre • Engineering Solutions • Intergrated Reliability Maintenance

MAINTENANCE MATTERS

Wire rope lubricator The wire rope lubrication solution from Lubrication Engineers NZ is suitable for a variety of applications from wharf cranes to deck winches. The manual lubrication of wire ropes via the drip, brush, spatula or rubber glove method has always been a difficult maintenance task. Typically messy asphaltic or ‘blackjack’ type products are employed that have coating abilities but little lubrication or penetration properties. The Viper wire rope lubricator provides fast and effective lubrication of wire rope from 5/16-inch (8mm) to 2-5/8-inch (67mm) in diameter, at speeds up to 6,670ft (2,000m) an hour. It eliminates the slow and labourintensive task of manual lubrication, at the same time achieving more thorough results by forcing lubricant under high pressure right through to the core of the wire rope. The system consists of the lubricator collar assembly that houses the polyurethane seals to suit the specific size

rope. The assembly is clamped around the rope and anchored to a fixed point. The rope is then pulled through the collar as the lubricant is applied with a highpressure grease pump. The result is a fully lubricated wire rope with a smooth minimal film of lubricant on the outer strands.

• Go to www.demm.co.nz/enquiry quote: D121029

Cooperative Production Reliability - Operator based maintenance To be truly eﬀective at manufacturing it’s essential that production and maintenance are working closely together to produce a quality product for the least possible cost. This on-site training programme has been developed to overcome communication barriers between maintenance and production, enabling both departments to work towards greater productivity through reliability and eﬃciency improvements. A cooperative approach to reliability needs a 3-way partnership.

The operators are the central ﬁgure and become owners of the asset but they are supported by maintenance and equally importantly, supported by management. Skills4work trainers will empower your operators and maintenance staﬀ to work together and develop a sustainable programme of operator based maintenance.

MAINTENANCE MATTERS

SKF conference countdown By Craig Carlyle, Secretary MESNZ At the time of writing, it’s only a few weeks until to the SKF National Maintenance Engineering Conference. It never ceases to amaze how fast the time goes by. Thankfully, the sage event management team invested a huge amount of time preplanning the conference before Christmas 2011, making the run through 2012 appear relatively easy. The buzz is happening in Rotorua with the area getting behind this year’s event. Finding space for all the exhibitors has been the biggest issue to deal with and conference registrations are rolling in every day. The event looks to be a cracker, so if you have not yet registered, you can avoid missing out by nominating your registration at the contact details below. While you are registering, don’t forget to put your name down for the preconference field trip. The technonerds will be well catered for this year with an in-depth display of gear manufacture at Precision Gears, one of those topics that we tend to take for granted, yet involves some respectful engineering to achieve. Check out the pre-conference training opportunities too, choose from courses in team management, health and safety, maintenance management, RCA, or ultrasonics. (Don’t forget to book these separately with the training providers). Unwind and catch up with associates at the evening Trade Expo with its rolling soapbox theme.

Craig Carlyle

Recent years have seen significant growth in the electrical sector, mirroring the crossover in industry as “reliability” adapts an holistic approach. Electrical backgrounds now mirror mechanical and services in the general make-up of attendees and exhibitors alike, creating the ideal one-stop-shop for solutions, no matter what your background or

The conference proper is two days of focused information balanced by ample breakout opportunities. responsibility. The November 7-8 event at the Novotel Lakeside in Rotorua is jammed full of presentations covering technical, topical and line management subjects providing attendees with inspiration, information and experience. The conference proper is two days of focused information balanced by ample breakout opportunities. Whether your interest lies in welding and corrosion performance of alternative stainless steels, hard facing, data collection for PM systems, life cycle costing, human factors in health and safety, RCA, industrial solar power or dealing with grumpy people, there is expert advice delivered with wit, relevance and candour. If you are looking for a non-threatening environment where you can browse

technological solutions, discuss your technical and line management issues with experts and peers in a relaxed environment, or explore the latest issues and developments to take back to your workplace, then Rotorua is where you need to be. Between sessions you can explore the latest in technical solutions, catch up with speakers, enjoy sumptuous refreshments, check your emails in the lounging zone, or hang out for one of the multiple prize draw sessions. The cost is $680 pp + GST. This is by far the cheapest two+ day event you can attend in Australasia. You can even bring extra buddies for only $440 + GST per head. The NMEC is brought to you by the MESNZ whose job it is to ensure you are kept briefed on any topic relating to maintenance engineering, manufacturing and line management. What better excuse to attend, than to ensure that you are fully up to date on the latest issues? You can nominate your intention to register on the society website www.mesnz.org.nz/nmec, as well as check the latest programme details. Register online or contact event manager Leanne Powley on (09) 296 1333, email conference@mesnz.org.nz.

Engineer your Future Success. Upskill yourself or your staff with an engineering programme from Manukau Institute of Technology. • Electrical Engineering

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For more information or to enrol call us on 0800 62 62 52 or online at www.manukau.ac.nz 30

October 2012

ROTORUA 7- 8 NOVEMBER

@ The Novatel Lakeside

king The forum-based open networ ineers. eng ce conference for maintenan

EXHIBITORS & SPONSORS

Welcome to the conference The path to Rotorua is rapidly becoming an annual Mecca for engineers and that’s OK with the organisers of the National Maintenance Engineering Conference. The event, now in its 10th year, is a permanent feature of the Rotorua landscape and there is a reason for that – growth. According to event director Craig Carlyle, the event has become so large it demands a location that can cope with an influx of people and is cost effective for engineers to get to. The National Maintenance Engineering Conference (NMEC) is run by the Maintenance Engineering Society of NZ, a technical interest group of IPENZ. The conference is a “must do” for anyone involved in manufacturing, reliability and supply. Based around a two-day event featuring experts and peers on technical and line management topics

surrounding maintenance, the conference has grown to include pre-conference training and field trips, social events and a major exhibition. It is the pre-conference free public trade exhibition side that reveals another reason behind the event basing itself in Rotorua. Carlyle says: “Our vision is for the exhibition side of this conference to grow to National Field Days levels. Already we are seeing international interest from companies such as Rio Tinto, BHP Billiton and Mitsubishi as they recognise the cost effectiveness of attending this event. “Whatever the organisers are doing, it must be right, the 2012 exhibition hall has the ‘house full’ sign out and plans for 2013 involve finding a still larger Rotorua venue.” As a non-profit organisation the Maintenance Society is able to return

