Demm Engineering & Manufacturing Magazine January 2012 by Adrenalin Publishing Ltd

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January 2012

> CONTENTS

Editor's

note

Natural but controllable Some weeks ago I visited the “Corrosion Capital” of the world (also known as Rotorua) to attend the National Maintenance Engineering Conference. Hydrogen sulphide, released by geothermal activity in the area, causes this city not only to smell like rotten eggs, but also accounts for accelerated corrosion. To me it was quite fitting to learn more about the effects of corrosion at a place like this. Corrosion is a naturally occurring phenomenon that deteriorates materials and causes costly damage everywhere, from pipelines, bridges and buildings to vehicles, water and wastewater systems. The annual cost of corrosion worldwide has been estimated at over 3 percent of the world’s GDP, or about US$ 2.2 trillion. The good news: corrosion can be controlled; you just need to know how. Our Maintenance Matters section showcases a proven method to protect steel from rusting: hot dip galvanising. My first experience with this technology dates back many years. I can remember my uncle driving off with our quite massive garden gate, which due to its complex structure had always been a pain to paint. When the gate came back, it showed a fresh silvery coat (and some little holes), and nobody ever had to grab sandpaper and brush again to get rid of those ugly rusty spots. To learn more about the benefits of hot dip galvanising and to eyeball New Zealand’s biggest zinc bath I recently drove to Perry Metal Protection’s new facility in Hamilton. The corresponding article starts on page 29. By the way: As of now DEMM Engineering & Manufacturing and Electrical Technology form a single publication, with the ET content having its own identifiable section. I hope you enjoy reading the first updated issue of DEMM!

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

Pumps & Valves

Discover how Vaughan chopper pumps solve problems and new ways to pump up efficiency.

Water Treatment & Wastewater Systems

Interesting developments in the world of water treatment & wastewater systems, including a show-off between Salsnes filter and primary clarifier.

Materials Handling

Read about how ISO makes a stand for safety and productivity and how Bridon gets more life out of wire rope.

Maintenance Matters

DEMM visited Perry Metal Protection’s new multimillion-dollar hot dip galvanising plant in Hamilton.

Electrical Technology

Includes an inside report on the generator business and answers the question how thermography can improve preventive electrical maintenance.

Stefan Richter Stefan@adrenalin.co.nz

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> PRODUCT WATCH

Upgrades of light fleet announced

Edit o choi r's ce HireQuip have upgraded their light fleet with a number of Youngman Richardson and Co Ltd brands. New additions include Genie access equipment and a variety of concrete tools including Husqvarna concrete cutters and Maruzen hydraulic breakers along with a selection of Mikasa compaction equipment. “HireQuip is once more demonstrating its commitment to its customers by investing in high quality market leading equipment brands,” says Youngman Richardson and Co Ltd Sales and Marketing Director Ed Richardson.

The Genie rough terrain scissor models are designed for the hire industry. They’re made to stand up to the rigours of frequent use in diverse worksite conditions. HireQuip have recently become the first company in New Zealand and Australia to take delivery of the new model Genie GS3369RTO. This new 4-wheel drive vehicle with oscillation axle provides outstanding rough terrain capability. In addition it offers narrow access abilities, a slide-out platform extension and working heights of up to 11.90 metres.

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January 2012

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The scissors are tough construction orientated 4-wheel drive machines with positive traction control and are ideal for increasing productivity in demanding outdoor worksites. Because time is money, the competitive lift speed and large platforms maximise handling requirement efficiencies and have the capacity to get to the jobsite quicker and finish working faster. HireQuip has also acquired from Youngman Richardson and Co Ltd some Mazuren hydraulic breakers, which are very powerful machines and weigh in at just 21kg and come with a lightweight power pack that weighs only 44kg. Powered by a Subaru/Robin OHC OHV petrol engine, it can be transported, much like other light equipment from HireQuip, in the boot of a car or in the back of a ute rather than hassling with large towable units. HireQuip have procured additional units of the latest Husqvarna K760.14, unmatched for its power to weight ratio. It also features a

new air filtration system, a 14" blade capacity and an anti-vibe handle. The range of Mikasa reversible plate compactors is ideally suited for the hire industry where these models are constantly in demand with civil engineering, construction and drainage contractors. Standard features include 150mm removable extension plates, a sturdy roll bar lifting frame and variable speed controls. The fold-up handle is perfect for HireQuip customers for both transportation and storage. Another product, the Mikasa MTX60 tramping rammer is powered by a 4-stroke engine so no fuel mixing is required. It also features anti vibration handle systems on the reversible compactors and rammers that reduce fatigue and enhance operator comfort. The Mikasa MTX60 has outstanding compaction ability and balance and has a roller fitted to the handle for easy loading. Go to www.demm.co.nz/ enquiry quote: D120102

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> PRODUCT WATCH

How much is too much? with a zero blood alcohol content. It has a modern design with clear visual and audio cues, and an easily replaceable sensor module so the user will not have to ship the entire unit for calibration, only the sensor. The Soberpoint can be customised with either coin or push-button operation. It utilises the latest fuel cell technology and complies with AS/NZ 3547 standards. The AlcoSense car ignition interlock

breathalyser FR9000 is a handheld breath alcohol analyser or breathalyser with a vehicle ignition system. The driver whose car is equipped with the unit must complete a breath alcohol test with a result below a preset limit before they can start the vehicle. It complies with the AS/NZ 3547 standards. Go to www.demm.co.nz/enquiry quote:

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The Alcosense Soberpoint is an industrial grade wall-mounted breathalyser.

Alcohol is a depressant; it slows brain activity and responsiveness, even at a level of only 0.030 percent BAC (blood alcohol content). This can create all kinds of problems in the workplace, especially if you are working hard to hit those targets or your deadline is closing in fast. ADT Corporation NZ Ltd has the sole agency for the Alcosense range of products, including industrial, workplace, personal and car interlock fuel cell alcohol breathalysers that comply with the AS/NZ 3547 standard. The Prodigy breathalyser is a state of the art instrument suitable for industry, corporate, medical, personal application and anywhere there is a need to screen for the presence of alcohol or to get a highly accurate reading of a subject’s BAC. It is specifically designed so anyone can use it, with minimal instructions, after a big night out or to screen multiple subjects on an ongoing basis. The Prodigy breathalyser is powered by AlcoSense FXCELL 3. With a BAC range of 0.000 – 0.400 percent and accuracy of +/- 0.005 the FXCELL 3 is a powerful fuel cell sensor designed for higher accuracy over regular tests. The user has full control over recalibration time warnings with advanced options; choose six months, 12 months or anywhere up to 1500 tests. The Alcosense Soberpoint is an industrial grade wall-mounted breathalyser which provides a tool to ensure OH&S regulations are complied with. The device gives you peace of mind by ensuring employees are working

MaxiCoat

Epoxy floor & wall coating system

MaxiCoat is ideal for heavy duty traffic areas; has a very high chemical resistance, is NZFSA approved and has the strength of conventional oil-based coatings, but with the safety and convenience of water as a solvent. Only two coats are required to give a durable long lasting finish, reducing cost and application time.

Water based & durable for a long lasting finish

Key applications:

* Forecourt & showroom floors or walls

* Car garages & workshops * Light & heavy industrial factories * Aircraft hangar floors * Food processing plants & freezing works * Cold storage rooms

* Fishing vessels, ships & offshore installations

KT KemTek

03 688 2160 www.kemtek.co.nz 3

> PRODUCT WATCH

In-line production of PE-Xa pipes for hot water and gas Krauss Maffei Extrusion has developed a special system technology for the production of PE-Xa pipes suitable for heating systems and gas transmission. The new system utilises peroxide crosslinked technology for polyethylene pipes supplied under an exclusive partnership agreement with Crosslink Finland OY, a leading manufacturer of infrared crosslinking ovens. The complete line from the specially developed twin-screw extruder with a conical processing unit and the pipe head through to the unique calibration and cooling system is ideal for the processing of the ready-mixed compound consisting of polyethylene, a stabiliser and peroxide. After the three components have been mixed, a diffusion process takes place and the liquid peroxide is absorbed by the granulated polyethylene. This produces an extremely homogeneous material mixture as

the peroxide is distributed inside the granule. The system provides a high degree of reliability and constant process conditions which ensures a high quality product with a consistently high degree of crosslinking. The crosslinking of the PE pipes takes place in-line in the specially developed infrared crosslinking oven supplied by partner Crosslink Finland OY which has been integrated into the Krauss Maffei solution. This approach eliminates the need for additional downstream production steps and reduces manufacturing costs including lower raw material costs. Crosslinked PE-Xa pipes have high flexibility, high resistance to heat and cracking

and are typically used in panel and radiator heating systems, as well as in the supply of hot water systems, drinking water, compressed air and gas lines. Krauss Maffei is represented in Oceania by HBM Plastics Technologies. Go to www.demm. co.nz/enquiry quote:

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Soloist with plenty of talent Free-standing enclosures are used in many areas of industry and in buildings services management. Typical fields of application are in compact machinery and equipment and their power distribution and automation components, which can be accommodated in a single enclosure. For such cases, Rittal has expanded its TS 8 system platform by adding the new system enclosure SE8. Unlike baying suites with frames and removable side panels, the body of the SE 8 – consisting of two side panels and a roof – is made from one piece of sheet steel. The rear panel of the enclosure is screwed on for easy access. Cable entry solutions can be employed

January 2012

on the integrated base frame, as in the TS 8 bayed system. The doors and the base/plinth of the SE 8 have also been taken over from the TS 8 program. Since the enclosure sections for interior installation are identical with those of the top enclosure system, SE 8 is perfectly integrated into the TS 8 system platform – with many advantages. Thus, the user benefits from improved expansion options on two mounting levels. The extensive system accessories that Rittal offers for the top enclosure can be easily incorporated into the SE 8. Go to www.demm.co.nz/ enquiry quote: D120104a

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> PRODUCT WATCH

Equipment line-up for enduring solutions Aurora Process Equipment’s range of specialised materials handling and fluid processing equipment is designed and industry proven to provide enduring solutions to customers’ processes. Simple and durable equipment constructed to withstand years of industrial use complements basic mechanicals for ease of maintenance. Full stainless steel systems are suited to food grade wash down situations, meeting IP requirements and hygienic standards where necessary. Aurora offers the remarkable Galaxy range of conveyors which includes powered rollers, belts, troughs, vacuum, or plain level and gravity frames to name a few of the available features. The Floveyors, GSI Elevators and Chain Conveyors or TR Troughed Belts are ideal for loading the Smart Silo range of bagging hoppers and silos, coupled with intake and discharge options. Flexflo coreless augers allow for simple product transfer, the Taylor bagging scales, both open mouth or valve bags, bulk bag filling units and Fischbein bag closing equipment for bag sealing or stitching. The reliable Magnattack range of magnetic separators helps keep contaminants

out of your quality products. Fischbein palletisers and wrappers wrap up our extensive range, completing a comprehensive packaging line. There is also an extensive line-up of equipment for fluid processing, including the market-leading Dimpleflo tubular/shell and tube heat exchangers and Mueller plate heat exchangers for proven performance in heat transfer.

