Demm Engineering & Manufacturing September 2012 by Adrenalin Publishing Ltd

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

Welding update • Wastewater Industry • Sensors • Operator based maintenance • Tauranga Business case

Now including

www.demm.co.nz

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• CONTENTS

Editor's

note

Engineering has been in the news a bit lately and not always in a good way, with enquiries into the Pike River explosion and CTV building collapse. Whilst some of this has been around the original design process and ensuring correct supervision and delegation, it has also highlighted a lot of issues about what happens to an item, whether it be a building or equipment, after it is built to the original design. People inevitably modify things during their life, often without much thought as to the potential consequences (such as drilling holes in beams to fit cabling). Of more concern, and a topic we are passionate about with our Maintenance Matters section, is that often routine and preventative maintenance is neglected or overlooked, with a fix it when it breaks mentality. Often this is about saving money, but it is a short term saving only - a false economy as it will come back and bite you later, and also comes with a substantial risk of compromising safety. We regularly read the employment court summaries, and a lot of injury accidents in factories are due to guards and safety equipment at some stage being removed - maybe for maintenance or maybe for convenience and never replaced, so those that come later aren’t even aware they are missing until someone looses a hand or similar from a preventable accident. Another common occurrence is where, because a machine keeps jamming, the operators devise work-arounds that bypass the safety systems with management often being blissfully unaware of what is actually happening verses what is supposed to be happening. Astrong maintenance team with a proactive rather than reactive brief will keep on top of this and liaise with production to ensure these issues are addressed. Phil’s article on the proactive involvement of operators in daily pre-start cleaning and checking of their machinery at Nelson Forests Kaituna Mill, in our Maintenance Matters section, demonstrates how a proactive approach can really pay dividends in terms of both ongoing reliability and staff engagement. Monitoring and maintaining your assets makes excellent long-term sense rather than leaving things to chance. New Editor Stefan has left the role of DEMM editor. From the October issue we will have a new editor Steve Hart. Steve has a strong background in journalism and has been a regular contributor to one of our sister magazines, NZBusiness. We are sure he will help us continue DEMM Engineering & Manufacturing as the leading publication for the sector.

Product Watch

Special Feature

Heat Exchangers

Water Treatment

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

The “Tauranga Business Case” campaign highlights the massive benefits of doing business in Tauranga and the Western Bay of Plenty.

Interesting water to air heat exchanging technology An update on the water and wastewater treatment industry

22 Pumps & Valves Keep your fluids circulating

25 Welding

We showcase new developments in welding including specialised pipe welding

Maintenance Matters

Sensors

Electrical Technology

Phil Hurford looks at implementing operator based maintenance we have a guide on using handheld equipment for predictive maintenance

An update on sensor technology and application

A look at new products and technologies for the electrical and automation industries

Cathy Parker - Publisher

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.

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

Subscriptions: Hilary Keen, Email: subs@adrenalin.co.nz Proof reading: George Ward

Adrenalin Publishing Ltd. 14c Vega Place, Mairangi Bay. P.O. Box 65 092 Mairangi Bay, Auckland, 0754. Phone: 64-9-478 4771 Facsimile: 64-9-478 4779 Printing: GEON ISSN 1172-4536 (Print) ISSN 2253-279X (Online) Circulation: 10,287

Supported by:

• PRODUCT WATCH

In-ear communications headset 3M’s Peltor Ora Tac in-ear system offers a combination of lightweight hearing protection, ambient (tactical) listening, and the ability to communicate via two-way radios in high noise areas, without the need for a boom microphone. The Tactical Function Mode allows the user to hear conversations, vehicles, warning signal and alarms, while protecting them from sudden impact and other hazardous sounds. Since the Ora Tac fits comfortably in the ear, it is also compatible with a variety of other PPE, such SCBA, full face masks, hard hats, welding and sandblasting helmets, eyewear and powered and supplied air respiratory protection. Ora Tac is designed for high noise/high heat

work applications including: manufacturing, smelting, mining, fire & rescue, military and aviation. In addition to the in-ear headset, it includes a push-to-talk (PTT) adapter and a quick disconnect cable.

The cable connects to individual two-way radios and can be changed when a new radio is purchased without replacing the whole system. Go to www.demm.co.nz/enquiry quote:

•

Edit o choi r's ce

D120902

Personal access granted

The Manitou Mani Access 280 TJ telescopic access platform available from AB Equipment is particularly suited to a variety of industrial applications as well as on construction sites. It has a working height of 28 metres

September 2012

and a maximum outreach of 21.45 metres and can hold two to three persons in a large basket measuring 2.30m x 0.90m for improved productivity and reduced work cycle times. The Manitou Mani Access 280 TJ has a number of other features including: a diesel 45 horsepower engine, continuous rotation, an oscillating axle and four simultaneous movements. The product also features a fourwheel drive, four-wheel steer and Crab steer. “The Manitou reputation for reliability and quality of IC and electric access platforms has contributed in no small way to the recognition of the Manitou 280 TJ features,” says AB Equipment Sales and Marketing Manager Rob Fuller. Go to www.demm. co.nz/enquiry quote: D120902a

•

• PRODUCT WATCH

Electronic control knob With the new electronic DKE01 control knob, Siko offers an innovative solution for the ergonomic positioning of rollers, shafts and tools in engineering applications. Building on the hand wheels with analogue mechanical displays that have been familiar for decades, the DKE01 brings a new dimension in flexibility, positioning accuracy, ease of use, ergonomics and haptics. This integration of a freely programmable LCD display into a hand wheel is simply a worldwide first, says the company. Back in 1963 Siko’s founder Dr Günther Wandres created a product consisting of a hand wheel with a built-in analogue display operating on the pendulum principle that has since become ubiquitous in mechanical engineering, being applied to a range of uses. Thanks to an innovative gear design it is now possible to combine the adjuster element and built-in electronic position display into a compact unit. The special feature here is that the force from the star grip acts directly on the output shaft, so allowing a high torque to be applied to the adjustment axis. The electronic position indicator in the DKE01 is freely programmable. It is thus possible to match the control knob to specific applications. Adjustable display values and divisors allow any shaft pitches or gear ratios to be displayed to the highest precision. Values may be displayed in degrees, metric or imperial units and negative and positive values can be read without ambiguity. Calibration of the unit to a reference dimension is at the push of a button on the unit itself. For relative adjustments, an incremental measurement function key is provided, allowing the most complex positioning tasks to be carried out with just one main unit. The LCD display offers a particular boon in terms of precision removing the varying readings of the position value on mechanical scales as a result of parallax errors. With the DKE01 the position value is shown clearly in digital form. Display accuracy is 0.1° for angular measurements or hundredths

or tenths of a millimetre for linear measurements. The shaft inlet has an internal diameter of 20mm and is easy to mount on the adjustment axis and there is no need for cables or an intermediate coupling. Simply push on, lock the set screw in place and calibrate the display at the touch of a button. The lowest power-consumption sensor technology allows a battery life of more than eight years for the replaceable button cell battery used. The DKE01 is completed by an acid and

alkali-resistant plastic housing. Together with ingress protection of IP65, this enables the electronic control knob to be used in a wide range of applications. The DKE01 is thus a real alternative to the traditional mechanical analogue position indicators and offers significant improvements in respect of positioning accuracy and flexibility. Article by Sven Wischnewski, Siko. Go to www.demm.co.nz/enquiry quote:

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D120903

MetalFix

Waterbased Primer For Heavy Rust

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

MetalFix® * * * * * *

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

MetalFix 1000® * * * *

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

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

• PRODUCT WATCH

Food & Beverage product and system solutions. At NHP we recognise that the Food and Beverage industry is a key driver for growth across New Zealand and in doing so have tailored a complete range of products, services and total value solutions for the market. From automation and process control, energy management, drive control, power protection, enclosure systems, to safety, NHP can customise industry specific value solutions for this industry’s specific application needs. This was on display when leading global packaging manufacturer Amcor, a major supplier to energy drink, soft drink, ready to drink (RTD) and beer producers, undertook a line expansion that sought to double its capacity from 300 million to 600 million aluminium cans per annum at their Wiri plant in Auckland. Calling upon the expertise of NZ Controls, whose ability to provide high-quality engineering and automation services for the local market made them the supplier of choice, Amcor presented a scope that required the design, build, install and commission

of a number of electrical panels and related electrical hardware. “At NZ Controls we specialise in food and beverage as well as water and wastewater projects, and this project was a natural fit for us. The Amcor Wiri Beverage can line expansion is a major project and to have NHP working alongside both us and Sharp Data Electrical, the switchboard builders on this project, was crucial in terms of the quality and timeliness of our project delivery,” said Nikk King, Project Director – NZ Controls. “It’s been a really good partnership with NHP who were able to bring us not only their Rockwell Automation range, but a range of other products round out their offering, he continued. Given the scale of this project and the necessity to reduce the downtime of existing line operations at the Wiri plant whilst the new line was being constructed, the logistical element of the project was also a major consideration. A major element of the project was the

automation aspect which was to be built into the second can line. With can sizes varying from product to product, reducing downtime between the production of each can size without compromising on efficiency and quality was a must – and through utilising the Rockwell Automation suite from NHP, this was achieved. “There are still some people out there that have the perception that the cheapest price is the best price rather than thinking about the whole perspective of what NHP’s automation offering can actually do for your company – i.e. what value can the automation on offer add to my company, rather than what is its cost. Kevin Grey, Business Development Manager – NZ Controls. “Instead of just saying ‘I want to sell you a box’, it’s more like ‘I want to sell you a solution to meet your need”. To view an online case study of this project, simply visit YouTube and type in ‘NHP NZ Controls’ into the search bar. Go to www.demm.co.nz/enquiry quote: D120904

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For the most demanding water supplies Motors and Drives are critical

nZ_deMM_201209_cows.indd 1

September 2012

9/08/2012 8:50:46 AM

• PRODUCT WATCH

Linear motor with circular motion The new XTS drive system (extended transport system) from Beckhoff offers new freedom for mechanical engineering. XTS combines the previously separate advantages of two proven drive principles: rotary and linear systems. The result is a new drive system that effectively turns the previous linear motor principle around. The motor is completely integrated together with power electronics and displacement measurement. One or more wireless movers can be controlled with high dynamics at up to 4m/s on an almost arbitrary and flexible path. The XTS, with its compact design, revolutionises drive technology and makes completely new machine concepts possible. The desired geometries, lengths and radii are determined by the number and type of the components selected. Complex wiring and drag chains can be eliminated. In addition, the position measurement system is already integrated. The machine footprint is

fully and efficiently utilised, since the outward and return path as well as the curves can be used for active material transport. In this way, not only is hardware saved, but so is expensive production space. There are virtually no limits to the application possibilities of XTS. The movers can accelerate, brake, position and synchronise themselves. They can take up absolute positions and positions relative to each other; they can group themselves and accumulate; they can create clamping forces in motion, drive through curves and along straights, recover energy through regenerative braking and use both the return paths and the outward paths for transport purposes. The XTS system is simple and modularly configurable; the motor modules form a complete unit with the movers and guide rails. They contain the electromagnetic coils and all other active functions necessary for

the operation of the system. The only further requirements are a power supply and an EtherCAT connection. The mover contains magnetic plates which, together with the coils in the motor modules, can generate propulsive forces. It absorbs the attractive forces of the magnets on both sides and compensates them as far as possible. This means that the rollers on the movers, which are equipped with a particularly low-wear plastic surface, can move at high speed in the guide rails. A mechanically robust encoder flag conveys the mover position to the motor module. XTS can be used in an unlimited number of ways in the most diverse industries. The solution is predestined for high-speed material handling; push product, adapt product spacing, reduce or increase product speed, clamp and move product, transport and discharge product, manipulate product, lift out, close, rotate, and screw cap on. Go to www.demm.co.nz/enquiry quote: D120905

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your Complete Hydraulic Provider - system design, sales, service, installation, certification, preventative maintenance and fault finding - NZ Wide. With an average over 15 years experience per sales and technical team member, Hyspecs can confidently handle any project that is presented from clients. Full turnkey systems, in conjunction with service division personnel, can be designed, quoted, and installed in any part of New Zealand. Our sales team is available to consult directly with customers in our offices or on site. Sales trips are regularly taken to all parts of New Zealand and our representatives are always contactable. Hyspecs has application experience in a wide range of industries including: Forestry Machinery, Marine (Pleasure and Commercial),

Agricultural Industries, Industrial Plant, O.E.M Machinery, Transport and Construction Machinery. Hyspecs also offer hydraulic training seminar programmes for customers and interested parties. Seminar programmes are normally carried out in both offices, but can be customized to suit client requirements. Custom seminars are also available to suit specific or specialist requirements. Talk with one of our sales engineers today using the numbers below, drop us an email or check out our Website for more information.

Industrial Mobile Access Equipment Servicing Marine Forestry Construction OEM Design Agricultural

FLUID POWER ENGINEERING

Auckland 0800 497 732 • Taupo • Nelson • Christchurch 0508 476 937 •hyspecs@hyspecs.co.nz • www.hyspecs.co.nz

• PRODUCT WATCH

Helping stroke patients

Researchers from The University of Auckland have developed advanced rehabilitation devices to help stroke patients strengthen their muscles while at the same time playing computer games. “The main goal is not to play the game but to stimulate the patient’s interest so while they are playing the computer game

they gain muscle strength, says Professor Shane Xie. Professor Xie and other researchers from the University,have developed two types of wearable exoskeleton devices for stroke patients, one for gait rehabilitation and the other for upper limb rehabilitation. They have also developed a wearable ankle robot to aid in the rehabilitation of ankle sprains. The devices have been tested on people with and without disabilities, and the next stage is to run more clinical trials involving stroke patients. Professor Xie, from the Department of Mechanical Engineering, is the University’s first ever Chair in Biomechatronics. Biomechatronics is the interdisciplinary study of

biology, mechanics, electronics, software and control. It focuses on the interactivity of biological organs with electromechanical devices and systems. He is head of the University’s Medical and Rehabilitation Robotics Research Group where the rehabilitation devices and robot technology is being developed. “Our research is targeted at people whose strength and coordination has been affected

by amputation, stroke, cerebral palsy, or ageing. We believe appropriate mechanical assistance can not only restore function but enhance performance beyond typical human limits. “Even 20 years after a stroke a person can gain mobility through rehabilitation exercises,” he says. Go to www.demm.co.nz/enquiry quote:

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D120906

Vermeer helps broadband rollout

Power Transmission “PACKAGED” To Suit Your Needs

Worm Gear Motors and Worm Gear Reducers

• Modular design with ISO standard flanged input together with output flanges, torque arms, plus simple connection of multiple staged reductions • 100% compatible with ISO flange mounted motors • Lightweight aluminium design • Available in 10 sizes with power ratings .09kW - 15kW and ratios of 7.5:1 to 6,400:1

RR Fisher & Co Ltd R PO Box 23293 Auckland

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

September 2012

Now that the Ultra Fast Broadband (UFB) evolution is well and truly up and running across the country, AB Equipment has been quick to recognise the potential of this project and has positioned itself to take further advantage of the opportunities that lay ahead with Vermeer and Baroid products. The UFB programme involves laying thousands of kilometres of fibre optic cable and ducting to bring UFB to more than 830,000 homes and businesses across New Zealand. The Vermeer Series II underground directional drill models D9x13 and D20x22, when combined with associated mixing tanks and locating

systems, have proven to be particularly popular with contractors on this project. Baroid Industrial Drilling Products have also become a vital ingredient in the overall package. AB Equipment stocks a full range of Baroid performancedriven products such as EZMUD drilling fluid additive and BORE-GEL boring fluid for horizontal directional drilling and construction operations. For instance, this year alone, one contractor, Coastal Cabling services, have bought two Vermeer Navigator D20x22 drills, one smaller D9x13 version, plus two MX125 mixing tanks. Go to www.demm.co.nz/ enquiry quote: D120906a

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• PRODUCT WATCH

Feeding forces of up to 400N The spindle drive program from Maxon has been extended with the new size of 16mm. This is an easily configurable complete system with integrated axial bearing for high loads. There are versions with metric M6 spindle or Ø 5 mm ball screw. Precision spindles combined with DC motors make it possible to transform rotary motion into axial motion. Gearheads, motors, encoders and controllers from Maxon’s standard program are used to drive the spindles. The individual components of the spindle drives are perfectly matched to each other,

resulting in high-efficiency drive solutions. A central component is the axial bearing, which must withstand the high tractive and compressive forces of the spindle. There are 14 different reduction ratios in the planetary gearhead available, from 4.4 up to 850:1. Depending on the reduction ratio and the type of spindle, this makes it possible to achieve feed forces between 35 and 370N and even up to 400N for short durations. DC or brushless EC motors can be used to drive the system; in total, nine different motor types are available. These motors can also be equipped with compatible sensors (encoders), which are

essential for precise positioning. EPOS positioning controllers are recommended for controlling the motor-sensor combination. These controllers feature a wide range of functions as well as CANopen or EtherCat. The controller can directly evaluate limit switches and other sensors. The programmable EPOS P version makes it possible to set up independent, standalone systems. The spindle drives feature robustness, flawless operation and a long service life. Go to www. demm.co.nz/enquiry quote: D120907

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Fire protection plain bearing A new plain bearing classified according to UL94 with V0 has been introduced by igus. The bearing, iglidur GV0, offers similar all-round properties as the proven plain bearing material iglidur G, such as an extremely high load capacity at low to medium sliding velocities and the proper wear resistance on most different shaft materials. Thanks

to the additional V0 classification, the inexpensive material is predestined for the use in areas with high fire protection regulations. This chiefly includes aircraft, automobile and rail vehicle interiors as well as building technology with elevators, escalators and similar applications. Go to www.demm.co.nz/enquiry quote: D120907a

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

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

Quality European Manufacturing • Motors • Gear Components • Control Technology

The powerful Movidrive range of controllers for when sophisticated positioning and control is required. Geared motors in a huge range of gear configurations, mountings, sizes and power. Fast customised assembly for every customer application requirement.