Free public trade expo November 6

“ The best bang for my the value to attendees and exhibitors buck any event I haveentry in the form of of radically reduced costs (as lowEVER as $440 + GST per person for attended” conference attendance). - Dave Extance Carlyle says: “The conference is a success because it understands engineers, the pressures and financial constraints on them, and their desire to lift their game. “But most of all, these are the real guys from the coalface, the real decision makers. The buck stops on their desk and they appreciate the opportunity to learn from each other and take the value back to their workplace.” The two-day conference will be held this year at the Novotel Lakeside Rotorua on November 7 and 8 with a free public trade expo on November 6.

a h c a e r o t e c n a h c y l n o d n a e n Your o ce

SKF

n a n e t n i a m l a n o i t na e c n e i d u a g n i r e e n i g and en k n a b e h t g in k a e r b t u o with

and eliminate unanticipated SKF has over 100 years downtime by using the suite of experience in rotating SKF products and services to equipment and its industry solve unwanted issues. relevant knowledge has been For over 80 years SKF have been built by working with different operating in New Zealand and customers and industries Official Media Sponsorare represented by distributors throughout the globe. This from Whangarei to Invercargill. knowledge is shared globally Please contact your nearest SKF and locally, and is used to Authorised Distributor or use support our customers in the email address marketing. maximising their business skfnz@skf.com for genuine SKF FOR DETAILS performance and profitability. advice. Our local teams of product specialists, application PME Supplies engineers and reliability PME Supplies has been engineers continually strive supporting the maintenance for innovation and excellence engineering industry for more by providing local industry than 14 years with portable expertise. Their vision is to machine tools and equipment. increase machine availability

Event details can be found at http:// www.mesnz.org.nz/nmec/

Among its range is the Climax Portable Machines & Welding Systems. This includes key mills, flange facers, shaft lathes, milling machines and valve repair machines. With its acquisition of Bortech, the firm now offers a family of automated bore welding and cladding systems. Another company’s products PME Supplies is proud to offer is the Mathey Dearman range of pipe cutting and bevelling machines, pipe clamping, and aligning systems. These are just two of the range of products PME Supplies takes pride in selling. See the website for full details. Web: www.pmesupplies.co.nz

Phone: 09 419 8335 Email: pmesupplies@xtra.co.nz

STAUFF Filtration Technology STAUFF Filtration Technology offers a complete range of filtration products and services with the highest level of contamination control demanded by today’s most sophisticated applications. Products include inline pressure filters, return line filters, elements, spin-on filters, suction strainers and desiccant breathers for various hydraulic, lubrication and fuel oils. Complementing an extensive range of filtration products, STAUFF exclusively distribute

Get in early to reserve your place and maximise your exposure…..

Refer to:

www.mesnz.org.nz/nmec/

Leanne Powley (09) 296 1333

National Maintenance Engineering Conference 2012

the range of CJC Offline Systems for the removal of particles, water and oxidation (varnish). Applications include, final drives, slew drives, crushers, engines, drills, tank farms and many other mining applications. Modular filter units are built to specific customer requirements – for oil volumes from two litres to 200,000 litres. Web: www.stauff.com.au Phone: +61 2 4271 1877 Email: info@stauff.com.au

company is now affiliated with Ash Air. As a result, Mbar is able offer a much wider range of products and services at highly-competitive prices. The company is constantly changing and adapting to customers’ needs, with training for staff and customers in choosing the right vacuum pumps and blowers to achieve greater reliability and efficiencies. Web: www.mbar.co.nz Phone; 07 871 8192 Email: info@mbar.co.nz

Mbar

SGS

Mbar has made its name on making “best” a reality when it comes to overhauling and servicing vacuum pumps and blowers. Led by Paul Vickers, the firm’s small dynamic team has many years of combined experience across all industries. Established in 2001, the

SGS is the world’s leading inspection, verification, testing and certification company. We are recognised as the global benchmark for quality and integrity. With more than 75,000 employees, SGS operates a network of over 1,350 offices and laboratories around the world. Registered in 1968, SGS New Zealand Ltd (SGS)

is integrated into the SGS Group’s worldwide network. Consequently, the benefits of the group’s commitment to providing expertise and quality services have been extended to its customers in New Zealand for over 40 years. Phone: +64 9 635 0260 Mobile: +64 275 241 380 E-mail: phil.schunk@sgs.com

Simply Synergy – Maintain It Simply Synergy provides customers with a supported preventative maintenance system that is simple, flexible, and powerful, to protect their assets and save them time and money. Simply Synergy was established by a hands-on engineering team who brought insight from the workshop floor and management of workshops. Combined with specialists in simple design software solutions, they developed Maintain It. Maintain It, is a secure online asset maintenance scheduling solution. With the customisable nature of the software, Maintain it is positioned to work with any business model. It is ideally suited for the operational requirements within industries such as infrastructure, i.e. hospitals, airports, councils; fleet management; service providers, i.e. engineering, laboratories; and processing plants. Web: www.simplysynergy. co.nz

Azzmax Azzmax with the Workmate CMMS solution are an asset, inventory and operation management solution provider. Workmate manages many billions of dollars of assets for many companies throughout New Zealand and overseas and has helped save hundreds of thousands of dollars by efficiently managing plant and equipment, inventory,

October 2012

regulatory tasks, and health and safety processes. Some of our clients include The Warehouse, TrustPower, Alliance Group, Hansells, Progressive Enterprises, Amcor, Wiri Oil Services, Sanford, Westland Milk and many others. Workmate is a New Zealanddesigned system and is easy to use, flexible, powerful and affordable! Web: www.azzmax.co.nz Phone: 07 827 0273 Email: andrew@azzmax.co.nz