The Mixquip fluid mixers and agitators use unique design features to provide superior efficiencies in product movement. The Compri product recovery and pigging systems are used globally for product recovery at the end of production and cleaning lines between batches. Go to www.demm.co.nz/enquiry quote:

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D120105

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

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> PRODUCT WATCH

Affordable 3D printing in high-resolution

3D Systems Asia-Pacific announced the availability of a new low cost personal 3D printer, making high-resolution durable colour parts accessible

to more designers, engineers, architects, marketers, educators and students. The ProJet 1500 prints high-resolution, durable plastic parts in up to six different colours. This compact desktop 3D printer is suitable for both the office and classroom, printing parts with excellent feature detail and smooth surface finish that bring designs to life at print speeds up to five times faster than any other 3D printer in its

class (manufacturer information). Parts printed on the ProJet 1500 are tough and suitable for a variety of functional testing and snap-fit applications. The printer is network ready, featuring email notifications and an intuitive web browser interface for shared access and it is office compatible, emitting no excess heat, odour or dust. “We packaged colour together with high-resolution durable plastic printability to

make the ProJet 1500 nearly fifty percent more affordable to own and operate than other alternatives,” said Buddy Byrum, Senior Director, 3D Printing for 3D Systems. “With every new ProJet printer introduction, we affirm our commitment to democratise access and accelerate adoption of 3D printers for the benefit of professionals and consumers alike.” Go to www.demm. co.nz/enquiry quote: D120106

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New triple sensing smoke detector Fire protection specialist Wormald is introducing a new triple sensing smoke detector. Offering a high level of versatility and performance, 3oTec integrates visible smoke, heat, and carbon monoxide (CO) fire sensors within one housing to deliver early detection and reduce costly false alarms. The use of three diverse detection technologies enables the triple sensing smoke detector to confirm the presence of fire more reliably in its early stages than detectors employing just one or two detection technologies. Furthermore, the device is fully certified and listed as a smoke detector, and can therefore be used to advantage in applications requiring smoke detection to comply with the New Zealand Building Code. 3oTec uses Wormald’s MX Technology, which can detect a wide range of fire types, even slow smouldering fires where visible smoke levels can remain at a minimum for several hours before the fire takes hold. Also, sophisticated algorithms increase the detector’s ability to distinguish between real fires and false alarms, such as those caused by burning toast or shower steam. The 3oTec triple sensing smoke detector offers two key modes of operation – Universal for maximum protection and Resilient for maximum false alarm rejection. In Universal

January 2012

mode, all three elements provide input to a sophisticated algorithm which automatically adjusts the detector’s sensitivity to the prevailing conditions. This results in timely and reliable detection across a broad range of fire types. With Resilient mode, all three elements are used in a similar way to Universal mode but the emphasis is on reduction of false alarms. This setting is intended for more challenging environments where reliable detection is trickier. Detection modes can also be adjusted to suit changes in occupancy. For example, Resilient mode could be used during the working day when the building is occupied and the environment is more likely to produce phenomena that could trigger a false alarm, with a switch to Universal mode at night when the building is unoccupied. The mode change is controlled from the associated fire alarm control panel, and may be initiated either automatically or manually. Another feature of the 3oTec detector is the opportunity to provide early warning, investigation, and control of a possible fire condition using staged warnings from each of the integrated sensors. This avoids the cost of the separate detectors that would otherwise be required. For example, an early warning of an incipient fire could be provided from the

CO sensor, with a more urgent alarm generated separately when the visible smoke sensor is activated, with escalation to a full fire evacuation alarm upon operation of the heat sensor. This makes it very easy to implement Type 5 and/or Type 7 fire detection systems of the New Zealand Building Code Acceptable Solutions, which require separate alarm action for smoke detector operation and heat detection. The addition of the CO sensor provides enhanced operation over and above that required by the Building Code, resulting in a system that is especially suitable for the protection of premises where occupants might be sleeping or otherwise disabled. The sensors may be used in other combinations also, to enhance detection or to reduce false activations. For environments where there is a carbon monoxide toxicity risk as well as the threat of fire, the 3oTec detector’s CO sensor can be used as a carbon monoxide toxic gas detector while the smoke and heat sensors continue to operate independently to detect fire. Go to www.demm.co.nz/enquiry quote: D120106a

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> PRODUCT WATCH

High-class looking door with low maintenance When it comes to replacing scruffy and torn PVC swing doors, the 4500 Series traffic door by Ulti Group offers an interesting solution. This “crash through” door for heavy usage environments is available in either single or double leaf operation and delivers a very high-class look to the user’s facility. The tough molded polyethylene exterior is able to deliver to the demands of these areas and continues to look great, work well, and has proven to be very low maintenance over time due to the unique pivotal hinge system. These doors deliver real life time value as

they keep looking smart for many years in harsh environments. The ULTI 4500 series door, with its high thermal insulation value, is an ideal solution for a premium traffic door as it will greatly help in keeping the warm air where it is needed most. With the optional 900mm high impact buffers to the doors, these are designed to take trolley impact with ease and help to keep the doors looking smart and clean long after actual installation. Among the facility owners who are now enjoying the benefits of traffic doors are Oamaru New World, Tegel Foods, Rangiora New World,

Affco, Ilam New World and Riverlands Meats. The doors are supplied and installed New Zealand wide by Ulti

Group including Egmont Doors and totalDoors. Go to www.demm.co.nz/ enquiry quote: D120107

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4500 SERIES Doors: No other crash through door is as strong, reliable – or keeps so good looking! • Doors are robust enough to allow forklift traffic, yet create a smart and professional store image • Insulated panel system ensures energy savings on Air-conditioning and energy costs

• Suitable for Chilled, and or full wash-down areas as well as retail or corporate applications • Includes Safety vision panels – signage optional. • Complete supply & installation service NZ Wide.

Group Incorporating; totalDOORS & Egmont Doors;

Call 0800 807 753, or visit our website www.ultigroup.co.nz 7

> PRODUCT WATCH

Air cleaners now even more energy efficient Energy efficiency is today’s buzzword, in all countries across all industry sectors. The Australian Government’s Clean Energy Future sets to cut pollution by at least 5 percent compared with 2000 levels by 2020, which will require cutting net expected pollution by at least 23 percent in 2020. The Australian Government has also committed to a long-term target to cut pollution by 80 percent below 2000 levels by 2050. Similarly, by adopting the Kyoto Protocol, the European Union has undertaken to reduce CO2 emissions by at least 20 percent by 2020. To achieve this climate goal, the EU adopted the the ErP Directive (Energy-related Products Directive). This new directive helps with studying the savings potential of numerous energy-related products and stipulating minimum requirements. These new regulations mean that up to 50 percent of existing electrical fans will need to be upgraded. Limits for fans were defined in June 2010 and are valid now. Fans are used in many areas of manufacturing and in many in-design products, so the EU changes could be long-lasting in

cutting CO2 emissions – not only in Europe but also in other countries like Australia. Machine tool-based mist extractors use fans and therefore will be subject to these new directives. Reven GmbH can deliver from now on all of its air cleaners with fans and motors that already fulfil the ErP directive. All of these air cleaners, also known as mist extractors, now wear the green ErP ready sticker. Dimac Tooling, Mulgrave, VIC, offers the German-made Reven Recojet oil mist separators Ultra Cleaners and Rejet-A air cleaners, which are highly efficient mechanical air filtering units using the mechanical separating system X-Cyclone. Air pollutants and contaminants from oil, emulsions and other fluids are separated from the ambient air as aerosols to a very high extent. The new extreme energy efficient ErP version comes with many more updates and improvements. The motor has been moved outside of the airstream, which leads to a higher lifetime for the motors. The ErP version comes with a much more compact door design, therefore the door is now more

resistant and is oil and waterproof. The fan housing is completely welded and therefore now 100 percent oil and waterproof. Go to www.demm.co.nz/enquiry quote:

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D120108

Airtight and hinged

The energy tube RX can be opened quickly in the outer radius.

January 2012

The innovative plastic energy tube RX from igus is almost one hundred percent airtight (2.7g chips after 251,900 cycles). The manufacturer has also carried out extreme tests underwater to comply with the absolute airtight requirement (IP40, TÜV Saarland). The rounded design without undercut or edges and the smoothly curved outer contour allows chips – from coarse to tiny particles – to simply slide off. In addition, the connection elements and fittings are concealed, so that chips cannot be caught on these either. The energy tube is easy to open and

can quickly be swung open in the outer radius. Alongside the three design sizes with an inner height of 52, 62 or 73mm, there is now a new design size available with a maximum inner height of only 42mm. The new size is available with the option of a high-temperature variant, resistant to hot chips up to 850°C, and as a variant with reverse bending radius (RBR). Dust, dirt, oil, aggressive environment conditions, humidity and heat have no effect whatsoever on the sturdy energy chains. Go to www. demm.co.nz/enquiry quote:

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D120108a

> PRODUCT WATCH

Ex-rated motors made in NZ A question often asked in the market is where to get Ex-rated motors. CMG pride themselves in being the largest supplier of Ex-rated motors in New Zealand. Whether Ex e, Ex n, Ex td, Ex d – CMG not only have these ex stock, they also have the only IANZ accredited workshop in New Zealand. “As the only electric motor company in New Zealand to be IANZ accredited for the overhaul, repair and modification of Ex-rated motors and enclosures, CMG New Zealand have been invaluable to the oil and gas industry for the last ten years,” says Craig Keesing, New Zealand Managing Director of CMG New Zealand. The company has also been ISO9001 certified and awarded Test Safe’s stamp of approval for the manufacture

CMGNZ_DEMM_1112_01_OUTLINED.indd 1

of Ex-rated products in New Zealand. It is for this reason that the company deems itself in the best position to advise on the repair and replacement of existing Ex-rated equipment. “A lot of Ex-rated equipment in service has non-standard shaft or mounting requirements and replacing may not always be an easy option,” says David Priestley, Service Manager of CMG New Zealand. “The ability to service and re-certify original equipment under our IANZ accreditation can save the need to create a new installation while providing the required documentation for a verification dossier.” Sometimes existing equipment is unable to be repaired or the repairs prove uneconomical. To minimise down time on repair, CMG New Zealand covers all

options when existing equipment breaks down. Certification covers voltage and frequency variations and modifications are conducted in-house. Special physical and mechanical requirements even for non-standard applications can be provided and be supplied certified. “The company’s IEC and ATEX certifications thus qualify the company to expand its services beyond New Zealand’s borders, enabling the company to provide a variety of certified products to anywhere in the world,” says

Craig Keesing. CMG New Zealand can offer a comprehensive range of Ex-certified motors. “It was a proud day for CMG when our Auckland based workshop was listed as a manufacturing location on both the ATEX and IEC certificates of conformity,” recalls Craig Keesing. “This ability enables CMG New Zealand to offer the fastest delivery times as Ex motors are now manufactured to order right here in Auckland.” Go to www.demm.co.nz/ enquiry quote: D120109

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13/12/2011 11:06:01 AM

> PRODUCT WATCH

Absolute multi-turn analogue encoder with teach-in function

The new AV58M adapts to an application, instead of the user having to adapt their application to the encoder. With this fundamental principle,