New Zealand Assembled • Fast, customised assembly for every drive requirement

Every finished assembled product is given a unique ID code to be backed by complete SEW-Eurodrive 24/7 service.

Application software is created for each customer requirement at our Auckland & Christchurch plants.

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

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

24/7 Service backup

E&M312

Customised assembly to each customer application specification.

INDUSTRIAL DRIVE TECHNOLOGY

• PRODUCT WATCH

0.0002'' Super precision CNC lathe by Hardinge Conveyor Components Company has been using Hardinge machines for a number of years. They recently purchased a T-42 Super Precision turning centre to join two other Hardinge CNC lathes and a vertical machining centre. Thom Rice, Manager, comments, “The Hardinge machines are used to transform unfinished aluminium castings into a housing assembly for a conveyor control, motion control, or level control device. Coming from an era of machining a product on several machines before reaching its final destination, the Hardinge VMC-1000 II has changed all that allowing for shorter running times, and less inventory needed on hand to fulfil our customer needs. Milling, drilling, tapping,

boring, and thread milling are some of the operations performed on this machine. Like the machining centre, our three turning centres are the lifeblood of our machine shop. They allow us to perform many machining operations on one machine with the final result being a completed part. The turning centres are equipped with ‘live’ tooling direct from the turret to allow for drilling, milling, and contouring parts. These machines are also equipped with a second spindle allowing for parts to be machined on one end then transferred to a second spindle doing work on the other end.” Rice continues, “The tight tolerances that we need to achieve are as low as 0.0002" on some turned parts and bored holes. Our newest Hardinge

Calling all

Mechanical Engineers: Your Trade Qualifications are being reviewed in 2013 The aim of the review is to streamline the number of qualifications at levels 1-6, and ensure qualifications remain relevant to employers and learners. This is part of the Targeted Review of Qualifications (TRoQ). The Competenz regional workshops in October are your chance to understand the system and have your say in the future of NZ’s qualifications for Mechanical Engineering. Don’t miss this opportunity to shape your industry. For more information and to register for a workshop, go to competenz.org.nz

machine gave us the ability to perform multiple machining operations in a single set-up. It reduced our overall number of tool changeovers. This provided a great savings in time and labour, and also increased our overall productivity. By decreasing our overall machining time, we have also been able to provide quicker ship times to customers. Some of the benefits of these machines are not only reduced times in machining a part, but also machining a part to its entirety with a much better quality finished part. Jobs are tooling-specific for us, meaning

every job has its specific tooling allowing for a program download and tooling change to take as little as ten minutes. We have one operator running all three turning centres simultaneously allowing us to reduce labour cost by one third. “Hardinge has been very supportive in providing tips and suggestions on the programming of the machines. The Hardinge training classes have been well worth the time and expense, and have provided an additional resource for our machine operators.” Go to www.demm.co.nz/enquiry quote:

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D120908

Another WORLD FIRST! Ryco’s new H6032 hydraulic hose passes 1,000,000 impulses at an incredible 400 mm bend radius. Rated at 420 BAR maximum working pressure, H6032 is a DN51 / 2" hydraulic hose which Ryco say provides unparalleled, superior strength and flexibility over any other equivalent hose available in marketplace today. It is the flagship of their new series of isobaric hoses. Ryco’s new isobaric hoses are: • Stronger and outperform their predecessors. • More flexible and have tighter bend radii. • Lighter and easier to install. • More cost effective, and therefore save our clients money. The isobaric hoses can do more work in less volume, providing a higher energy/work density. Clients can select the hose series to match their circuit working pressures with the only decision that remains being to select the cover style required for the application. Ryco’s standard Avenger cover, is MSHA flame-resistant and carries full third-party accreditations for marine and general engineering use. Ryco’s Diehard cover, is FRAS (Flame resistant and anti-static) and is very abrasion resistant. Ryco Diehard hoses are available with full third party for marine, mining and heavy engineering use as standard. If the application calls for extreme abrasion resistance, then Ryco Slider gives abrasion the slip. Ryco cautions against using non-matched hydraulic hose assemblies as often the ‘hose’ meets an industrial standard, but the hose assembly does not. Remember hydraulic hose is only half the story. It is the hydraulic hose assembly that must perform and meet industry standards; not just the hose. Hydraulic hoses require hydraulic couplings that are designed and engineered to suit their tolerances and construction. The Ryco hose and coupling is a matched system as required by SAE, ISO and EN standards. Ryco has a fleet of impulse test machines that operate around the clock, guaranteeing a matched, safe and reliable hose assembly. Go to www.demm.co.nz/enquiry quote: D120908a

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September 2012

• PRODUCT WATCH

Mobile option cuts cost at Horokiwi Adding a new mobile screening option has improved efficiency and reduced cartage costs at Horokiwi Quarries Ltd in Wellington. The company’s purchase of a new Metso ST272 mobile screening plant from Mimico has reduced double handling of waste material. Quarry foreman Gary Clouston says by adding the mobile screen, the company needs one less dumptruck carting waste. “Before the ST272 arrived, we were carting rock 700m from the new block down to the primary plant, then carting the 65-down material we don’t want back up the hill to the waste area. “The new block is producing a lot of fines, so there was a lot of double handling. The trip from the primary plant up to the waste area is a 15-20 minute round trip.

By screening out the 65-down material near the new face and taking it straight to the waste area, we can take one truck off the job.” Because there is no room to screen at the face, the Metso mobile screening plant is positioned 250m away, and 20003000 tonnes of rock is stockpiled there for a single operator to ‘walk through’ with a 45 tonne excavator and the Metso screen. The Metso two-screen process produces three products: 600mm down to 110mm for the primary plant and some for sale as decorative rock, 110mm down to 65mm rock for sale or further processing, and 65mm-down to go to waste. The company trialed two screening plants for the job, and settled on the Metso. It was the right size for the job, it

had superior ground clearance for working on uneven ground, and the product belts were a lot higher, which allowed bigger stockpiles and more room for loaders to work. Mimico were also prepared to rent the machine to Horokiwi for a month, then take the rental cost off the purchase price. “That made the difference, because we were able to make sure the machine would do everything we wanted before we decided to purchase. “Mimico’s service staff made some adjustments to the plant to suit the material we are working with. Now the plant is pretty well set up the way we want it.” The plant is processing 250-300 tonne an hour, but Gary says the operator can’t feed the plant flat out because the new rock is not as clean as other

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

material at the quarry. A 45 tonne excavator has been feeding the ST272 but Gary says a 35 tonner would probably be a perfect match for the brown rock being handled. Horokiwi is one of Wellington’s two biggest quarries, producing a full range of roading and concrete chip, basecourse, sand, plus landscaping and decorative materials. The greywacke quarry has three fixed processing plants – primary, sand and basecourse. Other Metso plant on site includes the Barmac primary crusher, an HP200 cone crusher and C100 jaw crusher. Go to www.demm.co.nz/enquiry quote:

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D120909

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

Tel Service Fax Email

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

• PRODUCT WATCH

High and low temperature aluminium wheels Richmond Wheels and Castors new range of high/low temperature aluminium wheels are suitable for use in demanding environments. Ideal as a replacement for phenolic wheels or cast iron alternatives, the new aluminium wheels are specifically designed for use in the food industry as well as any oven baking application that requires continuous exposure to temperatures up to

300°C with peaks of 400°C as well as chillers and freezer applications down to -30°C. The aluminium wheels are available in a number of wheel and castor configurations from light to heavy industrial frames with different boss width and axle sizes. Key features are: • Resists thermal shock due to rapid rising or falling temperatures. • Anti-corrosive properties. • Resistant to most solvents, oils, acids and chemicals.

• Chip and crack-resistant surface compared to traditional phenolic wheels. • Greater tensile strength, able to withstand sudden impacts compared to phenolic wheels. • Reduced wear characteristics increase longevity and decrease maintenance costs. • Material will not dry out and become brittle under normal baking times. • Provides structural integrity to the castor for a smoother ride. Go to www.demm. co.nz/enquiry quote: D120910

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Regal (CMG) appoint a new general manager Retiring Managing Director Craig Keesing, has announced David Priestley as the New General Manager for Regal New Zealand. David started as an apprentice in 1984 and has been involved in every aspect of the motor industry. As New Zealand service manager, David helped CMG move into the repair and rewind industry. David also has a very good understanding of all aspects when it comes to ISO and IEC certification.

As part of the CMG operation, Ex plays a big part and requires up-to-date Audits. David’s role will be to grow the current business and work towards helping New Zealand market into a greener environment in the Electric Motor industry. Part of his plan is to get apprentices back on the books, focusing on efficiency, and working with ECCA to adhere to all codes of practices in the Electric Motor Industry.

CRC 5.56 Industrial is a high performance variant of CRC 5.56. It is fortified with PTFE to provide additional lubricating performance and is non-flammable making it safe to use in industrial applications. CRC 5.56 Industrial leaves a thin film that clings to surfaces providing multiple benefits; Effective lubrication, penetrates through corrosion to free rusted components, inhibits corrosion by forming a continuous protection barrier and displaces moisture.

crc.co.nz www.crc.co.nz 10

September 2012

CRC_3242_DEMM

• TAURANGA

Building a case for Tauranga The “Tauranga Business Case” campaign by economic development agency Priority One highlights the massive benefits of doing business in the Western Bay of Plenty. Part two of the article presents three more case studies to further substantiate this case. Case study: Oasis Engineering Ltd. “Tauranga is a great place to be an exporter. The strong infrastructure allows easy access to national and international markets. Compared to Hamilton and Auckland, rates, operating and power costs here are relatively low. And the lifestyle Tauranga has to offer is great,” says Andy Cameron, Managing Director, Oasis Engineering Ltd, and adds with a grin, “You just caught me coming out of a swim. Tauranga is the sort of city where you can do that.” The company’s beginnings can be traced back to Gisborne, though. “A gentleman called Tom Boyd worked in the maintenance division of Oasis Soft Drinks in the 1970s and 80s in Gisborne. Then Oasis was taken over by Coca Cola Amatil. The soft drink producer decided to change the bottling technology from reusable glass to disposable PET bottling and phase out the bottling plant maintenance division. Tom obtained some of the workshop equipment and decided to set up a new business in Tauranga. He intended to take advantage of the local forestry and dairy industry, the port and the proximity to Hamilton and Auckland, where he had some old customers,” says Andy. Tom came to Tauranga with two employees in 1983 and started machining precision parts for bottling lines. About that time New Zealand’s budding compressed natural gas programme encountered some technical difficulties. “No manufacturer in the world was able to produce small stainless steel valves that could handle the 3600 psi operating pressure necessary to fuel CNG cars and buses,” remembers Andy. “Tom was well known for his quality of workmanship and innovation capabilities, so Caltex chose him to develop a range of valves, check valves and couplings to be used in the new CNG fuel technology.” But rising gas prices and plummeting petrol prices drastically changed the outlook for the still young technology, and by the late 1980s New Zealand had largely abandoned compressed natural gas. “CNG became

Andy Cameron, Managing Director, Oasis Engineering Ltd.

economically unsustainable in New Zealand, and all the companies that had spearheaded the new CNG technology in NZ became exporters.” Oasis Engineering takes pride in being the world’s leading developer and manufacturer of flow control solutions for CNG. “There are about 22 million CNG-powered vehicles in the world. And approximately a quarter of them are filled up with equipment made by Oasis Engineering,” says Andy. “We consider ourselves the innovation leader in the market; people look to us and the technologies and products we have introduced are being adopted by our competitors quite quickly. We understand CNG applications, they are our tightest focus, and we can bring new products to market much faster than anybody else can.” The company runs intensive tests on their valves – and also on competitors' valves. “We have a complete simulation of a CNG filling station, where the valves are exposed to temperatures from -40°C up to 80°C and also to chemical ageing. We’ve yet to find a competitor valve that – exposed to the same testing conditions – lasts even a third as long as our products do.” Besides CNG, Oasis Engineering also supplies a lot of other highpressure gas applications such as helium, nitrogen and carbon dioxide and offers a range of valves for the NZ dairy industry. “Our main focus at the moment is improving the safety record and performance of CNG stations. We’ve got a new range of products

that can reduce filling times by 90 percent. This allows the large commercial trucks used in the US market to be filled up and returned to service quite quickly.” Andy, who used to live and work in West Africa, considers Tauranga to be a great place to bring up a family. “We always wanted to raise our children in the Bay of Plenty, and thought the environment here was ideal for them,” says Andy, and adds, “We give our employees a two-hour break at lunchtime on Wednesday, making room for activities such as going down to the beach for a swim or walking around the Mount. The idea is to improve health and well-being of our employees by using the environment here.” Tauranga’s environment also helps attract much needed expertise. “We’ve got a multinational workforce with staff coming from England, Kazakhstan, the Philippines, Brazil, Chile and Holland. Bringing them to Tauranga was easy; they were immediately attracted to the idea of shifting.” Andy is also very proud of the company’s apprenticeship scheme, but sees difficulties in retaining qualified young people. “Since I bought the business in 2003 we have trained 12 apprentices but we have only retained five of them; the others started higher-paying jobs overseas or went on to study engineering at a higher level. It is a nationwide issue, not one that only concerns Tauranga. I am convinced that the new university campus will change Tauranga’s complexion and make

• TAURANGA

The Altex Coatings team (left to right): Jen Divehall, Marketing Co-Ordinator, Paul O’Sullivan, Operations Manager, Mike O’Sullivan, Managing Director, Ricky Collins, Sales Manager Australasia.

a big difference to how people perceive local career opportunities and the potential to stay in the area.” Andy sees the company’s future path of growth in expanding in the Western Bay of Plenty. “We think it is an ideal location to attract experts to. We need them to look at new technologies in areas such as titanium applications, working with cryogenic fluids, new welding techniques and manufacturing new products for oil and gas exploration. The Titanium Industry Development Association and other high-tech enterprises will bring a lot of technology-driven jobs into this region. Our biggest impediment to growth is going to be shortage of manufacturing expertise, we need more engineers, certainly more machinists, and more people who can design products and are familiar with technology such as laser sintering and metal injection moulding.” One of the most important benefits of doing business in the Bay of Plenty is the supportive business community, says Andy. “You can approach Priority One, Export NZ Bay of Plenty, Food VIP, Food Bay of Plenty, Innovation Waikato, the Smart Business Network, the Icehouse programme… there is a vast number of networking opportunities. If you have a problem, there is peer-to-peer and mentoring capacity available. You receive world-class advice on how to build and grow your business. I have found that the network is especially strong amongst exporters. No matter what market you want to expand into, somebody has already been there

September 2012

and willingly provides you with assistance, contacts, advice and tips. It’s a wonderful community.”