Allied Industrial Engineering The genesis of Allied Industrial Engineering (AIE) was in providing precision engineering services to heavy industry, with a particular focus on the requirements of Pulp & Paper. Now, as AIE’s exposure to a wider range of industries (power generation, marine, dairy, defence and component manufacturing) increases so have its capabilities, investing in specialised machine tools, associated equipment and large lift capacity Underpinning this has been implementation of world-class quality and safety systems. The firm is a leading provider of engineering services to New Zealand industry through focus, commitment and ongoing investment. Complimented by a skilled work force, its dedication to overcoming any engineering challenge ensures delivery that exceeds expectations. Web: www.aie.co.nz Phone: 07 323 8877 Email: info@aie.co.nz

John Brooks John Brooks can offer a range of products from geared motors, linear automation systems to the general transmission chain, bearings, and couplings. At our stand this year, we will be exhibiting the Oriental Motor Company’s brushless

NovotEL Lakeside 7-8 November

motor and control to replace high maintenance DC brush motors. High guard chain from DID Japan that’s triple the strength of stainless steel chain is ideal for use in places that are exposed to rain or sea water. Other quality products include the Dodge ISN bearing blocks from USA. They take half the replacement time of installation compared to normal bearing plumber blocks, as no feeler gauges are required. Web: www.johnbrooks.co.nz Phone: 0800 484950 Email: salesakl@johnbrooks. co.nz

South Pacific Industrial AN ISO accredited company with its own CBIP welding inspectors, and ACC WSMP certified, South Pacific Industrial provides instrumentation, electrical and mechanical maintenance services to a wide range of industries including all the utilities, oil and gas, dairy and food, timber, etc. A ‘one stop shop’ for industrial plant preventative and shutdown maintenance from project management to final commissioning, we also provide an extensive range of specialist welding, pipe spooling, light to heavy fabrication plant installation and erection services. With a median staff of around 130 and a large database of skilled and reliable contract staff, we operate nationally from sites in Auckland and Northland, servicing large corporates and smaller companies. Web: www.spiind.co.nz Ph: 09 432 578 Email: phebb@spi.co.nz

Eurotec Eurotec will present the Testo range of portable measuring instruments including the latest in thermography for the maintenance engineering and

preventative maintenance applications. We will also display a comprehensive range of data loggers, supervisory and tele-maintenance solutions and wireless monitoring & control solutions. Come and talk to us about your control, measurement & instrumentation requirements on our stand at the NMEC Expo or contact Tom Aldridge. Web: eurotec.co.nz Tel: 09 579 1990 Email: taldridge@eurotec. co.nz

Fluke Since its founding in 1948, Fluke has helped define and grow a unique technology market, providing testing and troubleshooting capabilities that have grown to mission critical status in manufacturing and service industries. Fluke’s constant ability to release new, leading-edge products in challenging environments is what we are renowned for. Products such as the new Fluke 805 Vibration Meter, a meter that eliminates the confusion of vibration screening and provides reliable measurements you can trust to make critical go or no-go maintenance decisions. People who stake their reputation on their tools, and use tools to help extend their power and abilities, use Fluke test tools as the only brand they know and trust. Web: www.fluke.co.nz Email: sales@fluke.com.au Phone: +61 2 8850 3333

EagleBurgmann EagleBurgmann is an international sealing solution provider with truly local New Zealand resources. We have the product range, local industry knowledge, experience, engineering and manufacturing (large Auckland based plant) to ensure we have a solution to

National Maintenance Engineering Conference 2012

meet your sealing needs. With a focus on all industries, our products meet international standards, and are backed up with local expertise, ensuring your investment returns the value expected of it. Our product range includes mechanical seals, supply systems, expansion joints, metal gaskets, bearing isolators and more. Ask about our total seal care programme and how it can benefit your plant. Web: www.nz.eagleburgmann. com Phone: 09 448 5001 Email: Will.Dale@ nz.eagleburgmann.com

Two Degrees Over the last two years we’ve been busy. Two Degrees has built a world class mobile network, delivers awardwinning customer service and we have reached our one millionth customer mark by providing New Zealanders with better value. With smart products and innovations such as carryover minutes, shared data and long-life mobile broadband, we’ve set New Zealanders free to communicate more often. We have a team of national business consultants and stores located across the country who are ready to show you how we can take your business to the next level. Give us a call today.

Web: www.2degreesmobile. co.nz Phone: 0800 022 249 Email: bizcare@2degreesmobile.co.nz

HV Power HV Power specialises in intelligent electronics for the power industries. We understand the role of isolated power systems and the need for effective earth-fault detection and location. For grounded systems, we offer solutions for monitoring the insulation health (earth leakage), enabling pre-emptive maintenance to avoid unscheduled downtime. With a solid reputation for providing comprehensive technical support to our customers, our team holds many years of industry experience. We pride ourselves on our knowledge and understanding of the applications, specifications and operations of all our products. More than just a supplier, HV Power won’t sell a product until we’re confident it does what it claims. Web: www. hvpowerautomation.com Email: Sales@ hvpowerautomation.com Phone: 09 377 2001

Dulux Industrial Coatings The Kulorthene series is a new range of super durable

thermoplastic powder coatings manufactured for Dulux Powder & Industrial Coatings. They have been developed specifically for enhanced longterm corrosion protection, high impact strength and excellent exterior weathering. The benefits include exceptional resistance against salt spray, humidity, most common chemicals, acids, and alkalis. Kulorthene coatings have high elongation properties, excellent mechanical resistance and are solvent free. They have excellent substrate adhesion and protection even to sub zero temperatures – without the need for primers – and offer superior chip resistance. Kulorthene has been independently tested in Germany to ISO 12944-6 Corrosion protection of steel structures by protective paint systems. Web: www. duluxpowdercoatings.co.nz Phone: 09 441 8244 Email: powdernz@dulux.co.nz

Engineering News NZ Engineering News – the journal of record for the engineering industry with original news articles, case studies, IT and product presentation. Now in its 43rd year, NZ Engineering News offers coverage of the country’s engineering sector and

enhanced readership with a website updated daily and a digital edition which hot links your advertisement directly to your website. Eleven editions each year targeted at the people who need your products or services. Web: www.hayleymedia.com Email: kfalloon@hayleymedia. com Phone: 0800 503 305

Prolan NZ Prolan NZ specialises in the manufacture of environmentally-friendly, high performance, protective industrial lanolin lubricants, corrosion inhibitors and antiseize greases. Prolan’s main ingredient, lanolin (natural wool grease), is one of the most versatile natural substances on the planet. Its unique properties surpass other petrochemical products in performance, versatility, longevity, protection, safety and asset maintenance. Use Prolan’s natural products on machinery, chassis of vehicles, ATVs, quad bikes, trailers, chains, tools, pumps, electrical linkages, saw blades, locks, marine accessories. Prolan will reduce costs, protect your investments longer, will increase productivity and is safe to use. Web: www.prolan.co.nz Phone: 0800776526 Email: murray@prolan.co.nz

ULTRA

TOUGH For enhanced long term substrate protection

Kulorthene Series ABCITE® thermoplastic powder coatings have been developed specifically for enhanced long term corrosion protection, high impact strength and excellent exterior weathering.