Siko has enhanced its product programme to include a magnetic absolute analogue encoder with teach-in function. Using the two buttons

on the reverse and two external inputs, the AV58M can be set to the required measuring range directly in just a few steps. Users thus have the full signal travel distance (0–10V or 4–20mA) across precisely the measuring range that they require. Irrespective of whether it is necessary to measure 2, 10, or 100 revolutions, the AV58M is the best choice for any task and thus makes storage of encoders with different gear ratios or measuring ranges no longer necessary. The encoder provides the measuring range set in a resolution of 12 bits (4096 increments) and draws

on wear-free and battery-free multi-turn technology in the process. Thanks to its double ball bearing, the low-cost encoder is designed for high loads. The wear-free magnetic measuring principle and the battery-free multi-turn technology predestine it for positioning tasks in mechanically challenging environments. Go to www.demm. co.nz/enquiry quote: D120110

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Transport containers offer optional IP65 sealing The K470 containers from Zarges come into their own wherever you need to protect valuable and sensitive equipment against extreme environmental conditions. For decades, a wide range of customers from all walks of life, such as the armed forces, scientists, explorers and numerous other professional users, have relied on Zarges containers. Up to now, the K470 containers have been supplied as standard with reliable protection against dust and splash water (IP54). Now, the new model can be used wherever you require that little bit more impermeability and increased protection against moisture, jetting water and dust – for example for assembly on vehicles, boats

etc. Ingress protection of class IP65 is achieved by means of an optimised lid seal with additional silicone sealing. To ensure that the lid can be opened reliably even after changes in air pressure, the K470 IP65 version is equipped with an automatic pressure compensation valve. A Gore membrane ensures that pressure differences are continuously compensated for and is at the same time impermeable to dust, salt, water and other liquids. And thanks to the automatic valve, operating errors can be ruled out. The K470 IP65 was subjected to rigorous testing for imperviousness to dust and jetting water by the TÜV SÜD, it passed the tests with flying

January 2012

Multipurpose K470 containers offer protection against moisture and dust, but are also suitable for the transportation of explosive, toxic, infectious, caustic or flammable liquid materials.

colours and was awarded the TÜV seal. The optional seal is available for all K470 sizes offered in the Zarges catalogue, with just a few exceptions. In addition, you can also choose to combine this new version with

additional UN approval for the transportation of hazardous goods. Go to www.demm. co.nz/enquiry quote: D120110a

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> PRODUCT WATCH

Software update

measurements and constructions. Shortcuts enable users to record all steps of a complex measurement into a single command that can later be accessed with a single mouse click. The Easy Move Wizard is of great assistance for measuring large parts when the need to reposition the device is often necessary to complete a measurement. The complexity of finding the correct target correspondence is taken away from the operator, cutting down on the time required for the repositioning and, at the same time, removing the risk of human error. Designed to make tactile and scanning measurements easier, the software also features an elegant and intuitive interface that enables users to customise the layout window optimising the measurement workflow. “To further increase the productivity of our existing and potential customers we developed a new software solution which combines new outstanding, useful and unique features with an unparalleled ease of use. www.faroasia.com/CAM2measure

ToTal Back Up At Total Lubricants we don’t just supply top quality product to your industry we back it up with top-notch service too. You’ve probably heard of our Rubia range of engine oils and Azolla, our hydraulic range – now find out how they are right for your business. Give us a call and talk to us about how Total Lubricants can work with you, phone 0800 868 256 (0800 TOTAL OIL) or visit www.totaloilsolutions.co.nz

ATTN11TOT63

Faro Technologies announces the release of CAM2 Measure 10, its new measuring software for the FaroArm, ScanArm and Faro Laser Tracker. This new release is built on the solid foundation of the previous CAM2 Q while also introducing key new features like Live Color Scan for point cloud inspection, Shortcuts and the Easy Move Wizard. These innovative functionalities are designed to improve measurement processes, whether tactile or scanning. The Live Color Scan feature adds point cloud inspection support to the geometry measurement functionality. Thanks to this new feature, CAM2 Measure 10 users can quickly scan freeform parts using the Faro ScanArm just as easily as measuring geometry with a tactile probe. In just a few steps they can complete a scanning inspection, viewing live colour information on their parts as they scan. Another time-saving feature of the new release is Shortcuts. It allows users to create new commands to measure features that are only available through combining

> PUMPS & VALVES

Chopper pumps solve problems in the wastewater industry

The patented features specific to Vaughan pumps provide assurance of reliable and clog-free solids-handling performance.

The use of Vaughan chopper pumps can be applied to any municipal or industrial application that involves pumping solids-laden slurries and fits hydraulically into the available performance characteristics. More specifically, Vaughan Chopper Pumps in the following applications provide a cost-effective method of eliminating clogging problems and optimising system performance. Small residential pump sewage pump stations are generally equipped with submersible grinder pumps, and larger pump stations with “non-clog” impeller pumps. However, pump stations can see an unusually high concentration of solids such as hair, rags or plastics, which cannot be reliably handled by these conventional pumps. Where heavy solids loading has been anticipated during the engineering stage, many of the larger pump stations include a macerator, grinder, or comminutor ahead of each pump. Vaughan Chopper Pumps have solved many pump station clogging problems and have eliminated the need for comminutors. In many instances, chopper pumps have directly replaced existing pumps without the need for repiping.

Generally, non-clog impeller pumps must be sized according to maximum anticipated sphere size, with hydraulic considerations secondary, whereas Vaughan Chopper Pumps for pump stations can be sized for hydraulic requirements without regard to minimum sphere passing diameters. For example, a requirement of 45 m3/h at a total head of 40m might normally require a 3" pump hydraulically, but a 3" non-clog pump is not able to create both the high head required and pass a 3" sphere requirement at the same time. Therefore, the engineer and/or manufacturer would be forced to use a 4" pump. This results in higher costs not only due to the larger pump, but also due to lower efficiency and higher power consumption. However, since

January 2012

a Vaughan Chopper Pump reduces the solids size prior to entry of the pump, sizing of the pump is based primarily on hydraulic requirements, with little consideration given to sphere size. Septage receiving pit pumping is a very tough challenge for most modern pumping equipment. Septage is made up of concentrated solids from septic tanks plus rags and plastics, which can plug conventional non-clog pumps. Vaughan chopper pumps eliminate plugging problems by chopping all incoming solids prior to pumping. Since conventional non-clog pumps often require oversizing to handle solids, another means of pump protection has been to pre-grind all material upstream of the pump. This is an unnecessary added

cost in the installation, operation and maintenance, when a Vaughan chopper pump does both jobs with one piece of equipment. One particular problem associated with sludge pumping is the “roping” of hair and other stringy material created by pre-rotation within the piping system. This problem is particularly worse for nonclog style and vortex pumps. Vaughan chopper pumps, on the other hand, eliminate roping completely by chopping these solids as they enter the pump. Another common problem is pumping greaseand-hair balls or other reformed solids. In digester recirculation, passing a grease-and-hair ball from the bottom to the top accomplishes nothing. However, if the reformed solid is chopped

> PUMPS & VALVES during the recirculation process, then the small chopped solids have a higher surface to volume ratio and are digested faster. Vaughan chopper pumps are able to handle higher solids concentrations that conventional non-clog pumps, in some cases up to 18 percent. In normal treatment plant processes, this means that sludges can be more concentrated without exceeding the pumps capability. Vaughan chopper pumps also reduce downstream clogging in pipework and friction losses associated with high solids content. The chopping of these solids creates a smaller solid with sharp edges that tends to scour the inner walls of discharge piping. Friction is reduced due to maintaining full pipe diameter, rather than choking flow with grease buildup on the inner pipe walls. The chopping and shearing action of the Vaughan chopper pump also tends to reduce sludge viscosity, further reducing friction loss. Vaughan chopper pumps play an integral role in Vaughan’s Rotamix process mixing system, which is widely accepted as today’s most cost-effective means of pumped mechanical mixing. The Rotamix system consists of an engineered arrangement of floor-mounted nozzles fed by an externally-mounted Vaughan chopper pump to provide unique dual rotation mixing zones to achieve efficient and effective mixing for a wide range of municipal and industrial processes. Rotamix can be applied in circular, rectangular, and oval tanks and basins, as well as other unique process configurations included egg-shaped-digesters, CSO tunnels and influent pump stations. At the “heart” of the Rotamix system is the Vaughan chopper pump, which prevents fibrous material from reweaving and eliminates the risk of nozzle plugging. As Rotamix essentially recirculates the tank contents, each subsequent pass through the chopper pump helps to

continuously break down and precondition any suspended solids. The action of chopping and conditioning material to reduce particle size is of proven value in sewage treatment plants. If digestible material is in smaller particles, then the surface area of these particles is relatively large in comparison to their volume. Bacterial action can then be more effective and rapid. Plants that have used Rotamix or Vaughan chopper pumps for digester mixing and/or recirculation have seen that the reduction of particle size increases both the rate of decomposition of digestible material and methane gas production. Rotamix is designed to provide over 90 percent active volume mixing in an anaerobic digester and to eliminate the formation of scum mats, a common problem for many treatment plants, which not only limits methane gas production, but eventually results in more frequent contract cleaning of the digester. By using Rotamix and stopping a scum mat from forming, the net benefit can result in increased digester capacity by up to 40 percent and increased gas production by up to 300 percent. Inherent problems with clarifier scum include plugging and air binding. As mentioned above, the Vaughan chopper pump addresses the plugging/ clogging problems. However, air-binding must be addressed an an indirect manner. The inherent recirculation around the inlet to a Vaughan chopper pump usually causes enough mixing to keep air binding from occurring in scum pits that have short retention times. If a scum pit has a long retention time, then the scum tends to concentrate and form a “blanket” on the top. As the pit level is pumped down, this blanket can block the pump suction. In this case, Vaughan’s solution would be to use a vertical wet well configuration chopper pump with optional recirculation

Installed through an existing manhole, the Scumbuster virtually eliminates scum blankets and prevents them from reforming by homogenising and conditioning through a recirculation nozzle.

nozzle fitted to the outlet to pre-mix the scum pit prior to pump-out. The heavy-duty oil bath lubricated bearings and sealing systems in the Vaughan’s vertical wet well range allows operators to completely empty the scum pit down to the pump inlet without risking damage to the pump bearings or seal due to loss of coolant or lubricant. This allows full removal of the scum during each pump-out. With the addition of a motor low current monitoring system in the pump controls, the “OFF” function can be based on low motor current draw rather than using a float switch. Once the liquid level drops to the point where air enters the pump inlet, the current draw will drop off and the low current relay shuts the pump off. All of the above wastewater treatment applications mentioned above are centred on the Vaughan chopper pump’s ability to handle solids from a pumping standpoint. However, this is not the only benefit. Vaughan chopper pumps can also eliminate seal and bearing failures observed in other pumps. Since the chopper pump design requires heavy shafting, an added benefit is longer life due to stronger parts and less vibration. Quite often, seal failures in generic submersible pumps are associated with solids wrapping or binding at the impeller or seal. The can cause severe

vibration that is transmitted through their longer overhung shaft and tandem mechanical seals to their lower trust bearing. This not only results in seal and bearing failure, but also introduces moisture into the motor. The heavier shafting and short overhang of the Vaughan chopper pump bearing and seal design address this problem and reduce maintenance costs as a result. More local authorities and engineering firms alike are discovering the economics of applying Vaughan chopper pumps into applications where conventional pumps have historically failed. These failures are generally due to clogging and/or seal-and-bearing failure, and all contain hidden costs that must be addressed. The largest fallacy of the “low bid” system is that a low initial price does not mean lowest overall cost. More often or not, “low bid” type equipment has a higher potential of failure and properly specified and purchased equipment. The solution starts with the requests of the treatment plant operator to obtain equipment that will operate maintenance free, and ends with the will of those having purchasing authority to think toward the future. Go to www.demm.co.nz/ enquiry quote: D120113

•

> PUMPS & VALVES

Pumping up efficiency pump pushing liquids at unnecessarily high flow rates? Is cavitation occurring?