Case study: Titanium Industry Development Association Inc. “TiDA is based in Tauranga because there are a number of individuals and companies here who are very forward thinking in terms of advancing titanium powder metallurgy and applying these new technologies to develop New Zealand’s manufacturing industry,” says Warwick Downing, Chief Executive of TiDA (Titanium Industry Development Association Inc.). “When it comes to innovation, Tauranga is a very eligible location, because its innovation scene is reasonably tight-knit; there is a lot going on, but it’s not hard to link into. And it was this cluster of people with vision, skills, knowledge and the desire to make it happen that ultimately allowed TiDA to get going.” Titanium has some very promising properties that make it quite interesting for a wide range of applications. “Titanium features the best weight-to-strength ratio of any of the metals,” explains Warwick, “It is about half the weight of stainless steel, and has about twice its strength. It is very corrosion-resistant; in many situations it’s about 100 times more corrosion-resistant than stainless steel. And the metal’s biocompatibility and non-toxicity make it ideal for medical applications such as implants.” The 22nd element of the periodic table also happens to be one of the most common elements in the earth’s surface.

Unfortunately the naturally-occurring form of titanium doesn’t have all those desirable properties. “The chemical process of turning titanium dioxide, which is a ceramic, into a metal used to be a very complex and expensive one. Things are changing in this area,” says Warwick, “but there is still another problem: a solid block of titanium is very tough to machine. That is why many people are putting the label ‘too difficult and too expensive’ on titanium applications. But that’s not necessarily the case.” TiDA’s answer to the titanium machining challenge was found in powder metallurgy. “We basically take titanium powder – either metal or ceramic – and consolidate it into solid parts, using technologies such as extrusion, laser sintering, injection moulding and 3D printing,” explains Warwick. Powder metallurgy also challenges the paradigm of traditional engineering, which can be described as ‘the more complex a part or structure, the more expensive it is to manufacture’. “Traditional engineering says that the manufacturing cost increases with every hole, cavity or spline you add to a structure. The possibilities facilitated by powder metallurgy turn this paradigm on its head. We now can proclaim that ‘the more complex the part is, the cheaper it is to produce. What is more, we can also create complex shapes that you couldn’t even think of manufacturing with traditional engineering processes,” says Warwick. You might think that something that has been created from powder can’t be very

• TAURANGA stable or durable. “That’s not the case,” says Warwick, “The powder consolidating process creates a very fine microstructure, one that is even finer than that of solid titanium. The consolidated part comes with an ultimate tensile strength (UTS) figure that in most cases equals or even outdoes the UTS figures you can achieve with a part machined out of solid metal. The textbook generally lists titanium UTS figures around 900MPa; the laser sintered parts we are getting come with figures between 1000 and 1200MPa, depending on what process we have used.” TiDA is an incorporated society, governed by a board and formed by a number of companies who had an interest in powder metallurgy. It is also supported by New Zealand Trade and Enterprise, the Ministry for Science and Innovation, and the Tertiary Education Commission. “Our ongoing research in metallurgy and manufacturing serves the sole goal of developing the industry in New Zealand,” says Warwick. “Powder metallurgy removes the big cost of machining titanium, creating the opportunity for applications in engineering and the marine industry to use it more frequently.

From a product design perspective, powder metallurgy opens the door for complexity. If you can imagine a complex structure, it can also be done. I think the future of manufacturing can be found in mass customisation. And with our technologies you can customise and individualise products very quickly and easily.” One of the driving forces behind TiDA is Ian Macrae, Managing Director of Page Macrae and also TiDA’s chairman. “In his vision, New Zealand takes advantage of the available raw materials and creates a hightech manufacturing industry. He and many others believe that our country can compete with any other country in the world – if we use cutting-edge technologies and new materials to conceive and design innovative products,” says Warwick. “But there are massive skill gaps that endanger this vision. The number of people in NZ with good product design skills and material science knowledge is very limited.” TiDa has teamed up with the Bay of Plenty Polytechnic to create a diploma course in metallurgy and provide those urgently needed skills. Warwick emphasises that this is the only

metallurgy course taught in NZ. TiDA has also formed a partnership with the Fraunhofer IFAM (institute for manufacturing technology and advanced materials) in Dresden/Germany. “It’s a very close relationship; we share information, ideas, teaching, and the head of the institute, Prof. Dr.-Ing. Bernd Kieback, has been here on various occasions to teach. And every year we are getting an intern from the German institute who is staying for six months.” Warwick reports that the last intern very much enjoyed learning to surf. “Prof. Kieback told us he was having no trouble convincing his students to come to Tauranga. It’s a very desirable place to come, and the city and its lifestyle certainly help attract and retain valuable skills. And Tauranga’s tertiary education opportunities make sure that our students are up to international standards.” According to Warwick , TiDa has developed a global reputation for being at the top end of powder metallurgy in titanium. “Next year we are hosting the world titanium powder conference, probably in November or December. TiDA wants to showcase the possibilities the future holds for this region,

• TAURANGA

Warwick Downing, Chief Executive of TiDA, in front of a Zeiss scanning electron microscope.

the businesses that can be developed, and the opportunities that can be brought into this region. We are enabling manufacturing companies to do things that just weren’t possible before. Titanium powder metallurgy fosters the design of complexity; product designs that couldn’t be realised before are now suddenly possible and affordable.”

Case study: Altex Coatings Ltd Altex Coatings’ success story kicked off in Tauranga in 1954. The company began producing and selling protective paints to local manufacturers and the marine industry. The business grew constantly, and in 1989 the Resene Group bought Altex Coatings. “We develop and produce heavy-duty protective coatings for new construction and maintenance, commercial and pleasure marine coatings and fire protection coatings,” says Mike O’Sullivan, Managing Director, Altex Coatings Ltd. “Our business is all about protecting steel in harsh environments. In the early years we only serviced local industries such as pulp and paper, power generation, the forest and the dairy industry, but meanwhile we supply almost every major industry sector nationwide and in Australia.” Altex Coatings is also constantly growing important export markets throughout the Southern Pacific, such as Samoa, American Samoa, Fiji, Mauritius, New Caledonia and Tahiti. “However, our operation in Tauranga is remaining our main service and distribution hub and also our research and development centre. This location provides easy access to our main markets in the Bay of Plenty, the Central Northern Island and

September 2012

the Taranaki region, and the port allows us to reach our export markets. What is more, the moderate cost of living and the relaxed lifestyle Tauranga has to offer help us attract new staff here, which is paramount to our future growth plans.” In 2009 Altex Coatings formed an alliance with Carboline Inc USA and became the exclusive manufacturer and distributor of Carboline coatings for New Zealand, Australia and the Southern Pacific. “Altex Coatings lost a 30-year licence with an US company that had been taken over by a competitor. We could have stayed a locally operating company, developing our own products, and missing out on a lot of growth opportunities. But we wanted to grow, and to do that we needed a global brand. So we teamed up with Carboline, an organisation with operations in over 90 countries and an extensive global service network,” says Mike. “The alliance with Carboline has brought us new innovative products such as pipe lining coatings, containment coatings, and extremely resistant coatings for chemical applications, and we now have opportunities in the global market we’ve never had before. To be successful in our industry you need local presence and locally-developed technology, but you also need international representation and a globally-known brand. The alliance with Carboline works very well for us.” Altex Coatings develop their own coating solutions and also run an extensive testing programme to simulate the effects sunlight, rain and condensed surface moisture have on various coatings. Some additional effort

goes into the localisation of products supplied by Carboline. “When we are receiving the global formulation of a coating system from Carboline, we have to localise it before we can service our local markets,” says Mike. “Sometimes the formula requires raw materials that are just not available in this part of the world, so we need to substitute them. Fortunately that doesn’t happen very often. Localisation also encompasses making sure we are able to manufacture the products in our plant. Carboline normally produces huge batch sizes, so we have to know how to reproduce them locally on a much smaller scale. We also have to get to understand the products, what it is that makes them tick, and how they fit in with the rest of our product range.” Ricky Collins, Sales Manager Australasia, says the market for protective coatings in New Zealand is very mature. “We have some new products and developments we are bringing to the NZ market to help us grow, but the Australian market offers far better growth opportunities to us. However, there is one thing that holds us back at this stage, and that is a severe lack of qualified staff. It’s an ongoing battle to get people into our industry and to fill vacant positions in our company.” Altex Coatings has just recruited a sales person from South Africa. “We have been advertising this sales position for about nine months, but couldn’t find a suitable person in NZ,” says Paul O’Sullivan, Operations Manager, “And we also have some problems filling basic operational roles such as paint makers, canners, and storemen.” Another battlefield is retaining qualified staff. “There is quite a gap between the type of people we want to attract and the average salary levels in the Bay of Plenty. We pay our staff quite well, but we are definitely unable to meet the top salary levels paid in Australia,” says Paul. “But being in Tauranga helps us attract and retain people; especially the younger guys appreciate the lifestyle here.” According to Mike, it is almost a secret that Tauranga has a lot of business opportunities to offer. “Tauranga has a reputation for being a really nice place to live when you’re retired, and for being an interesting holiday destination, but do you want to do business here? A lot of people don’t think it to be a career opportunity to go to Tauranga. But the truth is that the Western Bay of Plenty boasts a lot of vibrant industrial companies, an active business community and lots of career opportunities.”

• HEAT EXCHANGERS

Water instead of air The industry trend toward higher cooling output requirements has intensified during the past few years. Water cooling, which is already established in IT applications, is increasingly seen as important by mechanical engineers and plant engineers. Rittal is therefore expanding its portfolio of air/water heat exchanger solutions: The LCP (Liquid Cooling Package) technology already established in server enclosures is now also available with an output of 10 kW

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FINTUBE AND HEAT EXCHANGER MANUFACTURERS

Air heater for drier in dairy company powder plant

Advance Boiler Services NZ Ltd are suppliers of fin tube and fin tube heat exchangers throughout Australia and New Zealand. Predominately we are a service provider for the supply, install and service of boilers but expanded our services to heat exchangers for improving energy efficiency of boilers. Introducing the manufacture of fin tube into our business has also allowed us to supply fin tube to

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other service providers like Tasocs Australia. We also manufacture heat exchangers that are used in the Timber Industry, Dairy Industry, Food Industry and Petrochemical Industry. With our McElroy No. 4 finning machine, using Aluminium fin, we can produce wrap on (‘L’) heater for heating air in and grooved (‘G’) fin on Oil timber processing plant stainless steel, carbon steel and copper tubes. Most industries require either 10 or 11 fins per inch but we have also supplied 13 fins per inch ‘G’ fin. (‘L’) fin can be used up to a maximum of 150 degrees C, and (‘G’) fin up to a maximum of 450 degrees C. As an alternative we can also produce a tension wound (‘T’) fin using stainless steel or carbon steel fin. We also produce elements with up to 180 degree bends, reducing the amount of welding required. Advance Boiler Services staff includes qualified ASME IX welders, machinist, and trained staff capable of all aspects of the manufacture of fin tube and heat exchangers. Our heat exchanger designs are either to AS1210, AS1228 and PD5500. With quality constancy in our product added to a favourable exchange rate many industries are turning to ABS for their fintube requirements. Oil cooler for gas turbine

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September 2012

– optionally scalable up to 20 kW – for industrial applications in mechanical and plant engineering. The Rittal LCP technology, which has been tried and tested for years, is now also available for use in mechanical and plant engineering for the first time. Due to a complete separation of the water circuit and electronic components in the enclosure, the air/water heat exchanger gives maximum protection against water. The Rittal TS 8 enclosure serves as the basis for the LCP Industry. Air routing in the industrial LCP is adapted to the requirements of enclosure climate control. Since the cold air has to be routed to the bottom of the enclosure, right in front of the mounting plate, the warm air is taken in from the top and blown out cold at the bottom. In the enclosure, a typical control temperature of 35° Celsius must be maintained. Two high-power blowers provide for very good air circulation. The TS 8 TopTherm Chiller combined with the product solutions for door, base and roof heat exchangers offers customers an integrated complete solution based on water-cooled systems. Go to www. demm.co.nz/enquiry quote: D120916

•

Coming up in the October issue SEnergy efficiency SThermal imaging SIndustrial coatings SFiltration STest & measurement SNational Maintenance Engineering Conference & Expo Previews Deadline editorial 7 September Deadline advertising 14 September

• HEAT EXCHANGERS

Performance in good hands Aurora adds market leading Alfa Laval Plate Heat Transfer technology to their range. “We are pleased to announce our latest success in increasing our heat transfer range with Alfa Laval Plate Heat Exchangers now onboard. This gives us the ability to provide ultimate solutions for our clients’ wide range of heat transfer needs.” – Mike Goddin, Director of Aurora Process Equipment. Mike says, “This is a great step forward for Aurora and Alfa Laval with the combination of increased service and support along with technical and industry knowledge will ensure the best solution will be provided along with fully qualified and dedicated backup service

and support all the way.” Aurora Heat Transfer can provide you with: • Full range of Alfa Laval Plate Heat Exchangers including gasketed, brazed, semi welded and fusion bonded to suit any application and achieve optimum efficiencies. • Modular Tubular Heat Exchangers including tube-in-tube, shell and tube and multi-annular • Outstanding service and quick response times for minimal downtime. • Skid-mounted systems including pumps, valves, controls, tanks, etc. for complete systems.