October 2012

For more information and case studies visit: www.kulorthene.com or call 0800 800 975

DuPont™” and ABCITE™, are registered trademarks or trademarks of DuPont or its affiliates and are used under license by Dulux Powder and Industrial Coatings a division of DuluxGroup.

NovotEL Lakeside 7-8 November

Kinetic Electrical The staff at Kinetic Electrical has a sound knowledge of machinery, industrialapplication electrical requirements and automation. Fault-finding skills have been honed over years of experience and training. The company provides advice on ways to anticipate problems, moving from “applying band aids” to suggesting improvements that are cost effective solutions. The Kinetic Electrical promise is to always think, work and look smarter. We listen to our clients and think outside the box. And you won’t find any scruffy-looking people or working for us. We take pride in our appearance and our workmanship. Web: www.kinetic-electric. co.nz Email: ken.parsons@kineticelectric.co.nz

practitioners in plant reliability and health and safety, offering software, system auditing, training, coaching, mentoring and remote management. We are the NZ representatives for BWM computerised maintenance management software, the most cost effective and user-friendly maintenance system in Australasia. We will be unveiling the new BWM 2012 version featuring new enhancements at the National Maintenance Engineering Conference as well as offering a conference special of a $2,000 discount on the normal software cost of $6,000. We will be providing two training sessions in health and safety and maintenance management at the preconference training day. Web: www.transform.net.nz/ training Phone: 09 2922919 Email: craig@transform.net.nz

Filtercorp International

Skills for work

If you have an atmospheric challenge from dust, liquid or ventilation in your workplace, Filtercorp has the answer. Over the past 36 years, this NZ family-owned company has built up a worldwide reputation for creating and manufacturing filtration solutions – many of which have world patents. As well as exporting, it also represents other leading global manufacturers. So whether you need a bag house, filter bags or other filtration products – Filtercorp can supply ex stock or engineer a unique solution. In New Zealand, the company services from Auckland, Hamilton and Christchurch; has facilities in Brisbane and representatives worldwide. Web: www.filtercorp.biz Phone 0800 4819999 Email: sales@filtercorp.biz

Skills4Work Maintenance Training Centre offer public courses and on-site training for maintenance managers, supervisors, planners, team leaders, technicians and operators. In particular, this year has seen a huge increase in demand for the popular planning and scheduling for planners course, which is linked to national unit standards and continues to receive excellent feedback from all who have attended. The on-site programme for operator-based maintenance has also been in demand in industries as diverse as fertiliser production and wood processing. Companies have seen good productivity gains by involving operators and maintenance in production reliability improvements. Web: www.skills4work.org.nz Phone: 027 488 6446 Email: p.hurford@skills4work. org.nz

Maintenance Transformations The staff at Maintenance Transformations are expert

John Brooks Automation Applications from one source

Linear motor for pick and place. Accurate multi positioning.

AC motor control, with built-in PLC function, PID, torque, and Modbus comms.

Touch screens or keypad interface, sizes 3” to 10.4”. Colour or B&W

Small geared motors, Stepper motors and control or mechanical linear actuators.

Incremental encoders, linear potentiometers or sinusoidal output.

Motion coordinator for single or Multi axis motion control.

Servo motors and control for single or Multi Axis machine control.

www.johnbrooks.co.nz Auckland Wellington 0800 48 49 50 0800 24 34 44

Christchurch 080037 38 39

Supersonic bolt tester Hydratight has launched a smaller version of its BoltScope II bolt load-monitoring device for joint integrity and safety. The pocket-sized device from the joint security specialist provides high levels of accuracy for industries concerned about joint security in bolting processes. These include building and construction, oil and gas, mining and energy, process and production engineering, manufacturing and materials handling, metals, shipping and fabrication and maintenance tasks. The ultrasonic monitoring device can measure bolt load, elongation, stress and percentage of strain at nanosecond intervals,

and resolutions down to a thousandth of an inch, says Neil Ferguson of Hydratight Australia. BoltScope Pro can store 8,000 readings in multiple groups for detailed comparisons. Readings can be stored offline for joint integrity reporting.

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Fast splicing without mirrors

Calibrator for hazardous areas WIKA has extended its portfolio of hand-held measuring instruments to include the CPH65I0 intrinsically safe pressure calibrator. With an accuracy of 0.025 percent of span and various additional functions, the new instrument is suited to a wide range of applications, and due to its ATEX approval, these also include hazardous areas. The new hand-held is available with either one or two built-in reference pressure sensors. This allows 24 different measuring ranges of up to 700 bar to be covered. In addition, the CPH65I0 accepts transmitter output signals (0 to 24 mA) and the ambient and medium temperature (-40 to +150°C) is measured by a resistance thermometer. A pressure switch test function completes the functionality. Thus users can calibrate all types of pressure measuring

instruments with the new calibrator. Although it is multifunctional, the robust CPH65I0 is simple to operate using just three keys. On the five-digit, backlit display, three measurement parameters can be displayed simultaneously. The battery power supply is designed for at least 35 hours of operation.