Image courtesy of Energy NZ.

Anyone involved in manufacturing knows how crucial reliable, wellfunctioning pumps are for keeping production on track and on schedule. However, fewer are aware of the massive energy saving opportunities often present in pumping systems. Of all the economic electricity saving opportunities in New Zealand industry, around 40 percent are in liquid pumping systems. Given this, it makes sense for EECA to help industry improve its bottom line and productivity by improving pumping systems’ efficiency. The pump unit may be operating reliably and to specification, but is it sized correctly? Is the drive system between the motor and pump efficient? Is the

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Call 06 3269444 For A FREE Copy

January 2012

New programme partners We’ve recently approved a number of engineers and energy auditors with pumping systems experience to work with industry under EECA’s auditing and project implementation programmes. By choosing an EECA Programme Partner you’ll be engaging someone who knows how to improve the performance of a range of different pumping systems, and is also au fait with how EECA can assist. EECA offers several funding options that can help reduce the risk for businesses wanting to invest in pumping system efficiency. Provided certain criteria are met, we can help fund an energy audit, a feasibility study on a system improvement, or project implementation. Examples in industry One company that has profited from investing in pumping efficiency is Rohm and Haas NZ Limited. An energy audit highlighted that significant electricity savings could be achieved through more efficient control of the cooling water pump at its Auckland plant. The pumping system was using 27kW to 35kW of power to pump water through its cooling system. But between batches when no cooling was needed, the pump still used 19kW of energy. A variable speed drive (VSD) was fitted to the circulation pump to allow the running speed to match the cooling requirements. The project reduced electricity usage on the pumping system by 28 percent and had a simple payback period of 1.7 years. A project we ran with the Aggregate and Quarry Association led to several profitable projects in quarries. In one instance we found that eliminating double pumping brought energy savings worth $25,000 a year (with a payback of 1.2 years). Another quarry found that fitting a VSD control system

(and a level sensor) on its process water pond pump brought annual energy savings worth $25,000 and a payback of just over a year. Tune your boilers for instant energy savings Another little-known area of energy waste in industry is boilers. EECA has already carried out work to ascertain the savings potential in improving boiler efficiency. Simple combustion tuning can deliver savings of 25 percent, immediately. What can this be worth? At Goodman Fielder’s Meadowfresh Plant in Christchurch, the company found savings worth $45,000 per year through boiler tuning – and that was in a system that had been tuned only a few months previously. Working with industry experts, EECA has developed a template for best practice boiler tuning and we’re now looking for companies to pilot this with. Under the pilot, EECA will contribute up to $5,000 towards best practice boiler tuning. This procedure examines boiler reliability, combustion tuning, heat loss, hot water or steam leaks, heat recovery, fuel quality and clean heat-transfer surfaces. The pilot is scheduled to run until February – but there is only a limited number of spaces. To find out more or to apply to take part, email EECA Business Project Manager Pramesh Maharaj on Pramesh.maharaj@eeca.govt.nz.

Article by Rod Treder, Industrial Programme Manager, Energy Efficiency and Conservation Authority

Sick and tired of pump clogging problems?

For guaranteed non-clog performance, invest in a Vaughan® Chopper Pump Is your pump station costing you money due to continual clogging problems and pump downtime? Are you tired having to constantly unblock rag and other stringy material from your so-called “non-clog” impeller pump? If so, come and talk to us about a submersible Vaughan® Chopper Pump and the non-clog guarantee. With thousands of proven pump station installations worldwide, Vaughan® Chopper Pumps will solve the toughest clogging problems. We guarantee it.

✓ Multiple configurations available ✓ Capacities up to 2200 m3/hour ✓ Heat treated & hardened components ✓ Easily retrofits to most guide rail systems Submersible Chopper Pump

✓ 50 years chopper pump experience ✓ Non-clog guarantee on all pumps

Pump Systems Ltd - Vaughan® Authorised Factory Representative (New Zealand & Australia) Free Phone: 0800 60 90 60 | Free Fax: 0800 70 75 76 | Web: www.chopperpumps.co.nz

> PUMPS & VALVES

Providing superior control performance Electric control valve actuators eliminate the problems of compressed air as a power medium. Today, a major technological advance is available to help control valve users avoid many of the problems and inefficiencies associated with compressed air. The new solution, using electric power, is appropriate and cost-effective for a wide variety of control valve applications in most process environments, especially where users experience problems with frozen air hoses, lack of process precision and stick-slip. In many instances, this technologically advanced equipment can substantially increase the output and efficiency of the process whilst helping to reduce maintenance and operating costs. Before discussing today’s latest technology, it’s beneficial to understand how control valve actuation has evolved. Decades ago, process control valves were controlled by varying the pressure of the air supply to the actuator between 3 and 15PSI. By balancing this air pressure against an opposing spring, a closed valve position would relate to 3PSI and the open valve position to 15PSI. Entire plants were controlled by compressed air channeled through small-bore copper tubing. However, with the advent of computers and PLCs, the days of the 3-15PSI control signals were numbered. They were replaced by electronic signals carried on much lighter-duty copper wire. This was a revolution in control technology, bringing with it cost savings as well as improved control capabilities. Another benefit of this change was the elimination of labour-intensive maintenance of the pneumatic control system. Filters, regulators, lubricators, and a multitude of small pilot control valves were replaced with PLCs and their final element controllers. In place of the 3-15PSI pressure signal, a 4-20milliamp current control signal was adopted. However, having used instrument air as the control medium in the past, it was perceived that there were benefits in retaining it as the power medium, so in time the instrument air was upgraded from 3-15PSI to 80PSI, allowing greater forces to be generated by smaller pistons or diaphragms. The resultant pneumatic spring diaphragm and piston actuators have become the default

January 2012

standard for positioning control valves. A “positioner” is used to translate the control signal from 4-20milliamps to high pressure acting on the diaphragm. The simple pneumatic positioner has evolved from the basic functionality of controlling high pressure air using a low pressure signal to today’s smart positioner, which gathers information to provide diagnostic information that can be transmitted back over the 4-20milliamp signal using a communications protocol such as Hart. This method is currently the standard for most process control valves. Why electric actuation may be better However, this may not be the best solution for every application. Just as electronics have usurped control signal technology, electric actuators now offer a viable alternative to pneumatic spring diaphragm and piston designs. There are many drawbacks to using compressed air as a power medium. Converting electrical energy into compressed air, transporting it via a filter regulator and lengths of tubing before directing it into a chamber for expansion is an inefficient method of moving power from one point to another.The inefficiencies of compression and friction losses in transmission can account for a 50 percent net loss of the applied energy. Compare this with the much more energyefficient method of transmitting the power via electricity and converting it into kinetic energy in a motor located directly at the valve. Basically, the electric motor drive has been transferred from the compressor to the actuator, eliminating the intermediate conversions and transmissions and their attendant losses. When considering the constant movement of large numbers of process control valves in a plant, the elimination of compressed air can be significant and result in a much more productive and cost-effective operation. In addition, plant reliability and availability is a significant factor. Air supplies require proactive and expensive maintenance to ensure that moisture and contaminants do not accumulate and clog the small orifices in smart controllers. Although many processes are in buildings

Rotork CVA all-electric control valve actuators

that protect the valves and instruments controlling the process, equally often valves are located in open areas and are vulnerable to temperature swings that can drop below the freezing point of water. Freezing temperatures can cause air lines to freeze and incapacitate pneumatic control valve actuators. Summary of features and benefits Electric control valve actuators can provide superior control performance, are easy to programme and eliminate the need for problematic air supplies.They are suitable for a wide range of linear and quarter-turn process industry applications including power generation, pipeline and gas installations, petrochemicals and mining. They are easily integrated into process control protocols, including Hart and Foundation Fieldbus. Rotork’s CVA actuators, for example, can be specified for single-phase AC or DC electrical supplies and provide extremely precise control valve operation, with repeatability and resolution performance at <0.1 percent of full scale. In addition, they utilise wireless Bluetooth communication technology for quick and easy set-up and adjustment. Rotork CVA actuators incorporate a data logger, which provides an extensive record of operational and maintenance-related data including valve torque profiles, dwell times and relevant statistical information. They also utilise built-in super-capacitors, providing an advanced, programmable method for fail-to-position protection. To read the full story go to www.demm.co.nz Article by Chris Warnett, Sales and Marketing Director, Rotork Process Controls Go to www.demm.co.nz/enquiry quote:

•

D120116

> WATER TREATMENT & WASTEWATER SySTEMS

With its compact design and small footprint, retrofitting a Salsnes Filter can increase existing wastewater treatment plant capacity by up to 40-50 percent with a minimum of plant modifications.

Salsnes Filter versus primary clarifier â&#x20AC;&#x201C; a competitive analysis Salsnes Filters are fully automated mechanical wastewater treatment systems for primary treatment in municipal or industrial applications. This analysis compares the performance of primary sedimentation tanks against the Salsnes Filter from a performance versus cost and reliability standpoint. Current internationally-accepted levels of treatment compliance are achieved by primary sedimentation tanks and the Salsness Filter. Primary treatment within the wastewater treatment marketplace has traditionally been performed by the use of primary sedimentation tanks. Primary clarifiers allow for grit and sludge settling, resulting in a separation of solids and water. The Salsnes Filter is a sludge/water separator which utilises a moving Kevlar/ fibre filter screen and a patented â&#x20AC;&#x153;air knifeâ&#x20AC;? cleaning system. Assuming a capacity of at least 10,000 population equivalent (PE), the construction of a primary clarifier constitutes a major civil engineering project

that consumes at least eight months on a greenfield site and can be expected to exceed $US 1.5 million. This does not include the cost of the land. Earthmoving on a large scale is necessary, and heavy duty electrical and mechanical support systems are essential. These require specialised skills and large numbers of contract labour, all of which cost thousands of dollars per week to support for the months they are needed on site. Nothing less than half an acre is going to be enough. Plant expansions are a major undertaking. The Salsnes Filter, on the other hand, is a commercially-available system in several different sizes to suit every application for

more than ten times less than a traditional clarifier for even the largest system. Its installation could easily be achieved within a matter of days. A low rated (<10kW) electricity supply, a simple domestic style hot water supply (<50 litres/day) and a shelter similar in construction to a typical carport are all that is required. A couple of tradesmen could complete the job in a few days. An area no bigger than a domestic single-auto carport is more than enough to house the largest Salsnes Filter and any ancillary equipment needed to provide primary treatment to a small town with a population equivalent (PE) of 10,000. This small space may well be available at an

> WATER TREATMENT & WASTEWATER SySTEMS

existing WWT plant and therefore requires no expenditure for the land. Increasing plant capacity and flexibility It is possible to take a primary clarifier off-line when not needed. But, there are a number of issues to be taken into account when doing so, such as the impact of leaving pumps and drives stationary and dry for long periods of time. Usually there is maintenance required to restart them. The Salsnes Filter simply requires the influent flow to be shut off via its control valve and a simple power switch. For long periods of idleness the filter has a drain valve enabling the contents (<100 litres) to be run off into any nearby drain. With a variety of high capacity pumps, rake motors and scrapers, a typical primary clarifier is a heavy consumer of energy, 10â&#x20AC;&#x2122;s of kilowatts at peak flows, and several kilowatts continuous consumption. For more than 95 percent of the time the Salsnes filter has two small electrical drives running that turn the belt and rotate the solids screw; less than 2kW at continuous operation. Worst, case scenario occurs during the automatic cleaning cycle (twice daily). At this time the filter consumes less than 4.5kW for a few minutes (to heat cleaning water and drive a wash pump). With a large number of pumps, bearings, valves and switches, the primary clarifier requires a fully-trained maintenance crew and a host of spare parts to be on call if uninterrupted operation is to be achieved. If the tank has to be pumped dry for maintenance then a whole host of plant upsets and problems may be initiated. The endless belt of the Salsnes Filter can be considered a consumable item. Due to the incorporation of Kevlar in its construction, a lifetime of at least one year is guaranteed, and two to three years is more typical. Any mechanical fitter can change the belt in less than two hours.