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• Customised solutions for greater flexibility • In-house selection and design capacity for faster turnaround and lead times. Go to www.demm.co.nz/enquiry quote: D120917

•

Planetary DC motor gearheads The GP 26A closes the gap which previously existed between the 22 and 32 diameters in the range of power-optimised gearheads. The GP 26A offers all of the advantages of the maxon motor gearheads, including modularity, precision and power. Particularly significant improvements over the previous generation are the higher permissible loads. The following features in particular are

responsible for the power increase: the integration of a robust, preloaded ball bearing, optimised gearhead geometry, the high permissible motor speed, and the optimised dimensions of the output shaft. This gearhead is part of the modular system and is available as one-stage to three-stage versions, with a total of nine different reduction ratios, from 5.2:1 up to 236:1. The maximum continuous torque of the one-stage version is 0.75 Nm and of the three-stage version is 4.5 Nm. The short-term torques are 1.1 Nm and 6.2 Nm respectively. Thanks

• PRODUCT WATCH to preloaded ball bearings, the tempered, rust-free output shaft has no axial play. Within the renowned maxon motor modular system, the new GP 26A gearhead can be combined with five different DC motor types. For the control functions, various one - and four -quadrant controllers as well as positioning controllers are available. Applications fields include engineered robotics devices to battery-operated tools, from medical technology to industrial automation. Go to www.demm.co.nz/ enquiry quote: D120917a

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• Waste Water Treatment

New water purification technology uses current to clean water A new water purification technology which removes contaminants in water while simultaneously disinfecting it against microbial contamination has been developed by the University of Waikato with the support of WaikatoLink, the University’s commercialisation company. The new electrochemical PEFT Cell technology which applies a low voltage current to contaminated water to remove contaminants is being developed for residential, commercial, horticultural and agricultural use. The PEFT (perforated electric flow through) cell works by applying a low-voltage current to contaminated water that is forced through a novel perforated electrode system. Contaminants such as iron, manganese, arsenic and microorganisms are subsequently removed by a combination of oxidation, coagulation and precipitation. This is brought about by the generation of chlorine from naturally occurring chloride ions present in water and the high electric fields produced by the cell. Jessica King, Commercial Manager at WaikatoLink, says the technology has a number of advantages over some existing solutions which can be bulky, expensive and maintenance-heavy. “While other electrochemical systems can provide chlorine on demand for water treatment purposes, they operate as offline devices using concentrated brine solutions and require specialised metering devices. Our system also minimizes the risk of harmful byproducts forming that can result from standard chlorination. This is due to the synergy between the high electric fields and the electrochemically produced chlorine which achieves markedly increased specific toxicity of the chlorine.” The technology draws on ten years of academic research at University of Waikato’s Chemistry and Engineering Departments under the direction of Associate Professor Alan Langdon and more recently through the doctoral research of Dr Hilary Nath. KiwiNet has supported the project with a $92,500 PreSeed investment, from their PreSeed Accelerator Fund (PSAF) from the Ministry of Science and Innovation, to take the initial lab-scale proof of concept to a working prototype to demonstrate the

September 2012

University of Waikato researchers Dr Hilary Nath (left) and Associate Professor Alan Langdon with their PEFT cell.

potential. WaikatoLink has matched this with a further investment of $92,500. Founding KiwiNet members include WaikatoLink, Plant & Food Research, Otago Innovation Ltd, Lincoln University,

AUT Enterprises, AgResearch, University of Canterbury, Industrial Research Ltd and Viclink. Support is also provided by the Ministry of Science and Innovation. Go to www.demm.co.nz/enquiry quote: D120918

•

Small tank nozzle mixing system Pump Systems Ltd is the Authorised Distributor for Vaughan Rotamix which is a highly-engineered mixing solution designed for critical high capacity processes, such as in municipal anaerobic digesters, sludge blending tanks, etc. The success of Rotamix is built upon 50+ years of experience in the wastewater and solids pumping industry, and through smart integration of the world’s first and most respected chopper pump – the Vaughan Chopper Pump, as manufactured by Vaughan Co., Inc., USA. Development of the local market of Rotamix by Pump Systems has called for a requirement to adapt the system to fulfill need at the lower end – lower end meaning 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 is now offering its customers a tailored, cost-effective pump and nozzle mixing system package 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 chopper 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-mounted Vaughan mixing chopper pump means that any solids such as rag, fibrous material, and plastics etc, are continuously broken down and preconditioned, further producing a homogenous slurry. 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

• WASTE WATER TREATMENT

cylindrical tanks from as small as three metres up to around 12 metres 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 for cost-effective and hassle-free servicing. There are no moving or rotating parts within the process itself, therefore no requirement for platforms, hoists etc, as would be required with most traditional mixing apparatus - i.e. submersible propeller mixers. 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. Cost-effective, easy to install, and extremely reliable, small tank mixing systems from Pump Systems are suitable for a wide range of applications found in most municipal or industrial wastewater treatment plants. Typical examples include sludge and/or process waste storage tanks, waste reception and digester feed tanks, blending tanks, flow balance tanks, etc. Materials of construction are flexible to cater for an extensive range of fluids including municipal sewage and sludge, mining and chemical industry wastewater, as well as food processing wastes such as vegetable, meat, fish and poultry industry wastewater, to name a few. Go to www. demm.co.nz/enquiry quote: D120919

World-class wastewater separation + dewatering technology. Läckeby Products A DIVISION OF LÄCKEBY WATER GROUP AB.

•

One unit fits all

Bürkert´s new multi-parameter controller mxControl 8620 is designed to automate the control of process variables within a water treatment system and reduce controller and instrument costs by as much as half. The 8620 integrates all control, monitoring and display features as well as data and event logging functions into one compact unit. The 8620 is ideal for primary water treatment processes, or ancillary processes in manufacturing, mining, and general industry. The mxControl 8620 is the first modular control system designed for seamless integration into countless chemical or skid control applications. The controller is easily configured to display, transmit and record flow, pressure, pH/ORP, conductivity, turbidity, O2, O3, Cl2, level and temperature. It accepts standard 4-20mA inputs from the field instruments and provides high level computations to

optimise the water treatment process. The compact unit is designed for use in water treatment, cooling towers, RO applications and boiler systems. The mxControl system is capable of processing up to four analogue, two RTD, eight digital inputs as well as five relays, four digital transistor outputs and four optional analogue outputs – totalling 23 I/O – simultaneously (model dependent). Sophisticated electronics and control algorithms ensure optimum process control is maintained with minimal operator intervention. Parameters are loaded by SD card or from a standard PC via the USB interface. An optional Ethernet interface can be used to configure and parameterise the controller remotely or be used to send email or SMS alerts in the event of an alarm situation. The standard SD card interface simplifies the controller’s parameterisation and application selection process. The user can freely select and download the software modules to suit the process. And the flexibility and ease of data transfer of the 8620 are said to be unique. All important variables and parameters may be raised via five soft-touch keys, with the operator able to grant varied access via the built in security system. The mxControl 8620 provides the continuous online monitoring and process control required to achieve the highest degree of precision, improved reliability and QA reporting in today’s demanding water treatment systems. Go to www.demm.co.nz/enquiry quote:

•

THE MOST EFFICIENT DRUM SCREEN ON THE MARKET

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SLUDGE DEWATERING TO OVER 50% DRY SOLIDS CONTENT

Läckeby WSP Wash Screw Presses • • • • • • •

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D120919a

• WASTE WATER TREATMENT

Christchurch bound pumps Mouvex Eccentric to help with the clean-up Disc Pumps Most of us are aware that there is a diverse range of construction products required to help with the Christchurch recovery programme. HireQuip have been active in this area, and by investing in the right equipment, their products are making a big difference to the overall reconstruction work currently being undertaken. One of the major products sought after is pumping equipment. With the assistance of New Zealand distributor Youngman Richardson & Co Ltd, several new Towerlight branded MVSS-340 series 6" vacuum-assisted (150mm) silenced pumps have been recently purchased by HireQuip and sent directly to Christchurch and put to work where they are needed most. The Towerlight Pumps are a relatively new product to New Zealand and although they have models with outlets ranging from 4" to 12", the preferred 6" model which can handle solids up 75mm was deemed the most practical for the jobs to be undertaken in the areas affected around the city. The Towerlight dry vacuum self-priming 6" pump features oil-lubricated silicon and tungsten carbide seals together with a twin-blade anti-cavitation impeller. The Towerlight 6" model is encased in high resistance aluminium, weighs 1250kg and is a compact unit at 2300mm long x 1000mm wide x 1300 high. The Towerlight has an adjustable and replaceable front wear plate and the long-run fuel tanks are fully bunded to protect against oil spills. The Towerlight dry vac pumps are powered by a Perkins 404C-22G diesel engine and housed in a noise-reducing canopy, with operating sound levels recorded at 65 decibels at seven metres. Go to www.demm.co.nz/enquiry quote: D120920

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Mouvex Eccentric Disc Pumps, supplied by Nu-Way Energy NZ, are self-priming, with clean-in-place capability, and low shear for sensitive liquids. Mouvex pumps are used for pumping of sheer sensitive, thick liquids or food products with entrained solids, glucose pumping, wine filtration, bottling and packaging and much more. The main features of eccentric disc pumps are: • Seal-less design that provides leak free transfer of product. • CIP & SIP Capability - Clean and flush C-series pumps without disassembling. • Ability to pump low and high viscous products; • Low shear and run dry capability. • Design specially made for the Hygienic markets with EHEDG and 3A certifications. • Low impact wear parts for industry leading mean time between repair (MTBR). Go to www.demm.co.nz/enquiry quote: D120920a

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Hydraulic power you can trust

Ph: (09) 636 2264 Fax: (09) 636 2265 www.hytoolsnz.co.nz 20

September 2012

• WASTE WATER TREATMENT

UV-disinfection on the rise Wedeco Spektron 250e

A BBC Research of 2011 states, “The global market for ultraviolet (UV) light disinfection equipment is estimated to be worth $885 million in 2011, and is expected to grow at a compound annual growth rate of 12.7 percent during the next five years. At this rate, the overall market worth will reach $1.6 billion in 2016.” Operators of drinking water and wastewater systems are facing the following challenges: • To eliminate pathogenic microorganisms such as Legionella and Cryptosporidium, which cause pneumonia or intestinal diseases. • Minimize the by-products that result from chlorination such as trihalomethane (THM) and halogenated acetic acids (HAA), which are suspected to cause health problems. • Cost-effective and energy-efficient treatment solutions to minimise power consumption and reduce carbon emission. UV technology is more and more considered as an alternative to chemical disinfection in Australia and worldwide. A German newspaper stated in February, “UV accounts for 30 percent of the disinfection techniques for drinking water. 50 percent is chlorination and 20 percent by other chemicals. Experts

believe that the ratio will switch in the near future in favour of UV systems.” In view of these challenges, UV equipment manufacturers are proposing a number of new technologies. One of the leaders servicing Australia for more than 40 years is Wedeco (Xylem Water solutions Australia). Wedeco’s newest innovation is the introduction of the Ecoray technology. This technology features optimally matched UV lamps and ballasts to guarantee high energy efficiency and a 20 percent increase in lamp lifetime. Since their introduction on the market, the biodosimetrically certified UV-systems of the LBX-e and Spektron-e series meet all the requirements of water disinfection standards and are installed in many applications in drinking and water-reuse facilities. Innovative features of the Ecoray lamps are a long-lasting coating, a gas and amalgam mixture containing 80 percent less mercury compared to conventional UV-lamps. Dr Sven Kaemmerer, Head of UVtechnology in the Xylem R&D department states, “UV lamps are often used dimmed during their lifetime to save power. The Ecoray products have been designed to maximise power

savings at typical operation conditions.” In addition to the energy efficiency, the hydraulic conditions also influence the performance of a UVsystem. Today computational fluid dynamics (CFD) allows for optimising the performances of UV systems. Wedeco have developed a ‘flow diverter’ under the name ‘OptiCone’. This ‘funnel’ creates a constant speed profile over the cross-section when water enters. Such an optimised hydraulic profile

is a prerequisite for the UV reactor’s high efficiency. Even under the worst inlet conditions such as a 90° bend at the inlet of the UV-system, a uniform velocity profile is maintained due to the ‘OptiCone’ flow diverter. The market for UV-systems is growing rapidly. This rising demand drives manufacturers to develop more sophisticated and innovative systems. Through efficient lamp and ballast technologies and improved hydraulic profiles, UV systems can be optimised in terms of energy efficiency, reduced operating costs and higher disinfection rates. Article supplied by Xylem Water Solutions. Go to www.demm.co.nz/enquiry quote:

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D120921

MAKING MODERN LIVING POSSIBLE

APP & PAHT High pressure pumps for the RO and UPW market

PAHT pumps APP pumps

Dedicated high pressure pumps for seawater RO- and ultra pure water applications: • Market-leading efficiency up to 97% • Small, compact and light design • Ultra-low maintenance Upon request pumps can be delivered according to API 674 and ATEX. www.nhanceenergy.com Phone: 07-8538903 Fax: 07-8538904

www.danfoss.high-pressurepumps.com

•PUMPS AND VALVES

New flexible rising main The Aquaplus Flexible Rising Main from Malcom Thompson Pumps is available in lengths of 200m+ and offers the added convenience of extensive stock holdings. Manufactured in Europe, the Aquaplus Flexible Rising Main has undergone rigorous testing and is backed by a fiveyear warranty. It is constructed from quality materials including polyurethane, with a polyester textile internal reinforcement, these materials offering resistance to high temperatures and acid water. It provides six main advantages: • Corrosion resistance. • Reduced vibration and noise. • Energy saving. • Self-supporting layflat riser.

• Suitable for irregular wells. • Permits higher water flow in narrow wells. The Series 25 is suitable for highpressure pumps. It is also appropriate for

Compact valve and modular block assembly solution

Bürkert has released a modular valve and block package designed to make systems quickly and easily. The Inox solution incorporates an all-stainless-steel pneumatically-actuated valve, and standard block modules with eight standard port channels. The ports are drilled open in accordance with block channel design, bolted together, and valves screwed in to complete the block system. Strainers, check valves, and sensors are easily included in block construction. Inox block systems support media to 180°C, 16 bar and 600mm2/s viscosity, and has high chemical resistance for process media including water, alcohols, oils, fuels, hydraulic fluids, salt solutions, alkali solutions, organic solvents, steam, air and more. System configuration eliminates the use of elbows

September 2012

and t-adapters, and reduces connections to a minimum, to avoid leaks and deliver high overall system performance relative to traditional block solutions. Small footprint, flexible configuration, and fast assembly make Inox systems ideal for manufactured blocks including temperature systems for injection moulding or die-casting tools, chemical dispensing in water or mineral processing, steam sterilisation systems, and any solution where high system capability and environmental integrity is necessary. Distributing, collecting and mixing systems with individual valve flow of up to 2.4m3/h are suited to Inox. Individual Inox valves are built for maximum integrity, based on Bürkert’s proven valve record. The cast 316L stainless steel body has integrated, self-adjusting packing glands to ensure high media tightness over the complete service life. The externally piloted valves have a compact design, and are available with threaded, external threaded and welding connection ports. Valves may be normally open or closed, with flow direction below the seat. Inox valves, block modules, bushing and other elements are cast 316L stainless steel, with PTFE valve seals and graphite gaskets. Go to www. demm.co.nz/enquiry quote: D120922a

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potable water and meets the requirements of Certification NSF 61 and WRAS. The ease of handling reduces the time and cost involved when installing submersible pumps, whilst providing low maintenance and a long service life. Additionally, Malcolm Thompson Pumps can provide complete borehole packages, which include borehole pumps and head works. The Series 10, which is suitable for low-pressure pumps, boasts similar features and applications as the Series 25. They are ideal for a number of applications in the agricultural and mining industries including obtaining underground water, Go to water monitoring and dewatering. www.demm.co.nz/enquiry quote: D120922

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PumpMeter keeps an eye on everything KSB New Zealand has introduced a pump monitoring unit, called PumpMeter, to its extensive range of products. It comprises pressure sensors, as well as an analysing and display unit attached to the pump, measuring suction pressure, discharge pressure, differential pressure and head. The measured and calculated values are shown alternately on the display. A typical pump curve graph illustrates in which range the pump is currently operating, showing at a glance if the pump is providing efficient and cost-saving operation or its availability is jeopardised. In addition, PumpMeter continuously analyses the pump operating data, establishes a load profile while calculating the energy saving potential of using a variable speed system. The new unit also simplifies commissioning of both the pump and the retrofitted variable speed system, since the pump’s operating parameters are continuously displayed. The data collected can also be made available to a central process control system via standardised interfaces. Go to www.demm.co.nz/ enquiry quote: D120922b

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We’re To tal Fa ns

s for all our “Total Oil supplies all our lubricant dling equipment, machines, mainly container han ek. running 24 hours, 7 days a we al Oil has come out They have never let us down. Tot and service.” on top because of their reliability

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kshop Foreman Bob Lloyd – Port of Napier, Wor – Total Customer since 2003

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

• PUMPS AND VALVES

Topaz Industro Float Valve 360 degree angle sensor for rotary actuators

Up until a few years, ago Jobe valves were mainly used in farm water tanks and troughs, but with their ongoing product development, Jobe has found niches in many types of light industrial applications such, as a quick-refill valve for the systems they produce ranging from evaporative cooling systems to car washes and spray pump equipment. With the demand increasing for a valve that can withstand higher water temperatures, Jobe trialed new materials to be used to manufacture their popular Topaz Trough Valve that could withstand more extremes than the current ABS material used for cold water applications. With all the materials available, the most suitable for the new Topaz Industro Float Valve housing was found to be Grivory HT. This material is 50 percent glass fibre reinforced and gives good performance at high temperatures providing parts which are stronger and have better heat distortion stability and chemical resistance. The Grivory HT FWA also has approvals that meet NSF standards for contact with foodstuffs and drinking water. All other seals and parts used are of a non-corrosive construction and greater tensile strength to endure in hot water conditions. The float valve is ideal for all applications requiring a valve with high mechanical strength and heat resistance such as industrial storage tanks and heated water cisterns. Some typical applications would be refilling cooling towers and storage tanks, high pressure cleaning and car wash systems as well as many light industrial, air conditioning and irrigation installations. Go to www.demm.co.nz/enquiry quote: D120924