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Fibre optic certification The latest Fitel S178A fusion splicer and the S325 cleaver simplifies the process of splicing and cleaving – saving time and reducing the complexity of the process. The cleaving process itself is now a simple three-step affair (down from seven steps). With these machines, simply place the fibre in the cleaver, cleave, take the cleaver head out to put directly in the splicer. That’s it. Fibre core alignment in

the fusion splicer is now automatically completed. Other features include a longer battery life, allowing you to complete up to 200 splices before recharging. That’s twoand-a-half times more than earlier models. There are no mirrors, meaning reduced cleaning time between splices and the splice time is reduced to seven seconds.

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October 2012

Take this portable fibre inspection and certification test set to site and it will provide the pass/fail certification for fibre end faces required under IEC61300-3-35. With contamination being the leading source of problems in optical networks, this unit inspects fibre end faces either with a probe (inserted into the bulkhead) or the fibre cord end is inserted directly into the probe. As you complete each test, store the results to the

unit, or to a USB (provided), for transfer to a PC for record keeping, printing and/or providing to your client.

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TEST and Measurement

Record anything The Hioki LR5000 compact data logger series easily records temperature, voltage, current, and instrumentation signals. Carried over from its highly reputed predecessor, this series offers seven times the recording capacity of former models, data import during recording, continuous measurement – even during battery replacement – and intuitive PC software. Flexible and easy-to-use at single and multiple locations, the new Hioki compact data

logger series is ideal for any application that requires simple set-up but long-term, reliable recording capabilities. Using its built-in memory, the LR5092-20 data collector allows up to 16 channels to be stored for data retrieval and downloaded to a computer for analysis. Users can increase memory storage capacity using SD cards. The loggers are all IP54 (splash proof) and depending on the settings, the battery life is up to two years. The data

The Hioki LR5092.

collectors come with bundled software for analysis and reporting. Recording intervals are from one second to 60 minutes. Various humidity and

The Hioki LR5001E.

temperatures sensors as well as current clamps and voltage leads are available.

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AirMapper for Android users

Anything in, anything out With more than 200 products and 1000s of variants and options, the APCS range of signal converters from Quasar allow virtually anything in and anything out. These devices are widely used in thousands of applications, including taking electrical signals and signals from sensors, providing 2kV signal isolation, signal processing & manipulating, and producing alarms, into a vast array of measurement and control applications. Most products are housed in industry standard DIN-rail enclosures. The range includes signal isolators, signal amplifiers, signal splitters, and signal converters. Available inputs include 4-20mA, mV, thermocouples, RTDs, vibration sensors,

frequency and speed sensors, slidewire sensors, bipolar signals, AC and DC current and voltage, mains frequency, pH, conductivity, DO, strain gauge sensors, one and three phase power, VA, VAR, and more. Functions include signal isolators and splitters, amplifiers, frequency to analogue, pulse repeaters, pulse scalers, multiplier/ dividers, exponential, signal limiter, position control, tap position, single dual and quad alarms. Power supply configurations include AC, DC, isolated, output loop powered, and input signal powered. Choosing the right device for each application is made easy by using the on-line selection wizard.

Fluke Networks’s AirMapper App, is the first application for Android devices that provides a visual heat map of Wi-Fi throughput performance on smartphone and tablets. While existing solutions can map speed and signal strength, or perform throughput spot checks, the App is the first to provide a visual throughput map, which is key to optimising Wi-Fi networks by taking the actual user experience of mobile devices into account. Wayne Allen, program manager, Fluke Networks, says full bars on a signal strength display do not mean a mobile device is working properly on the network. A study by the firm shows

many organizations are not yet ready to address performance challenges with mobile devices in the workplace – particularly with devices brought to work by staff. It says nearly 82% of organizations let employees use personal mobile devices on the wireless LAN (WLAN). However, 51% are concerned with how people’s devices will affect bandwidth consumption. Allen says his firm’s AirMapper can help companies bridge this performance gap and design wireless networks that meet business and user expectations.

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Battery power keeps the lights on ABB is making inroads installing its Li-ion battery units to smooth out the peaks and troughs of power generation by renewable sources in countries such as the UK and Switzerland. The power landscape has shifted towards greater use of renewable energy in the form of wind and solar. Although this type of power generation is more sustainable, it makes delivering reliable power, on demand, a major challenge for power generating firms. Wind and solar power installations generate power intermittently and with a variable output. When the wind is blowing or the sun is shining, excess power should be stored and made available during suboptimal generating conditions or during peak demand. This requirement has led to greater demand for alternative energy storage facilities to support the grid. Such fundamental changes in the architecture and controllability of the grid, calls for smart, efficient power transmission and distribution networks. These require the storage of energy at appropriate times and locations, both to balance generation with consumption and to maintain grid stability. ABB’s track record in the delivery of energy storage solutions includes pumped hydropower schemes going back over a century and more than a decade’s experience in battery energy storage systems. The company’s technologies cover a wide range of power needs from tens of kilowatts up to hundreds of megawatts, and continue to be deployed by utilities, industrial customers and rail operators around the world. These facilities help balance power demands and supplies, stabilising network voltages and frequencies, providing power bridges to support short-term gaps, and safe shutdown and backup needs. Solutions that are designed to enhance flexibility, increase energy securities and minimise environmental impacts. Examples of ABB’s recent installations include those in Switzerland, Sweden and the UK. The company recently commissioned the largest battery energy storage project of its kind in Switzerland with EKZ, a leading distribution utility and one of the largest energy companies in the country. To provide additional power to the grid on demand, ABB supplied and installed

October 2012

When the wind stops, ABB has the technology to keep a city running.

a battery energy storage solution using Lithium-ion (Li-ion) batteries that can provide one megawatt of power during 15 minutes. The storage facility is integrated into EKZ’s power distribution network and is being used to evaluate performance in key areas such as balancing peak loads and intermittent power supply, and the viability of the solution for grid optimisation. Falbygdens Energi is a Swedish utility with a significant portion of wind power connected to the grid in the Swedish city of Falköping. ABB supplied a dynamic energy storage solution for the utility’s power distribution network, to maximise the integration of renewables into the power chain. For this project, the firm used its battery energy storage expertise to store locally produced energy from wind turbines to create a storage capacity of 75kW in cycles of up to 60 minutes. The stored energy will be used to stabilise the grid and help balance peak

loads during the day. In the UK, ABB worked with Power Networks, which supplies power to more than eight million homes and businesses in the UK, to develop a dynamic energy storage solution. The installation enables renewable energy generated by local wind power plant to be fed into the power network when needed. It also ensures that some of the energy is kept in reserve to regulate power flow to compensate for the intermittence of wind power and to support power quality in the event of a fault. To meet these needs, ABB implemented a turnkey DynaPeaQ solution, incorporating SVC Light, which included eight stacks of 13 Li-ion battery modules located in an 11kV grid. Together, these high-power density modules can store up to 200 kilowatt hours kWh of electrical energy. The installation provides dynamic voltage control in the distribution system and, at the same time, enables dynamic storage of surplus energy from the wind power plant. This surplus energy is used to level out peaks in grid loading to provide grid stability.