January 2012

The performance of a primary clarifier is directly linked to load and therefore requires careful operation. If good control techniques are followed then the 50 percent TSS and 20 percent BOD removal targets are possible. However, allow too much sludge to build up and the pumps become overloaded, possibly damaged, and hydrogen sulphide gas is produced. This is very corrosive and detrimental to any biological secondary treatment process downstream. Get the suspended solids and BOD removal rates wrong and poor food-to-mass ratio is a real possibility downstream, possibly upsetting settleability and final effluent

cost savings downstream. Coastal and university towns often experience sudden increases in population during certain times of the year. Switching on an additional primary sedimentation tank would be an ideal response to such an event as long as the tank was switched on ahead of time so stabilisation could occur. However, $US 1.5 million in capital costs, not to mention the environmental and plant location concerns that are usually voiced by the local population, often prevents such an approach being taken. The normal response is to try to optimise the plant to achieve high loading by use of expensive chemicals

For larger-scale operations, Salsnes Filter units can be installed in parallel for capacities up to 400 litres a second.

quality. The filter, on the other hand, is designed to exceed 50 percent TSS removal and 20 percent BOD removal. It automatically adjusts itself to suit the influent load, thus stabilising its effluent. Hydrogen sulphide cannot be produced within the Salsnes filter as retention times are in the order of minutes and sludge blankets cannot be formed within the filter anyway. Influent flow rates effect on performance The worst operational problem for traditional sedimentation tanks are variability of the influent flow rate (loading). Too high a flow rate and the tank is washed out, too low and retention times go up causing pumping problems or the requirement to install expensive instrumentation (level detectors and solids analysers) to the clarifier in order that pumping is controlled. Such instrumentation is not only expensive, but in certain circumstances its reliability has been questionable. The filter beltâ&#x20AC;&#x2122;s speed is variable with relation to flow rate. As the flow increases so does the belt speed. This ensures consistent solids removal and therefore load stabilisation to any secondary treatment process. All of this contributes to

and sophisticated control systems. The Salsnes Filter utilises a flow or level switch to turn on the filter only when needed and to control the variable speed drive for the belt during load changes. Multiple filters can be interconnected for larger flow applications. The pumps that draw sludge from a typical primary sedimentation tank are efficient at pumping solids up to around 4 percent (40,000mg/l). Above this, electricity consumption becomes prohibitively expensive, and pump damage due to overload is a real possibility. The net result of this is that thickening and dewatering facilities are required downstream of the primary clarifier if sludge of an acceptable dryness is to be achieved. Without the aid of any additional process, equipment or chemicals the Salsnes filter is capable of achieving a solids dryness of between 25-45 percent within its own footprint. The solids that leave the filter are suitable for trucking without any further treatment. Article by J. Bidleman, Aqua Technologies Corporation Go to www.demm.co.nz/enquiry quote:

â&#x20AC;˘

D120118

crude and refined oil. Hydrocarbon Fluorimeter Miniature In-situ • Environmental impact assessment • Hydrocarbon detection around drilling rigs

APPLICATIONS

• Oil spill monitoring

•

Biomass indicator studies (CDOM)

• DesignedSySTEMS for use on profiling, towed, > WATER TREATMENT & WASTEWATER

UviLux

• Sub-sea pipeline leak detection

moored or ROV deployments

• In-situ hydrocarbon detection / monitoring of pollution • Coastal • Airport apron runoff. pollution monitoring• Biogeochemical oceanography crude and refined oil. • Environmental impact assessment • Hydrocarbon detection around drilling rigs • Biomass indicator studies (CDOM) • Oil spill monitoring • Designed use on profiling, towed, Miniature In-situforHydrocarbon Fluorimeter • Sub-sea pipeline leak detection moored or ROV deployments

Monitoring hydrocarbons in ourAPPLICATIONS water • Airport apron pollution runoff.

• Biogeochemical oceanography

In-situ hydrocarbon detection / monitoring of • Coastal pollution monitoring Recent events have•highlightspill. They will drift with the ed the need for monitoring crude andcurrent refinedand oil.transmit a signal • Environmental impact assessment effluent in our waterways and on the marine AIS system • Systems Hydrocarbon detection around drilling rigs coastal zones. Sensor (Automatic Identification • Biomass indicator studies (CDOM) Ltd specialise in oceanograph- System). Any vessel within • Oil spill monitoring ic instruments for scientific range (10 nautical miles) • Designed for use on profiling, towed, applications. The company which is leak fitted detection with AIS • Sub-sea pipeline moored or ROV deployments represents offshore system compatible Vessel Radar will providers who have• recently showpollution the buoy runoff. location on Airport apron • Biogeochemical oceanography Main Image: UviLux shown in use with PD introduced instruments for their screens. The advantage of data download features of Inserts: Flow Through Chamber, Roamer Wireless Data-Li environmental engineers who this is that all vessels involved very simply hand-held probes are tasked with analysis and in the clean-up exercise will with download capability monitoring pollutive substanc- be able to track accurately via cellphone and internal es in both marine and fresh the movement and size of the data logging. These detectors • High rejection of ambient daylight • Small, low water. Aanderaa of Norway spill. Chelsea Instruments of cost in-situ fluorimeter are looking for very minute can now supply buoy drifters. UK can offer very sensitive amountsavailable of hydrocarbon, down • Low noise, high sensitivity • Range of wavelengths These are quite small and can hydrocarbon detection and to parts per million. be deployed by helicopter or analysis systems. canoutput in engineering units • Low turbidity breakthrough • These Digital Go to www.demm.co.nz/ Main Image: UviLux shown in use with PDA. thrown from a vessel into a be in-situ with appropriate enquiry quote:asD120119 • UserData-Link adjustable dynamic range • Additional analogue output standard Inserts: Flow Through Chamber, Roamer Wireless

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• Range of wavelengths availableDESCRIPTION• Low noise, high sensitivity

Zero air consumption at rest position! Save on compressed air PLUS other modern features: The

low cost, digital in-situ UV fluorimeter that offers the user sig • Low sensitive, turbidity breakthrough • Digital output in engineering units UviLux is an innovative,

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• User selectable sampling rate, 0.1Hz - 3Hz

n IP65/67 protection for tough environments n Optional ASi versions available • Profibus, Low power consumption

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• High rejection of ambient daylight

The UviLux is an innovative, sensitive, low cost, digital in-situ UV fluorimeter that offers the user significantly increased Low noise, high sensitivity • Range of wavelengths functionality compared to existingavailable UV fluorimeters. It can• monitor in real-time the concentration of refined hydrocarbons (365nm) hydrocarbons rangeturbidity of coastal, oceanographic and fresh water • Low breakthrough • Digital outputorincrude engineering units (450nm) in a wide applications. It has been designed into an acetal housing suitable for deploying independently as well as from User adjustable range • Additional as systems. standard This robust,•compact, submersible vehicles, analogue moored oroutput profiling lightweightdynamic fluorimeter has very low power consumption, is easy to use and gives accurate and repeatable measurements.

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DESCRIPTION

The UviLux is an innovative, sensitive, low cost, digital in-situ UV fluorimeter that offers the user19 significantly incre functionality compared to existing UV fluorimeters. It can monitor in real-time the concentration of re hydrocarbons (365nm) or crude hydrocarbons (450nm) in a wide range of coastal, oceanographic and fresh applications. It has been designed into an acetal housing suitable for deploying independently as well as

DEMM 201107 HP.indd 1

14/07/2011 1:25:54 PM

> WATER TREATMENT & WASTEWATER SySTEMS

A well-rounded benefits package Bolted steel storage tanks are becoming first choice with more and more local councils in New Zealand.

Travelling around New Zealand, it is obvious to the keen observer that local councils have, up until quite recently, regarded concrete as the primary option for building high volume potable water storage facilities. That however is starting to change as enlightened councils recognise the numerous benefits and savings of utilising the latest innovative bolted steel storage tanks. The latest New Zealand council to make the switch from traditional concrete storage tanks to a bolted steel storage tank for its potable water storage is Nelson City Council. Located at the top of the spectacular South Island, Nelson is one of New Zealand’s sunniest regions with a goal of making the city more sustainable over the next generation and beyond. Ian McGregor, New Zealand’s territory manager of Australasia’s leading storage tank company, Tasman Tanks, says the move by councils to consider alternatives to concrete tanks when looking at storage solutions makes a lot of sense.

January 2012

Lower whole of life costs “Bolted steel storage tanks are now steadily overtaking alternatives such as concrete because they are generally less expensive to build, have lower whole of life costs due to ease and cost of maintenance and can be aesthetically blended into their surroundings. “Welded steel storage tanks do not appear to be an option as they are far more expensive to construct on site,” he explains. While Ian McGregor admits some local councils are reluctant to change in the beginning, he says once they have annualised the figures and had the engineering and design reviewed by their engineers, they are quick to realise the benefits and do not need any more persuading. “For example, when the Nelson City Council recently put out a tender for a 2,500m³ potable storage reservoir for a new subdivision behind Stoke, they originally called for a concrete tank, however a bolted steel tank could also be offered for consideration by Council,” says Ian McGregor. “When it got to the formal

review stage of the different storage reservoir designs, conducted by an independent engineer, our price was slightly lower. But when they analysed the whole of life costs of the reservoir, which included maintenance and the other anticipated costs over the 80-year design life, we moved further ahead in cost-effectiveness,” he says. Mr McGregor explained that while not built in an isolated region, the storage reservoir is positioned alongside a major fault line and required a high level of seismic engineering by Tasman Tanks’ independent engineers. “It was then reviewed by CPG engineers before being reviewed again by the council’s own engineers before the design was accepted.” The design included the use of a base setting ring embedded into the concrete foundation and base, which incidentally proved extremely successful in the recent Christchurch earthquakes, where it has been used on commercial storage tanks. “To the best of our knowledge, this is the first time this design has been used by a municipal authority here in New Zealand,

> WATER TREATMENT & WASTEWATER SySTEMS

but is extremely common overseas including the West Coast of the United States and other high seismic regions around the world. Also, by using the concrete floor as the medium to retain the water, the design negates the need for an internal liner allowing greater capacities than those used in other steel and timber-staved tank options currently available,” says Ian McGregor. Regarding the storage tank’s roof, the territory manager explains that the council used a trough deck roof with hot dipped galvanised trusses and Zam purlins, all powder-coated, along with ultra-steel roofing to ensure its longevity. However he says another option would have been a full aluminium geodesic roof. Mr McGregor explains that traditionally in New Zealand concrete has been used for larger storage tanks (reservoirs), with liner tanks with timber stays used for the smaller capacities. “But there are limitations with these types of tanks when it comes to size. However our affiliation with US-based Tank Connection, a global leader in storage solutions and containment, allows us to offer a more cost-effective solution for larger volumes.” Happy with product and service Ian McGregor says Nelson City Council is extremely happy with the innovative tanks and the service Tasman Tanks provided. “Nelson City Council is a

well-informed council that appreciates the benefits of proven technology that is new to the New Zealand market. Over the years, we have built a strong relationship with several councils who appreciate the excellent service, constant communication and attention to detail we provide. We don’t just walk away and leave the customer with the tank or reservoir. We provide outstanding backup and ongoing service,” he explains. “And following the success of the Nelson City Council project, we now have numerous councils from all over New Zealand not only looking at the bolted steel tanks for both potable and waste water, but including this design into their tender specifications.” Ian McGregor points out another major factor giving impetus to the adoption of bolted construction throughout Australasia is suitability and speed of construction in remote and climatically challenging areas. “Bolted site construction allows for control of all quality processes in good and bad weather. It is not subject to uncontrolled factors from outside influences, which – in the case of concrete – can impact upon mixture specifications and joint connections.” According to Ian McGregor, councils and companies on both sides of the Tasman and the Pacific region who are contemplating the move away from traditional concrete tanks or reservoirs should talk to the experts in this area.