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With the new RI-DSU35 device series, Turck’s inductive resonant circuit measuring principle is being implemented for the first time in a dual sensor design for analog angle measuring on rotary actuators and valves. The automation specialist is thus also offering its interferenceimmune angle measuring principle for the optimized detection of valve and flap positions. Unlike with the conventional dual sensor, the user can select the switch points as required from the entire rotation range from 0 to 360 degrees. This eliminates the need for any time consuming setting and readjustment of the actuating element. Turck is planning to offer the series with an output signal from 0…10 V or 4…20 mA from the fourth quarter. Intrinsically safe devices with a 4...20 mA output signal are planned for explosion hazardous areas up to zones 1 and 21. The process connection on all modules is implemented via an easily accessible terminal chamber or standard M12x1 male connector. Turck’s RI sensors do not detect angle positions with a magnetic positioning element, but by means of an inductive resonance coupling circuit. This makes the sensor absolutely immune to magnetic fields, such as those generated by large motors. Due to their robust design, sealing and high degree of protection, the sensors are also able to supply precise signals over long operating periods. Go to www.demm.co.nz/enquiry quote: D120924a

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edwardc@wmbpumps.com.au Ph: 09 273 3166 24

September 2012

• WELDing

The Miller Pipeworx pipe welding machine The Miller Pipeworx 400 from Weldwell NZ is a multi-process machine designed specifically to weld pipe. It provides high-quality welds on carbon or stainless steel pipes with increased productivity. Using the specially-modified MIG processes of RMD (Regulated Metal Deposition) for the root run and Pro- Pulse for the fill and cap welds, it is possible to produce full penetration x-ray quality pipe welds in a fraction of the time it would normally take to complete the same weld using TIG and stick. Welding can be performed in any fixed position or with the pipe rotated. All welding for the complete pipe joint can be performed with one wire and one shielding gas. There is no need to change wire type, size or gas. The machine is very simple to set up and to select the welding process, which is all done from the front panel. There is no need to change cables or hoses or change polarity. The machine automatically adapts to provide the correct conditions for the chosen process. In RMD and Pro-pulse the arc length is set by the operator and this value is maintained regardless of the contact tip to work distance. This is possible because all the arc conditions are monitored many thousands of times per second. This results in very controlled and controllable arcs. The welding technique is not difficult to learn. A competent welder should be able to produce quality welds within a matter of

Optrel Galaxy Welding Helmet with hard hat adaptor

hours. A trainee welder should be able to learn the technique within a few days. The machine stores the last used parameters in memory for each welding process and all parameters can be stored to a memory card for future recall. Accu-Power is the instantaneous output power while weldingused for calculating heat input during welding. Enter the output power display value into a simple equation to calculate the heat input for a particular weld operation. The Accu-Power function can be turned on or off with use of a memory card. Range Lock Card (Option). Parameters can be locked or have limited adjustment, to prevent unauthorised tampering during procedure welding or other critical work. When welding stainless steel pipe, dependent upon the application, it may be possible to qualify a weld without back purging the pipe. This is because the RMD root run is so stable and controlled that minimal oxidation occurs on the penetration bead and the joint edges inside the pipe. The degree of oxidation is acceptable for many applications. The Miller Pipeworx 400 is supplied with either a single or a dual wire feeder, cable kit, Pipeworx MIG gun(s), Memory card, Gas regulator, Drive roll kit(s), four-wheel trolley and bottle rack with cable hangers to reduce clutter. Go to www.demm.co.nz/enquiry quote: D120925

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VIKING NEW ZEALANDS MOST COMPREHENSIVE RANGE OF DUST EXTRACTION AND SPRAY BOOTH SYSTEMS.

SPRAY BOOTHS • Kit set open face booths • Auto spray lines • Heated spray and bake booths • Heated drying rooms • Paint work stations

Give welding workers peace of mind with the Galaxy High Impact Welding Helmet by Optrel from Honeywell. It features a passive shade 10 welding filter and replaceable high impact lens cover for even greater protection when electric arc welding, electrode welding and even grinding. It is the only passive flip-front, high-impact approved welding helmet on the market, and it has been rigorously tested to Australian Standards and approved by SAI Global. The helmet is also available with a hard hat adaptor to suit PA620V and MSA V-Guard Elite hard hats which provides maximum protection for the head without the need to switch helmets and hardhats, plus maximum wearer comfort, making it ideal for use at construction sites. Go to www.demm.co.nz/enquiry quote: D120925a

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DUST EXTRACTION • Reverse pulse bag filters • Camfil Gold series collectors • Cyclones and static filters • Fans and rotary valves • Design build, project management • Sheet metal and general engineering

• V-Duct modular ducting • Welding and fume extraction T: (09) 835 4090 F: (09) 835 4070

www.vikingltd.co.nz

• WELDing

Weco Discovery Inverter Keyhole TIG welding demo plant

The Weco Discovery 161T is an advanced single phase Inverter Power Source for TIG DC and MMA welding with excellent arc characteristics. The Weco 161T is a direct replacement for the popular 151T heralded by many professionals as the best performing compact DC TIG welder available. • Due to its light weight and tough construction it is ideal for both workshop and field use. • A user friendly digital interface allows precise parameter settings and the HF control provides 100 percent rapid and precise arc ignition. • The TIG DC functions include Pre Gas, Post Gas, Up Slope, Down Slope, Final Current, Slow to Fast Frequency Pulse (step variation 0.5÷250Hz) controls, and 2T/4T trigger control. • For MMA welding a factory optimized Hot Start, Arc Force and Anti Sticking facilitates welding with up to 3.25mm diameter electrodes. Duty cycle (40°C): 100% @ 100 amps. Power source weight (KG) 5.4. Weco welding machines are designed and built entirely in Italy and are imported exclusively into New Zealand by Multi-Mig (NZ). Go to www.demm.co.nz/enquiry quote: D120926

Australian welding innovator Keyhole TIG (K-TIG) Limited has launched a $150,000 demonstration plant that displays the speed, precision and cost-effectiveness of its world-leading Keyhole TIG welding technology. The system comprises a welding torch, the controller unit, under floor power supply and a rig that can hold and rotate large pipes while they are welded. Located at its Salisbury head office, the working system demonstrates to customers, prospects and potential how Keyhole TIG (Tungsten Inert Gas) welding can achieve in minutes welds that traditionally take hours. Listed on the Australian Small Scale Offerings Board last year, K-TIG Ltd is commercialising its patent-protected welding technology, which was originally developed by CSIRO. K-TIG welding can weld thick gauge materials, such as stainless steel and titanium, in one-tenth of the time possible with standard TIG welding. K-TIG CEO Gordon Kay said the new plant demonstrated how achievable the benefits of K-TIG welding were. “With this, we can do a weld in three minutes that would normally take as long as six hours, as well as the demo plant, we’re also about to launch a series of videos that show how companies can achieve required welds”. Go to www.demm.co.nz/enquiry quote: D120926a

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Joints on the outside a ‘winner’ for Fume Arms!

Health and Safety of the workforce is high priority to ‘sealing’ solution provider EagleBurgmann in Albany, and the purchase of a stainless steel Fume Arm from New Zealand Duct&Flex has provided an excellent solution to the specialist room where the carbon seal faces are manufactured. The specialist work room at EagleBurgmann is clean because

their new Fume Arm can easily be pulled and re-positioned very close to the workers tool area, when previously a ‘fixed’ arm they used did not capture the dust as efficiently. Richard Elliott, EagleBurgmann Operations Manager, chose a Stainless Fume Arm knowing it’s an easy surface to keep clean as well as being a durable surface for his situation. Carbon dust is

September 2012

problematic, not only due to its abrasiveness, but because of the additional effort required to keep the work areas clean of the very fine light carbon dust. Geoff Ebdon, General Manager from New Zealand Duct&Flex, says the Fume Arms have been a big success with more sales than expected being stainless models going to pharmaceutical companies or companies dealing with food dust issues such as milk powder. “Other Fume Arms have the hinges on the inside and can become difficult to use, due to the dust jamming up the hinge mechanisms.” Cheaper Fume Arm models often comprise piece of flex with a cone on the end and all the hinges are on the inside. With these internal components are difficult to clean, and become coated and abraded by the particles being sucked up the

Fume Arm. External Joints allow a much smoother more efficient air flow and are a very economical, versatile and durable method of capturing impurities. New Zealand Duct&Flex offer a complete range of quality European made duct arms with articulation on the outside of the tubes, in more diameters and lengths at competitive price points (The smaller arms list at $499). Each Fume Arm comes complete with the separate wall mounting bracket. There is a wide range of extending boom arms to give even greater reach and telescopic arms. For specialist applications, the Fume Arms can fitted with US FDA or EU Approved Food Grade Flexible connections, High Temperature (300°C) or Antistatic Flex from existing New Zealand Duct & Flex stock. Go to www.demm. co.nz/enquiry quote: D120926b

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• MAINTENANCE MATTERS

Simplifying predictive maintenance on three-phase equipment

Absolutely anything you need for Dust and Fume Extraction New Zealand

Traditional techniques for predictive maintenance have relied on observing trends on a number of key measurements. Artesis MCM takes a completely different approach based on using a mathematical model to assess the equipment being monitored by measuring voltage and current. The technology offers a number of very significant benefits including: • Simple to install and configure. • Suitable for fixed or variable speed applications. • Suitable for high or low voltage. • Easily linked to the software package using network or wireless devices. • Simple connection. Once the system has been installed, the users have very little to do other than respond to information being provided to them by the system. Such information can be communicated as local ‘traffic lights’ on the unit, control system inputs, computer displays or emails. During initial ‘learn mode’, real-time data is acquired from the physical equipment before applying advanced,

DUCT & FLEX Flex

In-stock for overnight delivery system identification algorithms to calculate a set of model parameters. The ‘learned’ model represents the normal operating condition of the motor and its driven system. This model-based approach effectively allows the three-phase motor to act as an advanced condition monitoring sensor which is not confused by pre-existing faults in the equipment. It is able to provide concise information about developing faults, recommended actions, and the probable time to failure. Artesis MCM can be used across a wide variety of sectors including the chemical, petrochemical, pulp and paper, water utilities, cement, food and beverage, automotive, textile and maritime industries. Go to www.demm.co.nz/enquiry quote:

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Modular Duct

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

D120927

• MAINTENANCE MATTERS

Implementing operator based maintenance A sawmill near Blenheim has found that a new programme on operator-based maintenance has changed the workplace culture. Chris Lambert, manager of the sawmill, said, “We’ve now got a more organised workplace with a daily cleaning routine in place and pre-start checks being carried out by operators. Equally importantly though, the operators have greater knowledge of their equipment and we now have the start of a new culture with operators taking greater pride and ownership of their equipment. We are seeing few stoppages which has the added benefit of uninterrupted workflow for the operators.” The Kaituna Mill site is situated 20 kilometres west of Blenheim and part of Nelson Forests, a well-established, high quality, forest estate located in the Nelson and Marlborough regions of New Zealand’s South Island. Kaituna Mill has an ongoing commitment to training and won the Forestry ITO’s (FITEC) Outstanding Business Performance through People Development award in 2009 after taking the runners up slot in 2008. This year two apprentices from Kaituna Mill were in the finals of the FITEC apprenticeship awards. Izaac Filipov for the Sawmill Modern Apprentice of the Year and Jamie Howieson for the Saw Doctor Apprentice of the Year. When asked why the leadership team decided to go down the route of operator

ARE YOUR STAFF NOT ‘GETTING’ IT? IS MAINTENANCE MANAGEMENT OR HEALTH AND SAFETY GIVING YOU A HEADACHE? Unlock your staff’s potential with either of our inspiring and informative short course training sessions: •Maintenance Management Basic Training or •Health and Safety Made Simple From only $220 + GST per person check our website for details and session dates

September 2012

based maintenance, Chris explained, “The driving force was the upgrade to the sorting and stacking processes. Going from what was predominately a manual operation to one that is now fully automated meant we could increase production and of course to sustain that, we need greater reliability from the upstream processes. TPM and operator-based maintenance has the benefits of giving the operators greater ownership of their equipment and frees up maintenance from some of the daily tasks to implement more predictive and proactive techniques. We saw it as a way to get operations and maintenance working closely together to increase equipment reliability.” While there was a will and the knowledge available to start the training the leadership team recognised that they did not have the structure in place themselves. The company was aware that training provider Skills4Work had a well-established maintenance training programme and contacted Phil Hurford, Programme Manager for Maintenance Excellence. “The Cooperative Production Reliability programme is an on-site programme based on TPM and autonomous maintenance that has been developed to meet the needs of NZ industry. In our experience, operators are more than capable of carrying out basic maintenance tasks, but organisations need support to build the processes and structure to enable that to happen, and that’s where we come in.” Before the programme got underway, Phil took a trip down to the site to take a look around to understand the challenges the organisation was dealing with. He found that there was an ongoing commitment to training at the site, but like many organisations, the general rule in the workplace was, ‘We’re operations and we run it and you’re maintenance and you fix it.’ Hurford said that “a lot of what we do is to provide the way for people to see things differently, to question whether the current system is working and provide a framework for them to develop the new ways of working.”

The focus for the training is that for any change to be sustained, there has to be changes to the work environment, as this is what will change attitudes and behaviours which is what will ultimately lead to a change in culture. While that environmental change can be something as simple as the layout of equipment and workflow, more often it involves more complex issues such as the priorities of management and staff or the way in which information is communicated. Both Kaituna Mill and Skills4Work were looking for long lasting change and not something superficial, but did they achieve that? Karen Way was one of the Mill Team Leaders who took part. She said, “The first thing we looked at was workplace organisation. Although we had some training for 5S a couple of years ago, it didn’t continue as part of the daily routine. We looked at the workplace, took a load of photos and did some root cause analysis to find out why certain things were or weren’t happening. From that, we were able to make some changes so that we could become more organised and that was really the starting point for us.” She went on, “The next phase was to gain a better understanding of the equipment we operate every day. We did some ‘know why’ training with Phil and our maintenance crew to understand why it is important to keep equipment clean and maintained. For instance, now that we know the basics of how a motor works, we know why it is crucial to keep the mesh on the cooling fan clean.” There were times when barriers had to be dealt with. “When the programme got underway there was initially some concern from the operators that they would simply be carrying out work currently done by maintenance and this would simply be loaded onto their already full workload,” Phil explained. “However, as the focus of the programme became clear, the operators embraced the concept of being the asset owners. Operator-based maintenance is a three-way partnership. The operators are the central figure and become owners of the asset but they are supported by maintenance and equally importantly,

• MAINTENANCE MATTERS

supported by management. It was this support that overcame the reservations of the operators. Maintenance was there to guide the development of the new procedures and management supported changes to work patterns and financed some changes to the physical work environment in the control cabins.” For the final phase of the programme, the operators had to come up with their own cleaning and pre-start routines. This required that they worked closely with maintenance to develop written basic care tasks. During this process, every person in the team had input and understood not only what had to be done but, just as importantly, why it had to be done. Last month Phil Hurford was invited back to Kaituna Mill to complete a review of the programme six months after the training finished. “When I went back, it was like walking into a different workplace. Where I was originally seeing a build-up of sawdust, it is now much cleaner because every day the operators complete the cleaning routines they developed. This allows them to check the equipment and report any faults to maintenance. The workplace is much more organised with all tools and equipment now kept in a designated place close to where it is used.” He went on. “The biggest improvement that I could see though was the change in attitudes and behaviours. This has

come about because management has continued to support the ongoing CPR work of the operators. Management made the investment in the physical working environment by revamping the control cabins and supported the changes being developed by the operators who had amongst other things, come up with their own roster to ensure the cleaning and pre-start checks were carried out. This is the start of a change in the culture.” The programme has now taken on a life of its own. The operators decided that to make the programme more successful they would take it beyond the initial pilot area and extend it to include the next equipment centre in the process, the re-saw. The change in culture can be seen beyond the confines of the programme. Recently there was an issue brought about by the unusual amount of rain causing the recycled waste that is used to power the kilns to become wet. The operators were given encouragement and the freedom to solve the problem. The General Manager, Matt Bond said, “Just after the meeting to discuss this I was off-site for several days and when I returned the problem was sorted. The operators questioned the priorities given to which products are stored under cover and after some research they found that those priorities were correct several years ago but not today. Consequently

by the time I got back to site, the store had been re-organised and the problem solved. Through the TPM and other training, staff has been empowered to solve this type of problem and that’s exactly what they now do. Another example of this would be when earlier this week Izaac, one of the Head Rig operators, suggested improvements to how the waste is removed from the edger. He was immediately given a budget and a time frame to work to and is now consulting with the engineers to ensure the changes are made.” This is a perfect example of what can be achieved with a cooperative approach to production reliability. Izaac the operator, who is the eyes and ears of the plant, identified the problem, discussed it with management and is now working with maintenance to make the improvements. With the support of management and full involvement of production and maintenance it is possible to improve production reliability and foster a greater sense of asset ownership. Karen, the Team Leader who has been helping to drive the programme summed it up when she said, “These young operators will eventually go on to run the saw mill and we’ve given them the tools to do that.” Phil Hurford is the Maintenance Excellence Programme Manager for Skills4Work. p.hurford@skills4work.org.nz

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• MAINTENANCE MATTERS

Hand-held test tools for proactive maintenance histories, reports and work orders. Once the data is correlated the operating condition of all assets can be analysed and reported on in an integrated format.