• Go to www.demm.co.nz/enquiry quote: D121038

Coming up in the November issue S Food Processing Industry

SMotors & Drives SHeat Treatment SGalvanising SElectrical Safety Deadline editorial 5 October Deadline advertising 12 October

WET-NZ’s power generating wave machine getting ready for transport to the US.

Power from the wave New Zealand-designed wave energy technology in being trailed in the United States, one of the world’s biggest and most important energy markets. The Wave Energy Technology-NZ (WET-NZ) wave energy converter, in partnership with US company Northwest Energy Innovations, has been made possible thanks to a US Department of Energy grant worth nearly US$2 million ($2.5m). The 18.4m long, 20kW device is being tested off the Oregon coast over the next two months, during which time it will generate electricity and data to enable further development towards full-scale commercialisation. “This US deployment is a great opportunity to promote New Zealand technology in one of the world’s most important energy markets,” says WET-NZ’s Gavin Mitchell, general manager industry engagement at Industrial Research. “Success of the design will show us as being global leaders in Wave Energy.” WET-NZ, a research collaboration between IRL and private Wellington company Power Projects

(PPL), developed the device’s ‘brains’, an innovative ‘power pod’ designed to extract as much energy as possible from more than one type of wave motion – heave (up and down), surge (back and forth) and pitch (a rolling back and forth motion). Moored to the sea floor in an upright position, the device reacts to the movement of passing waves, with the energy from those movements converted into electricity by a system of on-board hydraulics. “This deployment will accelerate our design and development towards commercialisation and secure NZ intellectual property,” says WET-NZ’s John Huckerby, director of PPL. The half-scale device being tested off the Oregon coast is the culmination of eight years of research, during which New Zealand government funding has enabled the technology to be scaled up from proof-of-concept to prototype and refined based on the results of deployments at various sites around New Zealand, as well as extensive wave tank modelling.

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The half-scale power generating wave machine being tested off the Oregon coast.

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

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

RR Fisher & Co Ltd PO Box 23293 Auckland

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

Light up the night A new performance car headlight bulb that produces up to 120 percent more light than a conventional halogen bulb could make nighttime driving safer. The new Plus120 from Narva, which is a first for this market, is claimed to improve driver vision at night by producing a beam that is up to 40m longer than the beam delivered by headlights on the average car.

The increase in light output doesn’t increase power consumption or heat, and the bulbs are suitable for use in polycarbonate headlamps fitted to many modern vehicles. The Plus120’s are ADR approved, street legal and prices starting from $85 a pair.

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New alliance sees the light A global alliance of lighting industry players, aiming to promote and stimulate the development of openstandard wireless lighting solutions and offer maximum interoperability, has been formed. Called The Connected Lighting Alliance, its founding members are GE Lighting, Lutron, Osram, Panasonic, Philips, and Toshiba. The initial focus of the alliance’s activities is on consumer lighting applications. An open association, its founders welcome all parties interested in contributing to its goals. The alliance aims to promote the global adoption and growth of interoperable wireless lighting solutions. At present, it says, consumers are “confused and frustrated” by the diversity of non-interchangeable wireless communication solutions on the market. By engaging with open standards bodies and regulators, and encouraging the development of a robust wireless lighting control ecosystem (e.g. component and solution providers), the alliance aims to make wireless lighting products and solutions interoperable and easy to operate. On the web www. theconnectedlightingalliance.org

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October 2012

Maxon gives Roboy his mojo Maxon Motor is supplying DC and EC motors, as well as sensors, so Roboy – a 1.3m tall humanoid robot that’s currently in development – can make high-precision movements. The drive specialist has years of experience in robotics, particularly in industrial automation and the astronautics industry. “High-precision electric motors are the artificial muscles of a robot,” says Eugen Elmiger, CEO of Maxon Motor. “Our drives are small, dynamic and efficient – just what robotics need. “For us, creative and ambitious projects such as Roboy are always an incentive to challenge ourselves and to try new things.” A fully operational version of the Roboy is to be presented at the Robots on Tour event on 9 March 2013 in Zurich. With an anatomy and motion characteristics that mimic people, the Roboy production team want to establish that serious production of robots will not be too far away. Roboy, will be equipped with tendoncontrolled drive technology, to gives it the ability to perform humanoidlike movements and to react to the environment. Elmiger says the know-how generated as part of the Roboy project is freely available to researchers, robotics fans and people interested in the technology. Maxon’s products are used in the two Mars rovers, Curiosity and Opportunity.

This is what Roboy could look like in March 2013.

On the web www.roboy.org.

• Go to www.demm.co.nz/enquiry quote: D121040C

Cool firm is light years ahead Using downlights in ceilings just got a new lease of life thanks to a range of newly-certified LED lights. Ecopoint, a Kiwi company providing environmentally-friendly LED lights, has received an IC-F rating for its small panel lighting range from the International Accreditation New Zealand (IANZ). The rating is the highest classification in its category and means that building insulation can safely and continuously be exposed to a temperature of 90 degrees Celsius, and is permitted to abut and cover the luminaire. That means, says Ecopoint, that insulation can lay on top of the light fitting. To achieve the IC-F classification, ecopoint’s ecoLED panel lights underwent independent tests relating to the degree of contact that is allowed between the light fitting and the surrounding building insulation.