“Tasman Tanks recognises that factors such as innovation, cost-efficient design and quality products are key to customer satisfaction.” Tasman Tanks is a recognised leader in the quality tank building industry, with in-house design, independent structural engineering by suitably qualified structural engineers familiar with liquid storage tank design and manufacture and installation expertise for prompt and professional performance. Each Tasman Tank is certified to all relevant codes, with independent engineers providing verification of specifications and performance. The company provides cost-effective storage solution in capacities from kilolitres to 30 megalitres. The modular tanks – which are speedy and safe to erect – offer a method of construction that can be readily and aesthetically blended with surrounding buildings in commercial and industrial applications such as mining, energy, resources, manufacturing, government and infrastructure, engineering, food and beverage processing, chemical and primary product processing, water and wastewater and fire protection. Tasman Tanks also specialises in turnkey projects and service and refurbishment work through its dedicated Service and Refurbishment Division. Go to www.demm.co.nz/enquiry quote:

Reliability and Maintenance

training courses

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The knowledge path for staff in their work environment

Training Needs Analysis: skills improvement for your staff today

The knowledge path for staff in their work environment

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

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structured approach to competency skillby assessment and where they need to Training Needs Analysis (TNA) starts with a good initialand understanding of where your staff isand today be to attain optimum plant performance. assessing their training needs through a progressive and structured approach to competency and skill assessment and where they need to be to attain optimum plant performance. The TNA enables this crucial understanding by combining SKF Reliability Systems experiThe TNA enables this crucial understanding by combining SKF Reliability Systems ence in training and our knowledge of maintenance and reliability. experience in training and our knowledge of maintenance and reliability.

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

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21 www.skf.com.au/training

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> WATER TREATMENT & WASTEWATER SySTEMS

Portable dual frequency Doppler flowmeter for rent When you need to measure the flow of liquids containing particulate, TechRentals now have the Polysonics SX30 portable dual frequency Doppler flowmeter available for rent. Typical applications include slurries, primary sludge, dredging and activated sludge. Unlike conventional Doppler flowmeters, which operate at a single frequency, the SX30 generates two independent ultrasonic signals at different frequencies. This provides excellent noise immunity, extending the environ-

ments in which this meter will operate. It features a sealed membrane keypad making the unit fully weatherproof. Its specifications include: velocity range 0.06 to 5.5m/s; pipe size from 12mm to 5m; operating temperature range -40 to 122°C, 90,000 point data logger and serial port for data retrieval with supplied software. Go to www.demm.co.nz/ enquiry quote: D120122

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Small bubbles, high efficiency

Aerostrip aerators are available in two widths (150 & 180mm), and a variety of lengths to suit different applications.

The Aerostrip aerator is a fine bubble diffused aeration system. According to the manufacturer it is the most energy efficient system on the market. Ovivo have become the exclusive NZ agent since establishing Aerostrip in Australia in 2008. Already, Ovivo NZ is providing a 1200kgO2/kWh Aerostrip system to a major wastewater treatment plant in the North Island. Twenty years of research, development and installation experience worldwide, along with extensive testing of oxygen transfer rates enabled Aquaconsult to optimise an already proven product and develop a highly improved, next generation aeration panel – the Aerostrip. Each Aquaconsult product comes with a 15-year guarantee, compared to the industry standard of five years. Aerostrip aerators have a bubble size of just

January 2012

0.9mm and oxygen transfer efficiencies of up to 60 percent with transfer efficiencies of 3.0-5.9kgO2/kWh. It can be used in a variety of biological processes. Recent installations within Australia and New Zealand have seen ten major projects which have utilised the Aerostrip for food and beverage, municipal and pulp and paper treatment. The technology has been used for processes including continuous activated sludge, sequencing batch reactors (SBR) and membrane bioreactors (MBR). Ovivo’s fully comprehensive aeration packages range from the design stage to manufacture, delivery, installation and commissioning – with all aspects of the contract managed and delivered in-house, ensuring total commitment and control at every stage. Ovivo can offer Aerostrip as a package inclusive of aeration blowers and aeration pipe headers. They can also assist in the selection of the most efficient blower, for example: Turbo v Positive Displacement. Product Features include: • Highest efficiency on the market (manufacturer information). • Long life guaranteed for 15 years compared to five year industry standard. • Smallest bubble size on the market of 0.9mm (manufacturer information). • Proven 20 years of installation experience

worldwide. • Oxygen transfer efficiencies up to 60 percent. • Aeration efficiency from 3-5kgO2/kWh. • 0-100 per cent control of air flow range. • Non-clogging diffuser membrane. • Intermittent operation capability. • Option for stainless steel design. • Low maintenance requirements and costs. • Durability – some plants have operated trouble free for more than 18 years. • Highly competitive product due to optimal aeration efficiency values. Aerostrip aerators have achieved excellent performance figures in wastewater operations; with tests showing a considerable alpha-value of ~0.8. An indication of energy efficiency can be found using energy consumption for BOD. At plants with extended aeration, energy consumption is 0.5 to 0.7kgO2/ kWh BOD. Ovivo say that due to the high efficiency of the Aerostrip less power is required to generate the same oxygen transfer when performance is compared to that of competitor products. The energy efficient aeration system offers considerable cost savings to waste water treatment plants. Go to www.demm.co.nz/enquiry quote:

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> MATERIALS HANDLINg

Making a stand for safety and productivity

ISO has received an award for making innovative improvements to stands used for loading pulp at the Port of Tauranga, and has taken action to address a significant hazard on a new class of ship being used for log exports.

Safety and productivity go hand-in-hand. By taking steps to eliminate health and safety risks, businesses can achieve major productivity gains and add real value to the bottom line. Waterfront cargo and logistics operator ISO Ltd understands this well. By investing in technology and process improvements it has achieved sustained reductions in Lost Time Injury rates, which consistently remain below the industry average. Alongside these are productivity improvements in excess of 20 percent in vessel loading and unloading alone. ISO employs over 400 people and has operations at Marsden Point, Metroport, Mount Maunganui, Gisborne, Napier, Wellington, Nelson, Picton, Timaru and Dunedin. As part of its commitment to continuously improving safety performance, ISO set up a team of four to identify more opportunities to refine its work processes. One of the things the team looked at was the company’s pulp loading stands and

how these could work more effectively. The team produced an improved pulp loading stand made out of decommissioned 40-foot shipping containers. Each stand is 12m long and 2.5m wide, with a ramp platform that folds out 300mm wider to 600mm. The new stands are a simple and effective design solution to improve stevedore safety and efficiency when loading pulp onto cargo ships. The stands provide a much more stable and functional environment for stevedores who work 12-hour shifts on the stands than the lightweight portable stands that are typically used across the industry for loading pulp. The secret to ISO’s success in coming up with an effective new stand was that it sought input from everyone involved in the loading process; Stevedores, marshallers and truck drivers. The new stands recently led to ISO receiving the 2011 Chartered Institute of Logistics and Transport in New Zealand award for Safety, Security

and Environmental Innovation. The award recognises a cost-effective innovation that significantly enhances an organisation’s operations and safety. “The stands are a good example of what you can achieve with a collaborative approach. The CILT award is great recognition for our commitment to health and safety, which benefits both our customers and our people,” says Greg Dickson, CEO and Manager Director of ISO. Realising productivity gains Stevedores working on the pulp stands no longer have to climb up and down ladders during every cargo lift. They also have more space to work in and they have shelter. The old stands had no protection from the elements. In addition, a safety hut is accommodated on top of the stand and forklifts no longer have to drive through operational areas during loading to re-stock it with safety equipment. As well as improving

> MATERIALS HANDLINg

staff safety, ISO found that productivity increased as stevedores could do their job more efficiently. The entire loading process has become more fluid rather than the ‘stop-start’ that often occurred using the old stands. “One of the biggest issues with the old stands was that they were lightweight so they moved around when loading occurred and trucks could sometimes bump them meaning at each break staff would have to realign the stands ready for the next load. The new stands solve all of these issues,” says Paul Cameron, ISO General Manager Stevedoring. There are additional efficiency gains from the new stands compared to conventional stands. They are easy to transport by truck, rail or ship to other ports, they take less time and require less machinery to set up and they are extremely robust, which means they are less prone to damage and do not need to be constantly repositioned. Currently ISO has built four of the new stands. Paul Cameron said the stands were originally designed with loading pulp in mind but they can also be used to load a wide range of break bulk cargo off trucks such as logs. ISO is planning to roll out the new stands to other ports where it operates as demand arises. At the moment the stands are kept in high use at the Port of Tauranga where ISO loads around 500,000 tonnes of Kraft pulp annually from Carter Holt

January 2012

Harvey’s Kinleith and Tasman mills. Going beyond regulation Aside from investing in new innovative solutions, the key to achieving unparalleled safety and productivity gains for ISO has been a focus on going beyond regulatory compliance. For example, in May 2011 ISO was loading logs onto a new vessel in Tauranga on its maiden voyage when a defect caused the ship’s crane block to fail, causing a 27-tonne load of logs to drop 1.5 metres into the ship’s hold. All work was suspended immediately and Maritime NZ was notified of the incident. While nobody was hurt, the incident was obviously considered very serious. An investigation by ISO found that a common underlying issue had led to the same problem on another ship loaded in 2010 of the same class and series as the one in Tauranga where the crane block failed, although in that instance there was no falling cargo. When faced with a requirement to again load a shipment of logs onto a new vessel of the same class in Nelson, ISO acted pre-emptively to keep its people safe. While Maritime NZ had been notified of the previous crane block failures on each separate occasion, the constraints of the regulations it operates under mean that it could not declare the crane blocks on the Nelson vessel unsafe until they had actually failed. “This was unacceptable to us. While

delaying loading the vessel carried a significant financial risk for the company, rather than risking another crane block failure and potentially compromising the safety of our staff, we insisted the crane blocks be taken away and modified before loading could take place,” says Greg Dickson. ISO also worked with the international crane block manufacturer to change the design of the crane blocks, and notified other vessel and port operators of the issue they had encountered with the ships. The result was that a significant risk was removed not for just ISO’s staff, but the safety for the stevedoring industry as a whole, both in New Zealand and overseas. This willingness to go beyond regulatory compliance has helped to create a strong focus on continuously improving safety processes. Listening to staff and involving them in formulating solutions has enabled ISO to go above and beyond to create a safe, positive and productive work environment. By taking action at management level ISO has also demonstrated to staff that it is serious about doing things right. “Our personnel have confidence that the company will always put their safety first, which is good for both productivity and morale and also empowers them to make safety their number one priority,” says Greg Dickson. Go to www.demm.co.nz/enquiry quote:

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> MATERIALS HANDLINg

getting more life out of wire rope Bridon’s products have achieved outstanding results on container cranes and straddle carriers operated by The Ports of Auckland. Stefan Richter learned that this success can be traced back to a tweaked construction and regular lubrication. Auckland-based Bridon New Zealand Ltd have plenty of reasons to be in a festive mood. Exactly 100 years ago William Cooke & Co (NZ) Ltd was established in Albert Street, and in 1961, 50 years later, the company’s rope making factory started production in New Zealand. But that is not all there is to celebrate. The company, which was renamed Bridon in 1974, has just announced some remarkable results their wire ropes have achieved in conjunc-

tion with the Ports of Auckland. Here the wire ropes are mainly utilised in two applications: the Ports’ container cranes and straddle carriers. “In recent times we have seen the life expectancy double on the crane hoist ropes. And our straddle carrier ropes outperform the competition by considerable margins,” says Andy Palmer, Product Manager Wire Rope, Bridon NZ. “The Ports have just finished testing a competing product from Germany on their straddle carriers,

The Ports of Auckland operate a fleet of more than 35 hybrid straddle carriers.

and it lasted for only about 4000 hours. With approximately 7000 hours we are getting a significant longer life out of our wire ropes.” “Predominantly we are talking hoisting wires here, though there are other applications on our ship-to-shore container cranes,” explains Derek Cowley, Inspector of Machinery, Ports of

Engineering Ltd

Auckland. “We require having a low maintenance, long-life wire rope which we can rely on to provide a predictable and well above average service life.” Bridon’s record-breaking products are named Endurance Dyform 6 and 8PI, with the eight-stranded version featuring a plastic encapsulated core.

Carbines Engineering supplying Motoman & OTC Daihen robots to New Zealand Industry for over 25 years, gives “Adept” as an example of the Motoman quality product. Picture shows 4x of the Multiple 6 axis 6kg Motoman Robots mounted and interfaced into Adept's “Toyo” Plastic injection MouldingMachines.

Since the first UP6 installation in October 2006 a further 12 Robots have been added to their family of tireless Machine tenders.

> MATERIALS HANDLINg

Bridon NZ is the only rope wire manufacturer in New Zealand. The picture shows Chris Loftin (left) and Andy Palmer in front of one of the company’s enormous stranders.

Bridon’s range of steel wire ropes are utilised in most applications covering plant, machinery and equipment operated within The Ports of Auckland’s port precincts.

Lubrication of the wire rope, even during its production, is one of the key ingredients to achieve a long operational life.

Whereas the former wire rope is manufactured in Bridon’s factory in East Tamaki, the latter rope is imported from Bridon in the UK. “The six-strand Dyform container crane wires have been developed specifically for our applications, using modern manufacturing methods and careful raw material selection,” reports Derek Cowley. “These wire ropes have been beating previous benchmarks for durability in service. And the eightstrand straddle carrier wires, though similar in specification to other products in the marketplace, have consistently provided an extended life and allowed us

to retain these in service for what has been an unprecedented 7000 hour operational life.” Recipes for successful wire rope A wire rope consists of a multi-wired core strand that has a number of likewise multiwired strands laid around it. The strands are produced in different combinations of wire materials and sizes to resist fatigue and abrasion and meet the specific needs of various applications. Understandably the company does not communicate the exact details on how to produce successful wire ropes that outlast competing products, but at least

January 2012

Andy Palmer gives a hint at how they managed to achieve their outstanding results. “At a meeting some time ago we discussed possibilities to improve the life expectancy of wire ropes, and Chris came up with the idea of slightly tweaking the construction, which means changing the recipe for our ropes. We did that and also started to subject the wire strands to a compaction process called dyforming or dyswaging,” recalls the Product Manager. This process modifies the shape of a wire and its dimensions without altering its metallic cross-sectional area, resulting in a denser wire, reduced friction within the strands and a stronger wire rope. The “Chris” mentioned by Andy Palmer is Chris Loftin, Technical Manager Wire Rope. He reveals another modification that contributed to the increased life expectancy of Bridon’s wire ropes: “The more wires you put around a strand the bigger the centre wire becomes, and with it the diameter of the wire rope, resulting in decreased flexibility and increased strain. We have therefore increased the flexibility of the rope core dramatically,

which helps us limit the overall diameter of the wire rope.” Chris Loftin also points out the importance of regularly lubricating the wire ropes – during their production as well as during their operational life. “The Ports of Auckland monitor their wire ropes frequently and they also keep extensive records and implement stringent inspection and lubrication programmes. This practise also contributes to the increased operational life of our products.” “The inspection and lubrication programmes in place have certainly contributed to achieving these high hours recorded,” agrees Derek Cowley. “Regular though not excessive inspection has allowed us to track deterioration in service and predict in good time the end points of these wire ropes with confidence.” Most of these ropes have automatic wire lubrication systems and where not fitted and manual lubrication is required, the key is to ensure that lubrication takes place on a regular scheduled basis. “The experience gained through trial and error has assisted us in the choice of the various lubricants selected in the different applications.” Go to www.demm.co.nz/ enquiry quote: D120126

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> MATERIALS HANDLINg

Designing storage systems to cope with earthquakes In this article Dr Murray comments on the performance of storage systems during seismic events, including the recent devastating earthquakes in New Zealand. Designing rack structures to cope with the unpredictable forces generated during an earthquake requires a combination of detailed engineering, sophisticated computer analysis and a degree of crystal ball gazing on the part of the engineer into how the storage system may be utilised over its lifetime. When structural engineers design a building, they can make reasonable assumptions, guided by design standards, about the likely loadings on the structure during day-to-day use. Warehouse storage systems, on the other hand, could theoretically be empty one day, and full the next. The total load, where loads are located and the height of racks all have a significant impact on the performance of a storage system during a seismic event. What happens to storage systems during earthquakes

In non-seismic areas, storage systems are designed to support mostly vertical loads – horizontal loads typically account for only around 0.5 percent of the vertical loads, making them relatively insignificant. However, when an earthquake occurs, ground acceleration can increase the horizontal loadings on storage systems by a factor of 10 or more. The storage system rack frames and beams respond by swaying to and fro, and the total mass within the racks – the stored pallets – begins to move in relation to the ground, creating inertial cross-aisle (transverse) and down-aisle (longitudinal) forces within the rack structure. The inertial forces acting in the cross-aisle direction will cause the rack to sway, increasing compression in one upright and decreasing the load on the other. The greater the horizontal seismic inertial forces acting on the storage system, the higher

Dematic has designed and implemented over a dozen major ColbyRACK pallet storage systems for customers in New Zealand.

the compression and uplift forces will be. These uplift forces result in the racks attempting to pull the uprights’ baseplates free of the ground anchors, which secure them to the floor. The need to accommodate seismic loads may lead to the use of bigger and stronger uprights and beams in the racking system. Alternatively, some suppliers make use of vertical and horizontal bracing to stabilise the rack in the longitudinal direction. Dematic avoids the use of down-aisle bracing whenever possible, preferring instead to opt for the use of “standard” racking uprights and beams,

increased in size as necessary to accommodate the seismic loads. The use of spine bracing at the rear of rack frames can be problematic since the bracing is prone to damage when putting away and retrieving pallets, possibly reducing its effectiveness under load. Dematic also employs chemical anchors and special seismic baseplates, designed to behave in a predictable manner in the presence of uplift forces. Dematic’s seismic design process In recent years, Dematic has designed and implemented over a dozen major ColbyRACK pal-

Whether your adding an additional line to your existing handling system or requiring a turn key solution for production, Conspec Engineering can provide a comprehensive and efficient solution for your business. We design, and install complete conveyor systems aimed at improving efficiency within your manufacturing operation, saving you time and money. With a team of skilled engineers and an exceptional standard in quality that our customers have come to rely on, we can implement the most efficient handling system to suit your requirements.

As part of our commitment to keep you up and running, Conspec also provide an onsite maintenance service for all your maintenance needs.

Phone 09 273 1966

For quality and reliability look no further than Conspec for your next project.

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> MATERIALS HANDLINg

• Installation to the relevant local standards and codes of practice (PS3). • An independent review and certification of the installation works (PS4). Dr Murray Clarke, BSc BE PhD MIEAust, Structural Design Manager, Dematic

let storage systems for a diverse range of customers in New Zealand including Progressive, Foodstuffs, Ezibuy, Brand Lines, Provet, Officemax and The Just Group, with all of the installations located in seismically active areas including Auckland, Christchurch and Palmerston North. Dematic’s storage system designs for seismic areas are proof-checked by specialist local consulting engineers. For example, in New Zealand, the storage systems follow the fourstep PS1-PS4 procedure: • Dematic structural engineering design and detailing to relevant local standards (PS1). • An independent review of the structural engineering design and detailing (PS2).

If in doubt, check it out It has been noted in several reviews of failed racking structures that existing and unreported rack damage may have contributed to rack collapses. Rack uprights and beams can be easily damaged during forklift operations, and a regular rack inspection and repair process is highly recommended. If you have any concerns your storage systems are not up to standard, or that the structural integrity may have been compromised, it is recommended they be inspected as soon as possible by an appropriately qualified engineer. Obviously a thorough detailed inspection of storage systems is necessary immediately following a significant seismic event. Also, should the usage of a storage system change significantly from

its original design, its suitability for other purposes should also be checked and verified before proceeding. Key inclusions in any rack audit should include: • Any unapproved changes to the “as built” installation drawings. • The structural integrity of any unapproved changes. • That the correct Safe Working Load signage is appropriately displayed on the relevant bays of racking. • Damage to rack uprights. • Damage to footplates and floor fixings. • The condition of any splices. • That the rack is correctly installed and is not out of vertical alignment. • The condition of horizontal and diagonal braces on rack frames. • Damage to beams. • That beam connectors and safety clips are secure, and that beams have not become dislodged. • That the welds between

beams and connectors are not cracked on beams that have incurred impact damage or overloading. • Any overloading of the rack. • The use of any damaged or inappropriate pallets that could compromise safety. • Additions to the original system. • Details about how the system may have been reconfigured. And finally, it is important buyers know what they are paying for when purchasing storage systems. Storage systems may all look similar, but their performance can vary significantly. The flood of cheap, imported and often lookalike racks into New Zealand means that storage system buyers should insist on detailed manufacturing specifications and any necessary certification to ensure they are actually getting what they pay for, and that it is fit for purpose. Go to www.demm.co.nz/ enquiry quote: D120128

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Key seismic storage system design parameters The following key parameters are used during seismic analysis and design. Seismic zone factor – (Z) Hazard Rating The current seismic codes in New Zealand covering construction, including storage systems, prescribe the use of different Hazard (Z) Ratings to accommodate differing levels of seismic activity throughout the country. Auckland, for example, which is classified as a lower risk area, has a Z Rating of 0.13. More seismically active areas, such as Palmerston North and Wellington attract Z Ratings of 0.38 and 0.4 respectively. The highest Z Rating of 0.6 is applied to the Arthur’s Pass area, which was the location of one of the 10 largest recorded earthquakes in New Zealand in 1929. Christchurch, which was badly damaged by the September 4, 2010 and February 22, 2011 earthquakes, previously had a Z Rating of 0.22, but this has since been revised upwards to 0.3.