Insulation resistance to ground

Fluke 810 vibration tester

To implement a proactive maintenance programme it’s important to know not only which equipment needs repairing, but also to understand the root cause of impending failures. Using test tools to regularly measure key indicators on critical equipment helps technicians uncover these. The following test tools can be used to make measurements, track equipment condition over time, and diagnose failure conditions: • Digital multimeters (DMMs). • Clamp meters. • Infrared thermometers. • Insulation resistance testers. • Thermal imagers. • Vibration testers. Proactive maintenance programmes vary from highly sophisticated, with continuous online monitoring and automated alerts, to more traditional offline programs that rely on inspection routes and manual measurements. Monitoring tools also vary in complexity, from digital spot infrared thermometers to thermal imagers, vibration analysers and power quality tools, to permanently mounted and networked sensors. Investigative tools vary from hand-held digital multimeters,

September 2012

clamp meters and insulation resistance testers to specialised motor circuit testers. Many facilities mix and match their approach, depending on equipment and scale of operations. What’s different is that these technicians repurpose tools, which are traditionally used for troubleshooting for proactive maintenance measurement programs.

Measurement guidelines Proactive maintenance measurements aren’t that different from troubleshooting tests. Technicians are looking for signs of potential failures, so they take measurements related to failure modes. For each type of equipment they need to: • Identify the potential failures and related key indicators. • Determine what measurements can reduce the likelihood of problems. • Determine how often equipment needs to be measured. • Collect and track the results, watch for trends and initiate repairs as needed. • Integrate all maintenance technologies into one computerised data tracking system so they share the same equipment lists,

Caution: before testing cabling and motors, disconnect any electronic controls as misapplication of high voltage test equipment can destroy them. Regularly conducting the following insulation resistance tests on loads and connections can help detect imminent equipment failure: • Ground testing line and load circuits at the starter will identify the resistance to ground of the starter, line circuits to the disconnect and load lines to the motor and starter windings. • General thresholds: AC devices can safely operate at not less than two megohms to ground and DC devices can safely operate at not less than one megohm to ground. • When measuring the resistance of a three-phase motor between the load legs of the starter, technicians should see high resistance and roughly equivalent measurements between phases. Note: Insulation resistance to ground tests conducted with an insulation resistance tester require disconnecting the components or cabling to be tested from the power system. Remember to incorporate this requirement into planned downtime.

Temperature Infrared thermometers are a low-cost monitoring option for quick, frequent measurements of specific components while equipment is operating. Identify key hot spots to track, compare those temperature readings to operational limits and watch for upward trends. For example: scan the bearing housings on motors, the switches in circuit breaker panels and the wiring connections at all equipment. For the best measurements, get as close as is safely possible to the target, make sure the surface being measured is not reflective and compensate for emissivity.

Thermal imaging Thermal imaging tools play a key role as screening tools in a proactive maintenance program. Technicians can use them to quickly measure and compare heat signatures for each piece of equipment on an inspection route without disrupting operations. With

• MAINTENANCE MATTERS a thermal imager technicians can quickly survey a much larger area than an infrared thermometer and see how the temperatures of different areas relate to each other. If the temperature or thermal pattern is markedly different from previous readings, technicians can use other maintenance technologies including vibration analysis, motor circuit analysis, airborne ultrasound and lubricant analysis, to assess the severity of the problem and the time needed to repair it. Thermal imaging applications: • Monitor and measure bearing temperatures and condition in large motors or other rotating equipment. • Identify “hot spots” or “cold spots” in electronic equipment. •Identify leaks and determine fluid levels in sealed vessels and tanks. • Find faulty insulation in process pipes or other insulated processes. •Find faulty connections in high power electrical circuits. • Locate overloaded circuit breakers in a power panel. • Identify fuses that are at or near their current rating capacity or that are improperly installed.

• Identify problems in electrical switch gear. • Capture process temperature readings. • Perform other equipment-specific troubleshooting and diagnostics.

Vibration testing Most industrial equipment is designed to operate smoothly and with minimum vibration, so when vibration is present it’s often an indication of problems with or deterioration in the condition of the equipment. As conditions within machinery change, the amount of vibration often changes. If the underlying causes of excessive vibration are not corrected the unwanted vibration alone can often cause additional damage. Vibration data is typically collected using an electronic data collection device and an accelerometer. Measurements are taken by placing the accelerometer near each bearing location along the drivetrain, using the most appropriate attachment method. For example, a magnetic mount or a mounting pad. Quick tips: • Locate the sensor as close as possible to the bearing, or on a solid structural member leading to the bearing.

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.

• Sensor position should be parallel or perpendicular to the floor whenever possible, • Avoid mounting the sensor on thin surface areas (such as fan shrouds) and cooling fins. • Attach the sensor to a clean, flat, bare metal surface if at all possible. Thick layers of paint, grease, oil or other matter will reduce both the holding force of the magnet and the high frequency response of the sensor. • If possible take measurements on both ends of the motor. • For consistent data over time it is important to place the accelerometer at the exact same location on a machine each time. • Do not take bearing measurements from a foundation or fabricated base. • Do not mistake seal locations for bearing measurement locations on pumps. The vibration from a drive train may change depending on the load and the temperature of the motor. The one exception to this rule is machines which have misaligned drive shafts. It is recommended to take vibration measurements when the machine is running in a steady state and at normal operating temperature. Machines tested while still cold may have

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

Caution: resistance measurements must be made with the circuit power off. Otherwise, the meter or circuit could be damaged. A digital multimeter can check the resistance across most connections. High resistance readings can signal degraded connections, which can cause reduced supply voltage, nuisance tripping and potential equipment failure. DMM Notes: most DMMs measure down to 0.1 ohm and some measure as high as 300 megohm. For accurate low resistance measurements, use the DMM’s REL function to eliminate test lead resistance.

DC and AC current significantly different vibration signatures than those at normal operating temperature, because temperature affects shaft alignment and operating clearances due to thermal expansion. In the case of pumps, cavitation, air ingestion or discharge pressure will affect vibration readings and pumps should not be tested with the discharge valves closed. However, if they must be tested in a recirculating condition, the recirculating valve may be partially closed to achieve a normal discharge pressure. When the data has been collected, it must be analysed to determine the source, location and severity of the faults. Used regularly as part of a proactive maintenance programme, vibration test equipment can often identify potential mechanical problems weeks, if not months, prior to a catastrophic failure.

Caution: after measuring current with a DMM don’t forget to move test leads back to their voltage-measuring connections before attempting a voltage measurement. Loads may draw a slightly higher current as they age. Regularly measuring current can help technicians track the reliability of equipment. Use either a clamp meter or a DMM combined with a current clamp to measure current.

Voltage balance A greater than two percent voltage imbalance can reduce equipment performance and cause premature failure. Use a DMM to check voltage between phases for voltage drops at the protection and switchgear delivering power from the utility and at high priority equipment. Voltage imbalance can be calculated with the following formulas:

Maintenance and Reliability Seminars 2012 Presented by industry experts 13 sEpTEMbEr 2012

26 sEpTEMbEr 2012

Infrared Thermography

Root Cause Analysis

Presented by Dr Ken Jackson, Science Directions • Basic thermal physics • Electromagnetic radiation • The infrared image • Thermographic inspections.

Presented by Bernie Piovesan, RCA Rt Australia • Frontline problem solving • Problem identification • Defining the problem • Effective use of the 5 Whys

FEE: $395.00

FEE: $750.00

MIT FaculTy oF EngInEErIng and TradEs For more information or to register, contact: Cheryl McLeod,

• Average volts = (ph1 volts + ph2 volts + ph3 volts)/3, • Percent voltage imbalance on ph1= ((ph1 average voltage)/average volts) x 100. Note: voltage drops across the fuses and switches can also show up as imbalance at the motor and excess heat at the root trouble spot. Always double check with a thermometer.

Current balance Another root cause for equipment overheating is current imbalance. Use a clamp meter or an AC current clamp with a DMM to check the current draw on each of the three legs. To determine average current, sum the current from all three phases and divide by three. Then, calculate the percentage imbalance by subtracting the actual on one leg from the average amps, then divide by the average amps and multiply by 100. More than 10 percent current imbalance can be a problem.

Inrush current If a motor isn’t performing correctly or if a circuit is tripping unexpectedly, check inrush current at start-up with a clamp meter or a DMM designed to capture inrush current. Inrush current can reach up to twelve times the normal operating current, much higher than the circuit breaker rating, without tripping the breaker, as long as the circuit isn’t overloaded. Evaluating inrush current depends on comparisons of inrush measurements over time for that motor. Article submitted by Fluke www.fluke.com.au

8-12 ocTobEr 2012

12-14 novEMbEr 2012

Machinery Vibration Analysis Category 2

Bearing Technology and Maintenance

Presented by Clyde Volpe, Vibration Institute of Australia • Maintenance methods • Principles of vibration analysis • Data acquisition & signal processing • Fault diagnostics

Presented by SKF Australia and NZ • Bearing basics • Fundamentals of lubrication • Bearing failure causes & analysis

FEE: $3,225 (excl. exam) $3,650 (incl. exam) 23 ocTobEr 2012

Hydraulic Maintenance • Basics of hydraulics • Filtration and flushing • Maintenance & fluids selection FEE: $395.00

FEE: $1,648.54 15 novEMbEr 2012

Fitting of Bearings Presented by Phil Williams, SKF Training Manager • Bearing fitting exercises • Bearing failures and how they can be prevented. FEE: $TBC

Maintenance & reliability centre D E D I C AT E D T O I M P R O V I N G T H E P R O D U C T I V I T Y O F N Z I N D U S T R Y

cheryl.mcleod@manukau.ac.nz • 09 968 8654 • www.manukau.ac.nz/shortcourses 32

September 2012

All fees include morning/ afternoon te a and lunch

2061

Resistance

• MAINTENANCE MATTERS

Government announces apprentice training review The Ministry of Education is reviewing the apprentice training industry in a significant document released in August. The Apprentice Training Review document, released following a speech by Minister Stephen Joyce, seeks views on a proposal to change New Zealand’s industry training system to improve its effectiveness for employers, trainees and the Government. The key proposed changes to industry training policy that the Ministry of Education are seeking feedback on are: • ITOs will focus on arranging training and skill setting for industry. • Greater simplicity, accountability and clarity of the ITOs’ functions and roles. • Higher expectations for qualification completions and programme completions for ITOs. • Industry will have responsibility for communicating skill needs directly to Government to create closer links between education, employment and industry. • Amalgamating all apprenticeships into the Modern Apprenticeships scheme, making the same level of support available for all apprentices, regardless of age. • Raising the current ten percent restriction on industry training at levels 5 and 6. • Either the Modern Apprenticeship coordination fee should be incorporated into

the Modern Apprenticeship training rate or kept as a separate rate. • Adjust to a more sustainable funding regime that increases the subsidy rate for traineeships (programmes of 40 credits or greater) and introduces a new, higher subsidy rate for apprenticeships (currently Modern Apprenticeships are 100 credits or greater). A higher rate per trainee is being considered as part of the expectations for improved performance. • Remove disincentives for allowing trainees to progress into employment and apprenticeships from a provider, and for transferring into a provider to complete a qualification if their employment situation changes. • Review quality assurance mechanisms to include management of the processes for assuring consistency of graduate outcomes as a role of the qualification developer. Review quality assurance systems for unit standards, with the view that, over time, new versions will be flexible enough to be able to be delivered in a range of delivery settings. The document does not indicate major change, but is a move forward to recognising the uniqueness of apprenticeships. The key areas of interest to the Maintenance Engineering Society (MESNZ) as vocal advocates of apprentice systems are the

proposed amalgamation of the Modern Apprenticeships scheme, increased subsidy rate and removal of disincentives for allowing trainees to progress into employment. The MESNZ has long argued that industry is affected by a trades supply chain that has issues at every level, governance that does not understand what an apprenticeship is about, a school leavers market flooded by devalued options and perceptions and a training industry focused on the modern scrap for funding. The MESNZ’s own industry survey underwrote these opinions but also reinforced a major point for readers; you must engage or accept your fate. The MOE document is a step in a direction and most importantly, it calls for engagement. The MOE webpage states: “The proposal will be refined following the consultation process. We would like to hear your views on the benefits and risks of this proposal for employers and trainees in your industry.” The deadline for providing feedback is Wednesday, 12 September 2012. Readers can review the document for themselves at http://www.minedu.govt.nz/NZEducation/ EducationPolicies/TertiaryEducation/ PolicyAndStrategy/ReviewIndustryTraining/ ConsultationOnProposalToChangeIndustry Training.aspx Craig Carlyle, Secretary MESNZ

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.