Paul Wilton, ecopoint’s director, says, “We are thrilled to have received this certification and are extremely proud to be the first LED light in the market to achieved this. “While these panels have many different applications, we believe the IC-F certification will make this product increasingly popular in the domestic market. This certification means that installation is truly a breeze and installing ecoLED panel lights will not interfere with the effectiveness of a home’s insulation.” Ecopoint’s ecoLED panel light are an eco-friendly alternative to a traditional downlight. They come in a range of colours and sizes and can be used in a variety of settings, from offices to homes. Lights without the IC-F rating, says

Wilton, must maintain a minimum 100mm clearance, which makes them even less effective at preventing heat loss, one of the main problems associated with traditional downlights. Ecopoint’s LED lights can reduce the amount of power used for lighting by up to 70 percent. “Their lifespan cuts down on maintenance and replacement costs associated with standard fluorescent lights, all while being less harmful on the environment,” says Wilton. “Ecopoint’s lights don’t flicker, are UV and mercury free and are 100 percent recyclable, and crucially, are easily retrofitted. They also come with a three year warranty.”

• Go to www.demm.co.nz/enquiry quote: D121041

Ultra-pure sensor

Temperature technology for the iPhone

With its Conducell PWSE Arc PG 13.5, sensor technology firm Hamilton has added a two-pole ultra-pure water sensor to its range that is suitable for standard fittings and offers all the functions of an arc sensor. The PG 13.5’s electro-polished stainless steel shaft allows it unrestricted use in pharmaceutical and biotechnological processes, says the firm. The sensor resists steam sterilisation, CIP cleaning and autoclaving. Its process connection is new and can be installed in all standard fittings. The sensor has been approved for a temperature range from 0 to 110°C (analogue interface) or 0 to 130°C (digital interface) and comes with two digital alarm outputs.

There are exciting new applications and innovations coming out every day for the apple iPhone, and the iCelcius temperature logging device is no exception. The iCelcius is a portable temperature probe that plugs directly into the communications port of your iPhone/ iPad, the other end of the cable is a convenient stainless steel probe that you can use to indicate the real time temperature of liquids, solids (ie fruit in a coolstore), or air temperature in ducts. The iCelcius device will also datalog the readings over a period of time, which are shown on the screen in graphical or data table format. This data can be published online, or sent to an email address for further analysis. Alarm set points can be added to provide an audible alarm, or text another device should these setpoints be breached.

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The urge to surge Measurement and control systems are vulnerable to transient surges and so require robust lightning and surge protection to avoid plant outages. In addition to providing highperformance protection circuits and equipment status monitoring, it is especially important to ensure surge protection systems are easy to install and expandable. Ensuring production plant availability is becoming increasingly important. Plant outages in any industrial sector generally entail substantial financial loss. Many demands are placed on surge protection devices (SPDs) in measurement and control systems. In order for lightning and surge protection equipment to do its part in ensuring production facility availability, the SPDs must have high-performance protection circuits. Moreover, the protection systems also have to be monitored. It is not sufficient just to report an outage after it has occurred; preventive information about the status of the installed SPDs is also required. The facilities to be protected are typically widely distributed, so it is helpful to be able to report and monitor the status of SPDs remotely, to avoid having to perform on-site inspections of the protection systems. The new Plugtrab PT-IQ family of surge protection systems provides a status report when protection devices have reached their performance limit. A yellow LED indicates this status. In large production plants or facilities that are difficult to access, such as remote wind power installations, performing on-site visual inspection of the surge protection equipment can be timeconsuming and costly. In such situations, it makes sense to use remote indication contacts to transmit the SPD status. The floating contact design of the Plugtrab PT-IQ allows users to select the transmission signal of their choice. Other components make it possible to integrate the remote indication contacts into intelligent reporting systems using the cellphone network or other wireless technologies. The latest technology integrates the remote indication contacts into the housing design of the surge protection device. Doing this requires using connection terminals that could have been used for protecting other signalling

October 2012

lines. The obvious solution is to put the remote indication and auxiliary power equipment into a separate external controller. Doing this is highly beneficial for the protection design, since controllers can be used to supply auxiliary power to multiple SPDs, making possible a group indication for the connected SPDs. This frees up all SPD connections to protect the signal lines. Up to five signal lines can be connected to the SPD, providing space and cost savings. The new Plugtrab PT-IQ product family uses a T-Bus as a carrier rail connector to minimise the power supply and status indication installation costs. If maintaining plant expandability is an important consideration, a surge protection system should be uncomplicated and expandable without requiring a great deal of installation effort. Such protection systems are also advantageous for handling last-minute planning modifications, which occur frequently nowadays. The T-Bus design also allows the protection system to remain flexibly expandable in these situations. To integrate additional SPDs into the protection design, the T-Bus can simply be placed onto the carrier rail and connected to the other connectors. Additional SPDs can then be installed on it. When selecting SPDs, it is important to consider not only the protection level but also the pulse discharge capacity. These properties, as well as many others, are established through standardised tests in accordance with the product standard. Users must differentiate between the types of standardised pulses that were used to determine the protection level. For example, due to the internal design, the protection level for a C2 pulse of 10 kA is significantly higher than the protection level for a C3 pulse of 50 A. Since the expected pulse strength often depends on the installation location, well-documented SPDs ideally carry specifications for a number of standard pulses. Measurement and control installations have small cable cross-sections, meaning that the resistance per unit of length (Ω / m) is relatively high. Comparatively

moderate current pulse peaks of a few kA may therefore be assumed. However, the devices to be protected against surges are more sensitive than line-powered devices. The protection level of the SPDs must be as low as possible. A good protection level can be achieved using voltage-limiting diodes (TVS – transient voltage suppressors). The current-carrying capacity of these devices is limited to several amperes. Gas discharge tubes (GDTs) provide good current-carrying capacity, but some require a relatively high trigger voltage of over 100 V. Two-stage surge protection devices combine the advantages of both components in one device: the low protection level of the TVS diode and the high current-carrying capacity of the GDT. This makes it possible to protect not only devices having low rated currents such as sensors, but also typically low-resistance actuators such as valves, contactors, and motors. Smaller signal path losses make thermal management at the installation site easier and more economical. Since each current pulse causes wear to the gas discharge tube as a function of the pulse strength, the increased current-carrying capacity of the protective diode and the protective resistors help extend the service life of the SPD. This is possible because the diode covers a larger current pulse amplitude range. The requirements for the highest level of production plant availability call for high-quality, high-performance surge protection products that are easy to install. These products must provide system-dependent advantages over standard products. Phoenix Contact’s new Plugtrab PT-IQ product family now offers a surge protection system for all current measurement and control application areas, which can be easily integrated into the plant’s protection equipment design and expanded as required. • Phoenix Contact is a leading developer and manufacturer of industrial electrical and electronic technology and has been operating in Australia and New Zealand since 1996.