Other SKF Services available:

• Reliability Training Solutions • Maintenance Strategy Design • Proactive Reliability Maintenance

• 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

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

www.skf.co.nz

The significant negative effects of ignoring power quality issues ‘Brownouts’, ‘inrush’, ‘unbalance’, harmonics and other mysterious ‘gremlins’ are causing unnecessary wastage, power and money loss to greater Auckland and other electricity consumers on a massive scale. Dirty power, particularly in Auckland’s CBD and a number of surrounding industrial areas, is costing landlords and tenants thousands of dollars in excessive maintenance, at the very least. And frustrating the ‘green’ ambitions of many. Jeff Mclaren, Singer Group CEO, and Auckland commercial maintenance manager, Kevin Dunbar, have been analysing more and more reports flowing into the industry leader’s Spaghetti Junction headquarters, and say that even modern warehouses built in the last few years are not immune. “Until now the tendency has been for Auckland CBD buildings, especially where a number of contractors have been brought in at various times to upgrade and extend power and distribution installations (to support the booming digital economy), in buildings often designed and built in the last century, to show those hard-to-identify root-causes, rather than symptoms. “That’s been ‘understandable’, although hardly desirable, particularly where neither landlords nor tenants have an overall power management and maintenance programme, and ‘creeping usage growth’ is in the hands of unsupervised, independent contractors with vastly-varying levels of skills and experience. All of which means there are seldom any records kept of who did what, where, when and why; and the ‘warranties’ tend to be of the ‘kerbside-on-the-backof-a-light-bulb-wrapper-type’. “There have been a number of unfortunate accidents and many nearmisses over the years, and yet many continue to ignore these risks. Those who dodge the proverbial bullet are usually on the phone, hours and sometimes minutes later, asking us to implement the proposals which have lain about collecting

September 2012

dust and static, while the expenditure has been repeatedly delayed by short-term ‘cost-saving’ programmes. That’s despite the excellent awareness EECA has created on energy usage in the last while.” Dunbar takes up the story. “We believe increasing power loads, with their associated even-faster-growing electrical charges, have reached the point where it is becoming a ‘no brainer’ to address this issue. This is especially so for responsible landlords and their large tenants in buildings, which often also have a number of other occupants operating smaller offices with anything from commercial, industrial, retail and the like. “Bottom-line is we are taking chances, as we always have, but the economic uncertainty that has prevailed over the last 18 months has caused companies and individuals to cut deeper into every ‘corner’ they see. They do that without thinking of the consequences or the option of a more positive outcome with greater benefits. “However, there are promising signs,” he says, “that some players in the insurance industry are, at last, starting to realise that they have either been picking up the tab for these take-a-chance practices, unnecessarily, or will do so in the future. “That means that dodgy ‘calls’ on power quality issues and the lack of power management and maintenance supervision will be penalised with either rapidly increasing insurance costs on the one hand (or cancellation of insurance protection); while those who can demonstrate they have proper management and controls in place will benefit from protection as well as lower premiums,” Dunbar says. “The days for waiting for an incident before taking corrective action are already over,” says Mclaren. What are the primary consequences of not knowing what the quality of your power is? “You’ll see it in your power bill, first off,” says Dunbar, “and you might notice it when your lights dip for an instant.

That could lead you – based on what a friend might have told you, to think you’ve experienced a ‘brownout’ or power dip, whereas you might have had a power surge, followed by a compensating dip, as the equilibrium in supply returns. “Electricity is not a power-source for speculating on what might or might not be happening. And that is before you get to destructive and invisible-to-the-naked eye factors like harmonics. “You need highly-trained and qualified specialists, with the best technology, which is usually expensive and complicated to use. And that often has to be in place for some time to identify which element is corrupting your power quality. “Secondly, particularly with harmonics, you need to have the ability to interpret the difference between symptoms and causes, much as doctors have to do to reach the root cause of an ailment. And then deliver, what we at Singer call a ‘Powerful Solution’ – a solution based on distilled facts, contextualised in the situation, analysed for alternatives and cost-effectively and sustainably implemented,” he says. Singer’s Bill Mitchell is one of a handful of Level 2 qualified thermographers in the country and, uniquely, a qualified electrician, to boot (as well as a member of Dunbar’s team). Professionally-qualified thermographers are essential to the first phase of identifying problem componentry. Mitchell identifies (alphabetically): • ‘Brownouts’. • Flicker. • Inrush. • Poor power factor. • Total harmonic distortion. • Transients (dips and surges). • Unbalance. as potential causes – either individually or in combination – of factors which could compromise power quality. “That gives you an insight into the complexity of identifying the root-cause, rather than a symptom: something we

Bill Mitchell and Kevin Dunbar

recently experienced with a customer who had been suffering a good deal of frustration, not to mention cost, as he installed ‘green lighting’ in a new building. “He had installed quality European light fittings, but he was popping upwards of 20 percent of these on a near-monthly basis. That’s a considerable cost in anyone’s language, but it is especially so when you’ve bought the best; you’re committed to sustainability; and it simply isn’t working for you. “That’s the symptom,” says Mitchell, “but what is the root cause? “Before you can provide the client with a Singer ‘powerful solution’, you need to check the records of the installation to ensure you know what are dealing with. “Then you allow experience and even a little intuition, to guide you in your choice of diagnostic equipment. Next, you diligently monitor that system. In this case, as I reckoned, a fifth harmonic was the cause.” Mitchell admits his ‘experience and intuition’ are guided by a thoroughly structured process, modelled on a number of root cause analysis (RCA) models derived from the classic data-driven improvement, ‘DMAIC’ concept, used for optimising and stabilising business processes and designs. It is at the heart of Six Sigma projects, although not exclusive to them. Mitchell again, “DMAIC is an abbreviation of the five improvement steps: Define, Measure, Analyse, Improve and Control. All must be used and followed in the correct sequence to be successfully deployed. “Briefly, that covers: “Define – crystallise the issue to be addressed. A vital process.

“Measure – gauge the size of the problem to understand the negative impact on the system or circuitry involved. Ensure you understand the relevance of appropriate data sets. “Analyse - comprehend the chain-ofevents which led up to the issue under investigation. Discover any causal chains. “Improve – identify which corrective actions will have to be implemented to improve the existing situation. Contain any issues which flow from that. “Control – which corrective actions will be required to control the now-improved situation? The corrective measures must be sustainable. “There’s no doubt that the secret of this approach is its simplicity and its focus on the ‘causal chains’, which ultimately provide the path to the solution. Once they are identified and thoroughly tested, effective and sustainable solutions can be applied at the root-cause of the problem.” Dunbar also outlines a recent case he solved where a standby generator kept starting up, even though the building seemingly had adequate power reaching it. The building had no instrumentation measuring the power quality, but the generator did. Correctly, it switched itself on to deliver clean power. Again, the ‘powerful solution’ had to be based on root cause analysis – poor quality power – rather than a ‘symptomatic solution’, which would have adjusted the start-up switch on the generator. The final word is with Mclaren. “You must understand that much of this more structured approach has its origins in PPM (Planned Preventative Maintenance) which has been at the very core of Singer’s approach since Kevin and I first got involved with the company. We have been passionate believers and promoters to companies, landlords and government organisations on only using service-providers who have the skills and insights to provide a complete picture of all your electricity systems, including wear and replacement; inefficiencies; ‘futureproofing’; sustainable options; and the consequences of delayed action. “This all comes at an affordable, budgeted cost, which is inevitably less than the crisis-driven short-term fix. Give Kevin a call and you can uncross your fingers. When dealing with electricity ‘gremlins’, you need certainty – not ‘hope-it-doesn’t-happen’.”

0800 474 643 www.singergroup.co.nz 35

NZEI Inc. Auckland branch monthly meeting July On 26 July 2012 a large group of Auckland branch members and general public involved in the electrical industry attended a very informative evening with guest speakers travelling up from Wellington. The speakers were Mr Peter Morfee, the Principal Technical Advisor Energy Safety Ministry of Business, Innovation and Employment (MBIE), and Mr Steven Oliver, the Deputy Registrar of the Electrical Workers Registration Board. On 1 July 2012, the Ministry of Business, Innovation and Employment (MBIE) was established. The purpose of the MBIE is to be a catalyst for a high performing economy to ensure New Zealand’s lasting prosperity and wellbeing. MBIE develops and delivers policy, services, advice and regulation to support business growth and the prosperity and wellbeing of all New Zealanders. MBIE integrates the functions of four former agencies: • Ministry of Economic Development, Including Energy Safety. • Ministry of Science and Innovation. • Department of Labour. • Department of Building and Housing Including the EWRB. Mr Morfee commented that their work will continue as business as usual in the short term while MBIE is established; we expect to see a closer interaction, and collaboration, between our operations and the activities of the EWRB and the workplace inspectorate from the previous Department of Labour A review of the certification of “installation wiring work” is almost completed. Some items raised by the speakers are as follows:

Electricity Regulations 2012 – Implementation of changes to the Certification of installation wiring: • Current Regulations and interpretations. • Regulatory systems (GRP). • Objectives of the Certification review. • Shape of Amended Regulations. • Details of the amendments. • Looking ahead (Review of risk categories).

Current Regulations and Interpretations: • The 2011 amendments to the 2010 Electricity (Safety) Regulations are now fully implemented and as a result, Amendments 1 and A to AS/NZS 3000 are now in effect. • The transitions for the installation of down-lights have all been completed and the 2011 relaxations for the installation of 10mA

September 2012

RCDs in schools introduced in 2010 are now in effect. • An interpretation of “connection” has also been promulgated to support the operation of the 2010 Regulations.

Connection: Connection is interpreted to be “last part of the Prescribed Electrical Work (PEW) that results, or allows, an installation to receive a supply of electricity”. Note also that the term “Authorised”, where it relates to persons performing PEW has the context of the Electricity Act, where it means a person both registered and holding a valid practicing license. • This will result in the Regulations relating to installations (Part 5) being amended in September 2012. • The amendments will come into effect in July 2013 with a transition that allows “work in progress” to be completed under either regime. • It will change the way in which all PEW on installations will be certified. • Department of Labour.

Safety of completed work: Regulation 13 contains the fundamental requirements for safe installation work: Doing work on works, installations, fittings, and appliances:A person who does work on any works or installation, or on any part of any works or installation, must ensure that the resulting works or installation, or part of the works or installation, is electrically safe; and if the work is on only part of any works or installation, that the work has not adversely affected the electrical safety of the rest of the works or installation.

Certification Changes: A review of the certification of “installation wiring work” is almost completed. This will result in the Regulations relating to installations (Part 5) being amended in September 2012. The amendments will come into effect in July 2013 with a transition that allows “work in progress” to be completed under either regime. The Certification Changes will change the way in which all PEW on installations will be certified.

Competency Programme Changes New requirements for the competency refresher courses were elaborated upon for a person requiring a Practicing License. Also the cost of the Practicing Licenses was under

review and the qualifying period is being looked at to extend it out from 12-monthly to 24-monthly which will line up with the CPR and competency courses which are current required every 24-months. A full script of the discussions is available on request from the National Secretary of the NZEI Inc Allan Hill National Secretary New Zealand Electrical Institute Inc.

Motor rewind workshops

Best practice maintenance of motors requires quality repair and rewind practices. By using a quality-certified motor rewind workshop you can be confident that motor efficiency and reliability are preserved through the repair process. There are twelve quality-certified motor rewind workshops located across New Zealand. Visit EECA Business website www.eecabusiness.govt.nz to find a workshop near you.

Motor replacement policy development In conjunction with industry, EECA has developed a ‘Motor Replacement Policy Guide’. The guide provides a step-by-step approach to establishing a policy and practical rules for making high-quality motor replacement and repair decisions. It is designed to assist managers develop sitewide policies to simplify decision making. In addition, EECA is offering 40 percent funding support (up to $2,000 per site) for businesses to establish site motor replacement policies, using the guide. This offer applies to sites with 500 kW or more of in-service electric motor capacity. To take advantage of this funding offer contact one of the following EECA Programme Partners: Demand Response Limited - Gerald Crawford, 04 472 6061. Enercon Limited - Kees Brinkman, 03 384 7905. Energy NZ Limited - Andy Logue, 09 909 0941.

cut costs and risks – choose a Quality-certified motor rewinder Using a quality-certified rewinder ensures electric motors are running at their best. Poorly rewound motors use more energy than they need to. They reduce productivity, increase the risk of expensive breakdowns and production downtime, and cost more to run. When it comes to maximising energy efficiency, following best practice is best for business – like using Telarc or ISO 9001 certified rewinders. Choose a quality certified motor rewind workshop to ensure you’re getting the best out of your rewind.

Quality-certified motor rewinder workshops in your area: Auckland

Bay of Plenty

Wellington

CMG Electric Motors NZ Ltd Avondale David Priestley – 09 820 3550

CMG Electric Motors NZ Ltd Mark Yeoward – 07 347 8624

Elektron Motor Rewinders Ltd Peter Alevizos – 04 237 8767

Gouk & Sullivan (BOP) Ltd Steve Milbank – 07 323 7733

Christchurch

Taranaki

ABB Ltd Peter Wortley – 03 338 3787

Hawera Rewinds Ltd Geoff Furborough – 06 278 4578

Invercargill

New Plymouth Rewinds Ltd Richard Lister – 06 758 2163

Wallace Murray Electrical Ltd Hugh Murray – 03 218 6947

Electric Motor Solutions Ltd East Tamaki Rich Noller – 09 274 7233 Gouk & Sullivan 1971 Ltd Mt Wellington Graham Gibbons – 09 573 1465

Waikato ABB Ltd Clayton Eade – 07 849 3002 Greene Bros Ltd Paddy Greene – 07 850 4109

For more information visit www.eecabusiness.govt.nz

Ogilvy/EEC2489

• sensors

Selecting sensors that work

The idea of using sensors to control lighting and cut energy costs can generate a lot of enthusiasm from whoever pays the power bill, but that same enthusiasm can evaporate where people working alone at night are plunged into darkness just because they happen to be working at their desk and not moving much. Electrical contractor Danny Collins says they have come across the problem including a school where the lights repeatedly cut out on teachers working late in their classrooms marking books. A director of Auckland-based contractor TS Bishop, Collins says the answer is straightforward: stay away from standard ‘movement’ sensors and install good quality Wattstopper ‘occupancy’ sensors that are specifically designed for the job. Unlike standard PIR sensors, Wattstopper purpose-designed occupancy sensors don’t require exaggerated movements to detect the presence of a person and will not switch off when someone is there. As well as lighting, WattStopper sensors can be used on HVAC systems to improve a buildings Green Star rating. WattStopper PIR occupancy sensors have high-density beams to pick up smaller movements and also have the coverage needed for large commercial spaces where you would otherwise need multiple sensors. For more precise sensing of smaller movements like a person concentrating at a desk, WattStopper offers ultrasonic sensors that do not need line of sight, making them a better choice for places like open-plan offices with screens and restrooms with cubicles. To capture the advantages of both PIR and ultrasonic sensors WattStopper also offer dual technology occupancy sensors. For flexibility the sensors have a separate 24 V power pack for easy integration into building management systems or running multiple sensors. The power pack and sensor can also form a standalone unit. Wattstopper also offers a range of daylight harvesting controls to automatically turn lights off or dim where possible, to make the most of natural daylight. You can gain 90 percent of the functionality straight from the box with no configuration

September 2012

necessary, but with extra adjustments are available for advanced functions which you can familiarise yourself with via Control Six, a short and easy to read booklet free from Eurotec, who also offer a free design service from a simple PDF sketch right through to fully detailed CAD drawings. Eurotec also offers another kind of support – helping you show the customer how the cost of installing WattStopper will be quickly repaid in energy savings and continue to produce a continuous return after that, as a rule of thumb a client can recover their investment in less than two years. The principle works just as well for modest retrofit projects like occupancy sensors in restrooms, stairwells and storerooms or larger projects like lecture theatres, common rooms, office areas, boardrooms, or infrequently used aisles in warehouses and libraries. If you control HVAC functions as well, payback can be even quicker. For more precise estimates, WattStopper has a small battery-powered occupancy logger that clips into a ceiling tile and has a USB port for downloading an occupancy log. For a couple of hundred dollars it offers proof of the power savings that can be made and can work for you as silent salesman with clients prepared to look at power saving options. WattStopper products also attract a new EECA subsidy that drops prices per sensor by 5 to 15 percent according to type. WattStopper was founded 30 years ago in the US to build occupancy sensors and today produces a comprehensive range of commercial occupancy and daylight lighting controls available from Eurotec. Go to www.demm. co.nz/enquiry quote: D120938

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Futek intelligent digital display The IHH500 is a multi-purpose digital display, it is primarily, utilised as a hand-held device, but it also can be configured as bench-top and/or wall mount. This model has significant improvements as far as performance, quality, resolution, and speed, it features 24 bits internal resolution (20 bits noise free). And can be utilised with FUTEK resolution calculator to play with the ultimate result.

Key Features: • Provides various outputs such as 0-5 VDC, +/-5VDC, 0-20mA, 4-20mA, 0-25mA, 5-25mA. • 2 Relay. • USB output. • ASCII Stream. • Data logging (21K points). • Live Graph • CE approved/RoHS Compliant. • LCD capable to display multiple lines plus unit of measurement. The IHH500 is offered in two versions: IHH500-Pro This version supports all the FUTEK models except the encoder of the rotary line. Example – TRS605. It still reads the torque, but will not provide TTL pulse. IHH500-Elite This is the full blown version of the IHH500. It includes the entire accessories plus the SENSIT software for data logging and live graph. It is also supplied as a complete kit inside a hard Pelican case. This is the sophisticated version that allows to read TTL pulses as well. Combination of TRS605 and IHH500-Elite would measure torque, speed, power, and angle. Futek Advanced Sensor Technologyis represented in Australia and New Zealand by Metromatics. Go to www.demm.co.nz/ enquiry quote: D120938a

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Interlocking safety switch The Euchner TP safety switches ensure that guard devices remain in the closed position until a hazardous movement, e.g. after running main spindle, has come to a standstill. Similarly, opening of the guard devices is prevented during a process. Due to their slim design, they are outstandingly suitable for universal fitment on profiles. TP safety switches have glass-fibre reinforced plastic housings. They thus provide best fitment opportunities for the automation,

fitting and handling technology sectors. Features include electrical and mechanical locking devices (optional), Emergency release from the rear, different switch contacts and three cable entries. Go to www.demm.co.nz/enquiry quote:

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2.. tober 2012 til 30th Oc n runs un Promotio

A new concept in express panelboards

NHP Concept Express is the combination of ‘NHP Drawing Express’, a software tool that enables the user to instantly design a distribution board from a website, and a new manufacturing line that employs a direct connection to the software tool and uses lean manufacturing methodology to

achieve incredible results. With NHP Concept Express, an NHP staff member can design the distribution board for their customer on the website by indicating all of the components that are required and more importantly, how they are to be connected. Within minutes of completing this simple process, an automatic drawing is generated which can then be forwarded to the customer. With a simple click of a button, this drawing can send the manufacturing information directly to the manufacturing line, thus enabling the distribution board to be manufactured within 48 hours of clicking that button. Traditionally the drawings alone took five to seven days to complete with total lead time of 20 days to the finished board.

Industry’s smallest power LED with highest lumen density

At a size that is 80 percent smaller than traditional power LED, the new Luxeon Z offering from Philips Lumileds is the company’s smallest LED package to date. With a total footprint of just 2.2 mm2 and high lumen output across a full spectrum of colours from 440-670nm, including white, the Luxeon Z offers luminaire designers the industry’s highest commercially-available lumen density. In addition, the ultra-compact, nonencapsulated package gives designers new flexibility in packaging and optical designs, helping to push the boundaries of next generation luminaire design. It will allow for integrated approaches

September 2012

that break with today’s paradigms in luminaire development. Unlike other products on the market, the Luxeon Z goes beyond the constraints of a typical 2x2 multi-chip package to allow designers the ability to create specialized 2x2, 3x2 or 6x1 monocolor or multicolor luminaires. With this breakthrough, configurations are virtually limitless, and with the ability to mount as many as 250 of the LED’s in one square inch, designers can reach new levels in lumen densities. Simplifying development of products such as wall-washers, moving head entertainment spotlights, and even remote phosphor applications, the Luxeon Z will also give engineers in the entertainment, architectural and specialty lighting segments, a modular approach to developing products. Moreover, the non-encapsulated chips are more readily adaptable to custom optics, eliminating the need for complex, inefficient secondary lenses. The company expects that a full line of semi-custom optics will also be available in the near future. Go to www.demm. co.nz/enquiry quote: D120940a

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With a short shipping time from Australia to New Zealand, customers are able to obtain a distribution board faster than ever before. This is a first of its kind panelboard ordering solution that revolutionises the way panelboards are ordered in the industrial electrical industry. Another important advantage of the NHP Concept Express tool is that it is also compatible for use via a tablet device (such as an iPad which all NHP sales representatives have) which delivers the same result and also provides an ‘ondemand’ drawing that can be viewed on the particular device. Since the launch of NHP Concept Express in June 2012, the response has been overwhelmingly positive. Go to www.demm.co.nz/enquiry quote: D120940

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Safety switch provides an integrated solution The AllenBradley 440NZ SensaGuard non-contact switch with a magnetic integrated latch combines a non-contact interlock switch and door latch into one integrated solution replacing the need to separately mount an interlock switch and door catch in lightweight guard doors. The switch features the latest RFID technology for coding, inductive technology for sensing and output switching signal device (OSSD) safety outputs. It is available with a uniquely coded sensor and actuator to help protect against operators or maintenance personnel defeating the switch, helping to enhance safety. In addition, an LED on the switch provides diagnostic status. Go to www.demm.co.nz/enquiry quote: D120940b

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satisfying you R food and BEVERagE aPPLiCation nEEds When it comes to the Food and Beverage industry, what really sets us apart from the competition? At NHP, we have the knowledge and expertise required when dealing with the food and beverage environment and manufacturing process, to help you in all aspects of your application. Be it the front/wet area that deals with the raw ingredients or the dry end where the packaging of product takes place, we have the complete range of product, solutions and services tailored to

this important market to get the job done. It is this agility to provide solutions that we really pride ourselves on. Our quality network of global supply partners, including leading automation supplier Rockwell Automation, forms the perfect complement to our local technical experts and sales teams who can promise to bring you a complete solution to meet your needs. So donâ&#x20AC;&#x2122;t wait any longer, put us to the (taste) testâ&#x20AC;Ś

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Fluke 320 series clamp meters Designed to be long-lasting and easy to use, the Fluke 323, 324 and 325 Clamp Meters are ideal for rugged, all-purpose use in residential, commercial, HVAC/R and light industrial electrical applications. The Fluke 320 Series Clamp Meters feature: • Slim, ergonomic design for comfortable all-day use. • Large, easy-to-read display. • CAT III 600 V/CAT IV 300 V safety ratings. • True-rms ac voltage and current for accurate measurement of nonlinear signals. • DC current, frequency and resistance up to 40 kilohms for motor testing. The 324 and 325 models offer a backlighted display for easy viewing in any setting, contact temperature readings from 10 to 400 degrees C (14 to 752 degrees F) and capacitance measurements from 100 to 1000 microfarad. The 325 model also offers dc current measurements up to 400 A, frequency measurements from 5 to 500 Hz and Min/Max function. Go to www.demm.co.nz/enquiry quote: D120942

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Affordable circuit control The issue: The crushing plant operator faced the challenge of trying to meet a full production schedule with limitations of a plant that did not have the benefit of electronic feed rate controls – they relied on the operator to manually adjust the feed rate and with a constant gradation changes in the feed material this almost became impossible. This situation resulted in very poor production rates, and expensive repairs – due to overload situations and very stressed operating staff. The Affordable Option came about due to the operator’s electrician experience with the automation of larger plants that could justify the use of expensive PLC controls. Based on this experience he investigated the use of the WEG CFW11 drive promoted by TR Industries. His attraction to the WEG CFW11 drive was the fact that it has, as standard, an inbuilt PLC. His approach to TR Industries resulted in TR Industries engineering staff applying the use of two CFW11 units with electronic sensors to create an affordable and very practical control circuit. The WEG CFW 11 – Crusher, screen and conveyor – circuit control. The operator pushes one start button. The system sequentially starts each section beginning with the out feed conveyor Once running, the system monitors the power draw (the load) of the crusher and automatically adjusts the in feed sections to maintain to maintain maximum throughput without overloading. When the stop button is pushed the system sequentially stops each section to clear all product, starting with the in feed conveyor. Extra control is achieved where the operator sets the power draw levels of the main crusher and systems automatically to this desired set level. Product Support The TR Industries application engineer involved in the original design of the control circuit was able to assist the electrician in the finetuning of the programming of the WEG CFW11 drives. TR Industries engineers are not crushing experts but their experience in electrical circuitry and electronic control coupled with their practical approach assisted in achieving the much needed production improvement. Flexibility: The system is able to adjust to various changes in the feed material or product specification changes. Once programmed, this ease of use has provided the plant operator with a simple method of production control. This results in improved production and less mechanical failures and most importantly less stress on the operators in managing the changes in feed materials. The use of the WEG CFW11 SoftPLC makes a control circuit like this a real affordable option for the many smaller plants operating in New Zealand. Go to www.demm.co.nz/enquiry quote: D120942a

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September 2012

Salisbury insulated tool range The non-sparking and non-magnetic insulated tools and tool kits from Salisbury, part of the Honeywell group, are manufactured from special aluminum-bronze and copper-beryllium alloys. The new range includes wrenches, pliers, cutters, screwdrivers, sockets and tool kits, which can be used within environments where hazardous, flammable or combustible vapors, liquids, dusts or residues may be present. Specifically designed to eliminate the risk of sparks at worksites where explosive atmospheres may be present, the new tools use the same high-impact resistant insulating material as the traditional line of insulated hand-tools, which means that the material is flame-retardant. With colour coded layers – a blue top layer and yellow under layer, the insulation also allows for easy safety inspection. If the yellow under layer is showing, the insulation may have worn and should be considered for replacement and removed from service, adding to the tools’ overall safety. To ensure the highest quality, the safety tools have been drop-forged and are corrosionresistant, making them suitable for use in ship-yards, laboratories and paper and pulp mills, as well as in the pharmaceutical, food product manufacturing, wine industries, mining and more. With a non-magnetic feature, the tools are also able to be used on special machinery with powerful magnets, such as MRI machines, military demining and explosives. Ideal for use in industries where nonsparking safety tools are required, Salisbury non-sparking safety tools are rated for exposure up to 1,000 VAC and dielectrically tested at 10,000 VAC. The tools also meet and exceed ASTM 1505-07 and IEC 900 standards and are necessary for compliance with OSHA 1910.333 (c)(2) and NFPA, as well as meet CSA-2462 standards. Go to www.demm. co.nz/enquiry quote: D120942b

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Electrical safety gloves NHP’S new Grizz-Bar isolation chassis Designed and manufactured in Australia, this isolation chassis has been designed to meet the needs of data centres, hospitals and any other application that requires maximum “up time” from its power distribution system. The new isolation Grizz-Bar chassis from NHP combines quality and unique features to raise the standard for busbar chassis systems. Some of these features include: • Super strong design. High short circuit current withstand ratings unmatched by any other isolation chassis on the market today. • Superior temperature rise ratings. The Grizz-Bar has a genuine 250A rating, tested to AS/NZS 3439.1:2002. The Grizz-Bar runs cooler. • All main busbars are fully encapsulated including the neutral bar. • The neutral bar can be isolated and is fully rated. • The Grizz Bar can be fitted with a captive padlock accessory to tag out individual circuits. • The NHP Grizz-Bar has identical dimensions to the CD and NC chassis and with its comparable Icw and temperature rise ratings it is a direct replacement. • The unique multi-pole attachment bar can convert a single switch toggle into a 2P, 3P or 4P toggle, ensuring multi-phase circuits cannot accidentally have one pole switched. • The Grizz-Bar chassis is available as a single end feed or a universal feed for total flexibility. • Suitable for use with standard NHP Din-T 6, Din-T 10 MCBs, RCDs, RCBOs and accessories such as Din-T Shunt trips, UVTs, alarms and auxiliary switches. Go to www.demm.co.nz/enquiry quote:

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D120943a

Salisbury gloves give workers protection against electrical hazards and are manufactured using processes that create a high-quality glove that is made to last. Unlike other gloves on the market, they are manufactured using a solvent based rubber mix. The production process creates stronger and more durable gloves, which are proven to last longer than gloves made with the water-based mixture used by most other manufacturers. With their smooth finish created by a special chlorinated wash process, Salisbury gloves are also easier to pull on and off, in comparison to their non-chlorinated counterparts, which can stick to hands or arms. This handy feature means that Salisbury gloves do not undergo the same strain often seen in glove cuff and finger areas helping preserve the gloves. For ease of inspection, Salisbury gloves are manufactured in dual colours, including yellow on the inside, with black on the outside or red on the inside, with black on the outside, this helps easily identify any deterioration, as, if the glove wears, the inside colour of the glove will show through.

Manufactured using glove forms with rounded fingers rather than square, they gloves are moulded to the human hand. The straight and bell cuff versions come in sizes 14", 16" and 18", with the straight being the standard make, while the bell cuffs accommodate bulkier winter clothing and allow greater airflow in warmer weather. The contoured cuff is available in size 18" and helps to prevent bunching or binding at the elbow while bending. They are available in a variety of classes, including Class 00 (500 Volts) through to Class 4 (36,000 Volts). To ensure that the integrity of the gloves is maintained, Salisbury gloves are carefully packaged in special box packaging, which prevents damage to the gloves while in transit or storage. Honeywell Safety Products recommends that electrical gloves are stored straight at all times to enhance their lifespan. Go to www.demm.co.nz/enquiry quote:

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D120943

LabVIEW electrical power suite

The LabVIEW Electrical Power Suite is a new toolkit specific to the power industry. With this toolkit, engineers can combine an NI CompactRIO system for power measurement with over 50 signal and sensor modules. With the NI LabVIEW Electrical Power Suite, engineers can combine standard IEC, EN and IEEE algorithms with the custom capability of NI LabVIEW system design software and NI reconfigurable I/O (RIO) hardware. Engineers and scientists can now develop a

custom three-phase power monitoring, metering or quality analysis application using LabVIEW. Using this toolkit, engineers can integrate power measurements with temperature, pressure, sound, vibration and control I/O for a complete monitoring system. Features: • Industry-standard power analysis for graphical system design – create systems that combine power measurements with other sensors and signals. • Full, streaming access to raw, time-based waveform data – implement diagnostic algorithms that may be unique to a local power service. • Ready-to-run example programs – integrate power analysis functions such as energy, frequency, voltage unbalance and event detection into a full test or monitoring system. Go to www.demm. co.nz/enquiry quote: D120943b

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Solutions Galore at the National Maintenance Engineering Conference Maintenance Engineering is a collection of trades, skills, sciences, theories and systems. Reliability requires an open, results-based approach and this truism is no better represented than at the Maintenance Engineering Society’s 2012 SKF National Maintenance Engineering Conference where electrical and mechanical engineers rub shoulders with academics, experts and suppliers in a common quest for maintenance solutions. The typical reality of cross-disciplined solutions is exemplified by Glenn Peppers Variable Speed Drive Failure paper, where root cause analysis is used to find a solution for a major drive failure. The results are intriguing, bringing both the mechanical and electrical elements into play and providing a solution that many engineers will keenly file away for future reference. Combine that with Larry Wiechern’s Industry Alert paper covering off the

For coming events

counterfeit materials and products issue that sparked TV3’s recent Stihl Chainsaw expose and the reader can understand why attendance is so valuable; staying up to date with industry can have a major impact back in the workplace. The November 7&8 event at the Novotel Lakeside in Rotorua is jammed full of presentations of this nature providing attendees with inspiration, information and experience. Attendees can arrive early to the two day conference and participate in the host of pre-conference free or elective activities. Unwind and catch up with associates at the evening Trade Expo with its rolling soapbox theme. 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. With attendees warming to the inclusive environment, the social night is a popular bonus. So if you have a need for networking, learning, exploration or inspiration, can you afford to NOT attend the NMEC 2012? It can’t be cost; at $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! It can’t be content; 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. You can nominate your intention to register on the society website www. mesnz.org.nz/nmec , as well as check the latest programme details. Attendance registrations are open and filling up already. Register online or contact Event Manager Leanne Powley on (09) 296 1333, conference@mesnz.org.nz.

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

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September 2012

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NC DOUBLE COLUMN HITCH FEED BAND SAWS Controller Functions: 1. AUTOMATIC KERF COMPENSATION: This function allows & calculates the blade thickness into the programmed cut length 2. AUTOMATIC LOCATE TRIM CUT: Machine will automatically ﬁnd the material end & set up trim cut to the programmed value 3. “Save-a-blade”: Retracts the material back approximately 3mm away from the blade preventing the blade teeth rubbing on the material on the return after completion of cut (H-400HA-NC, H460HA-NC, H-530HA-NC) 4. AUTOMATIC SHUT-OFF: For ﬁnished jobs or out of stock 5. SIMPLIFIED SELF DIAGNOSTICS: Error code display 6. LCD SCREEN: With touch screen display

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