• Go to www.demm.co.nz/enquiry quote: D121042

Safety regulations and standards updated The amendment No 2 of Electricity (Safety) Regulations 2010 is nearing completion and is expected to be approved for use by the government and the electrical industry from 1 July 2013. This amendment sets out the requirements for the forms and procedures for the certification of prescribed electrical work (PEW), effective 1 July 2013. The main changes will be: • The new forms to be used for the PEW certification; and • That all PEW (including repairs) will need to be certified; and • The ability to use a certification form produced on your computer from a template on the Energy Safety web site, and for a limited range of “low risk” work the certification can be simply a certification that the PEW work carried out is lawfully done (by a registered worker) and is “electrically safe” on the account for payment of the PEW done; and, • There are a number of other minor changes due to the changed requirements for final certification of “high risk” installations by electrical inspectors. • It is currently expected that a further amendment (No 3) to the regulations will be released in 2013 to cover changes to schedules 2 and 4, to cover changes made by amended standards issued 2012 to 2013. It is also expected that some consequential changes made by AS/NZS 3000 amendment 2 will also be covered.

Public comments received to the draft document were considered at a meeting of EL-001 committee held in Sydney in July 2012. The drafting work has been completed and is awaiting committee, Standards Australia and New Zealand and New Zealand Ministerial approval to proceed to publication, which is expected to be completed by the end of 2012. Until schedule 2 of the Electricity (Safety) Regulations 2010 has been amended, the full application of the amendment 2 cannot take place. In general, the adoption of the new requirements of amendment 2 can be used for the approval of PEW as an interim arrangement until the regulations schedule 2 has been amended. AS/NZS 3001 amendment 1; Transportable Structures (Caravans). The AS/NZS 3001 amendment 1 has been published, and these will supersede amendment A provisions. Until schedule 2 of the Electricity (Safety) Regulations 2010 has been amended, the full application of the amendment 1 cannot take place. In general, the adoption of the new requirements of amendment 1 can be used for the approval of PEW as an interim arrangement until the regulations schedule 1 has been amended. This amendment introduces new arrangements for the removal of the neutral to earth link in caravans with this feature, this has been changed to a mandated requirement that requires the fitting of an

Standards There a number of projects to update standards. These include: AS/NZS 3000 amendment 2; Wiring Rules for Australia and New Zealand.

RCBO in the caravan if the neutral to earth link is proposed to be removed, as removing of the link only lowers the existing level of electrical safety of the caravan, and hence would not comply with the transitional arrangements in the 2010 regulations. AS/NZS 3010 Generating sets. Extensive re-drafting of this standard is expected to commence shortly. It is expected that publication of the amended standard will not occur until early 2013. AS/NZS 5033 PV Arrays. This standard was recently published as a completely revised standard, a number of submissions have been made on some provisions of the revised standard. These proposals are to be considered during September and a committee meeting (if required, in late October/November) and small amendment produced to cover the submissions made. AS/NZS 5033 will form part of an IEC standard on the same scope of this standard. AS/NZS 4777 Grid Connect Inverter Systems. Drafting work on a completely revised standard is nearing completion and is expected to be circulated as a public draft shortly. Publication is expected to be late 2012 or early 2013. Alan Cuthbert NZEI Inc Standards Committee Representative

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

Email: nzei@xtra.co.nz

ATEX certified RFID tags Arnlea Systems, which provides Frequency Identification (RFID) products to the oil and gas industry, has launched a new range of ATEX-certified RFID tags designed for use in hazardous areas. The company designed the tags for use on FPSOs, drilling rigs and offshore platforms to allow fast and easy attachment to a wide range of equipment. This enables users to uniquely identify the item by scanning the tag. Extremely robust and designed for a wide range of

environmental conditions, the product is expected to survive for the life of the equipment it is attached to. “The oil and gas industry has been looking for simple, costeffective solutions to easily identify, monitor, and track the wide range of equipment and materials in use in the industry today,” says Arnlea managing director Kevin Boyd. “Now, with the release of these new RFID tags, the key to such a solution exists.”

• Go to www.demm.co.nz/enquiry quote:

D121043

Data acquisition takes a leap Dewetron has introduced the Dewe2 series of data acquisition platforms with Trion plug-in modules. The modules combine the modularity of PXI with a larger front panel capable of containing 8RJ45 connectors for strain gage sensors, six or eight IEPE sensor connectors, or four or eight isolated highvoltage inputs on a single Trion module. The modules are inserted from the front of the Dewe2 chassis and each module can be combined and exchanged directly by the user in seconds. They plug in and out using the same locking/ejector mechanism made by the PXI standard. This allows the adaptation of Dewe2 instruments for every sensor and every application quickly. The function of every single measurement channel, as well of the connected sensors, can be proofed easily via a system check. This results in a reduction of user errors, which saves time. The new Dewe2 series feature analogue, digital, can bus, GPS, counter – even video signals are hardware-synchronised

already during the measurement. This is guaranteed by the syncclock technology. Another highlight is the super counter. It is absolute phase and amplitude correct and enables the perfect synchronisation to analogue as well as to all other inputs. Any online and offline analyses are simplified due to synchronous stored data. There are Dewe2 instruments offering from four to 18 Trion slots, with or without a built-in computer. The Dewe2-A4 is an all-in-one platform with four slots for any combination of Trion modules It features an Intel i7 processor running Windows 7 OS, and a built-in display and keyboard. The Trion modules feature a

separate 24-bit A/D converter on each channel, strain gauge, IEPE, current, low and high voltage.

• Go to www.demm.co.nz/enquiry quote: D121044

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October 2012

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