January 2012

Soil type – A to E The soil type in each area must also be taken into consideration during design. These range from Type A, which is rock, through to Type E, which covers very soft soils and silt. Areas such as Palmerston North and Christchurch are located on alluvial flood plains, which are prone to liquefaction during seismic events and, accordingly, are rated Type D. The firmer ground under Auckland typically sees this area categorised as Type C. The choice of correct soil type is very important. The seismic loads associated with Type D soil may be 50 percent larger than for a Type C soil for a typical racking structure. Design life As with most structures, storage systems are typically designed for a theoretical design life of 25 or 50 years. Because of their longer anticipated working life and potential for increased exposure to risks, systems designed

for a 50 year design life feature stronger rack components. Importance level Another factor that comes into the equation is how “important” the system is. For example, if the system is being used to store items such as radioactive waste or urgent medical supplies this will receive a higher importance level than consumer goods. Occupancy level With today’s streamlined and high velocity supply chain, stock is turning over faster than ever. In a typical DC, this means pallets are constantly cycling in and out of storage systems, reducing the storage system’s typical occupancy rate. Under current standards, designers often use 60 percent as the storage system occupancy rate, however, following the recent earthquakes, there is debate within the engineering community in New Zealand that this may be increased to raise safety margins.

> MAINTENANCE MATTERS

First-choice option for steel protection Perry Metal Protection’s new multi-million dollar hot dip galvanising plant in Hamilton offers a level of capacity and capability not previously seen in New Zealand. Stefan Richter drove to Te Rapa to inspect the new facility that will be operational as of 16 January 2012. It inevitably occurs every time iron or steel, atmospheric oxygen and water come together. Iron oxide, better known as rust, is formed in an electrochemical process on the surface of the steel, and the red-brown colour we perceive indicates that the metal has started to degrade. One of the possibilities to prevent steel from rusting is to completely envelope its surface in a protective coat of zinc to prevent any contact with the corrosive environment. That is exactly what happens during the hot dip galvanising process in which the two partners zinc and steel form a metallurgically-bonded coating that provides outstanding abrasion resistance and long-term protection against rusting. Perry Metal Protection, a division of the Perry Group, have been utilising this process since the early 1970s and offer their services at five locations in New Zealand: Auckland, Hamilton, Tauranga, Wellington and Christchurch. The company has just opened their newest facility on the site of its existing galvanising facility in Te Rapa, Hamilton, which now houses the largest zinc bath in New Zealand. “We have been in the business for 37 years, and now our existing factory is outgrown and so we needed to build a new one. It took us three years to research, plan, design and finally build this

new facility,” says Duane Baguley, General Manager, Perry Metal Protection. “And with an overall investment of $NZ 8 million we were asking for a significant amount of money, which required a quite stringent approval process from our board to secure the funding.” The new plant will be able to treat steel structures up to 18 metres in length. “Currently the maximum size suitable for galvanising using the double dip method in the country is about 14 metres,” says Duane, “and in our existing facility we can dip structures up to 11 metres. We are therefore taking a quantum leap forward compared to the maximum dimensions of steel structures that can be treated by our competitors.” Perry Metal Protection service the construction industry by galvanising structural steelwork and pipes, and they also treat cowsheds, agricultural sprayers and more for the agricultural industry, and help the leisure industry by making trailers more durable. But you could as well approach the company to get your garden gate or a beam covered with a zinc layer to protect it from rusting. The General Manager says that the new plant has doubled the capacity of the existing plant. “We strive to provide a better service to our existing customer base,”

says Duane, “But we also believe that the ability to treat larger steel structures will provide a greater range of choices and opportunities for the construction industry that haven’t previously existed.” Perry Metal Protection has employed a business development manager to promote galvanising as the first-choice option for steel protection. “His mission is to get out into the market place and talk to the specifiers, the architects, design engineers and fabricators,” explains Duane. “We have found out that there is a reluctance to specify hot dip galvanizing due to lack of information available to the architects and engineers. And when a specifier or engineer does not have enough information and/ or experience with this technology, then they are not going to specify and utilise this form of protective coating. So we highlighted the need to provide further education on the advantages of hot dip galvanising.” In the field of metal protection the two main systems “competing” with hot dip galvanising are paint systems and zinc arc spraying, with the latter being an alternative method of applying a zinc protective coating. “When it comes to achieving the specifications and a reproducible result, the galvanising process is much simpler than any of these two other procedures,” comments Duane. The galvanising process According to Wikipedia it was a French chemist by the name of Paul Jacques Malouin who

in 1742 described a method of coating iron by dipping it in molten zinc in a presentation to the French Royal Academy. And in 1837, another French chemist, Stanislas Sorel, obtained a patent for a method of coating iron with zinc to protect it from rusting. “The electrochemical basics of galvanising haven’t changed since that time,” says Duane, “What has changed and improved are the process technology, the materials handling and the environmental control mechanisms we put in place.” Galvanising does not simply apply a coat of zinc to the steel item, the coating does not just stick to the surface like paint does. Zinc and steel undergo an electrochemical reaction and form an alloy which is metallurgically bonded to the steel. To achieve this durable bond galvanisers utilise five process steps. Degreasing The steel structure to be treated is dipped in a hot caustic solution bath where grease, oil, paint, organic materials and other surface contaminants are removed. Pickling The next bath contains hydrochloric acid solution and rids the steel of rust and mill scale. After this step the steel is rinsed with water to remove any pickling acid residues. Fluxing This process step is necessary to remove the oxide film that forms

> MAINTENANCE MATTERS

structures are immersed.

Duane Baguley in front of the gas-fired zinc kettle. It has a capacity of 300 tons of molten zinc which is kept at a temperature of 450 degrees Celsius.

after the acid treatment. A further oxidation before galvanising the steel item would affect the quality of the zinc-steel bond to be formed and jeopardise the complete and consistent coverage of the steel surface. The flux solution usually is 30 percent zinc ammonium chloride with wetting agents, which is kept above 65 degrees Celsius. After this process step the item is dried. Galvanising The steel is fully immersed in molten zinc which is kept at

around 450 degrees Celsius. Draining and venting holes provide an escape route for hot air and allow for the molten zinc to reach the inside surface of hollow spaces in the steel structure and for the excess zinc to leave those spaces after the structure is taken out of the zinc bath. The period of immersion does not determine the thickness of the alloy layer formed. Anyway, the galvaniser has to wait for the steel item to heat up to the temperature of the molten zinc, which can take up to several minutes when massive

For advice on service, quotations and technical knowledge on hot dip galvanizing, contact your local Perry Metal Protection site.

Auckland 09 820 8471 Tauranga 07 541 1344

Hamilton 07 850 0120 Wellington 04 568 4139

Christchurch 03 349 0290 Email enquiry@perry.co.nz Website www.perrymetalprotection.co.nz

January 2012

Quenching The steel item is quenched to cool the item and passivate the zinc surface to prevent early oxidation. After this step the item is ready to be deburred, inspected and, if desired, painted. The benefits of galvanising “We at Perry Metal Protection believe that galvanising constitutes the premium-protection system for steel, and there is a lot of research data available which proves that this established process provides effective corrosion protection,” says Duane. The list of benefits that the General Manager provides is quite impressive. The process of applying paint to a surface is much more dependent on variables such as temperature, humidity and air quality than the galvanisation process. “And when the painter is having a bad day and does not clean the surface properly, or applies the paint unevenly, then the overall result can be severely affected,” says Duane. “Galvanising on the other hand is not subjected to the skills of a specific person; it is an industrial process with reproducible results and consistent quality outcomes.” It is also impossible to apply paint to the inside of a hollow space, resulting in an unprotected surface. Another problem with paint systems is known as underfilm corrosion. This term refers to the possibility of rust forming beneath the paint coat on the steel surface, for example after an impact damage has occurred. The steel might degrade undetected until the component ceases to function. “Because the zinc forms a durable bond with the steel, galvanising makes for a tougher and more abrasion-resistant coating when compared to paint systems. Transport and erection damage is therefore less likely to occur as the treated item can take a lot of knocks and punches.” This is also the reason why galvanised surfaces are low in maintenance.

“Most paint coatings require frequent inspection and renewal, and when the coating is breached, corrosion begins at the affected area and quickly spreads,” says Duane. “Galvanisation is the ultimate solution, especially for applications in coastal areas where rusting and corrosion are boosted by salt air and water. We think it is absolutely necessary to use galvanised components more often in these so called sea spray zones.” Duane reports that there are light poles in Australia that have been up for 150 years – untouched. “In New Zealand it would be very easy to achieve a lifecycle of 25 to 30 years without any problems,” says the General Manager. This fact has to be taken into account when talking about the costs of various steel protection systems. “Sometimes galvanising is higher in first cost than paint systems, but inevitably zinc beats paint in the area of life cycle costs because galvanising needs less maintenance and lasts longer.” Last but not least, zinc is also a very sustainable solution. ”All of the by-products we create in the galvanising process, namely ash and dross, are marketable products that can be sold on and reprocessed. And zinc itself is fully recyclable.” Perry Metal Protection’s new hot dip galvanisation plant is operational as of 16 January, and the old factory on the same site was decommissioned over the Christmas break. “Hot dip galvanising is a proven process to protect steel from rusting,” says Duane. “The NZ Transport Agency and KiwiRail trust this technology and have all their light poles, their guard rail systems, their gantry signs and their overhead line masts galvanised. Many Government agencies specify hot dip galvanisation because they know they get the best result for the best total price.” Go to www.demm. co.nz/enquiry quote: D120130

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> MAINTENANCE MATTERS

game promotes welding trade careers Recent research has shown that finding skilled workers is set to prove a challenge for engineering companies. To help meet supply, a new and innovative approach is needed to attract our youth into vocational careers. One solution is to introduce students to career options through gaming. Gaming and school work are not usually two activities you would associate together – but gaming is increasingly present in schools as the new way to engage and educate. Coined “edutainment” – combining education and entertainment – TIG Welder is a welding game which teaches and inspires, but is also fun. The game was developed by Competenz, the industry training organisation for the engineering and manufacturing sector, and is available now to play online in Flash on any computer or as an iPhone app. The TIG Welder game supports the bid to increase the supply of tradespeople by exposing students and the public at large to what a career in the welding trade entails. In the game, players must perform a series of TIG, or tungsten inert gas, welds with the aim to join together three sections to form a steel wall, strong enough to protect from a deadly swinging demolition ball. The game is scored on an accuracy basis and requires a fair amount of skill to weld to a standard worthy of a high score. TIG Welder not only promotes trade careers but also educates students about key welding concepts relevant to their course

curriculum. The basic TIG Welder game is free for the world to play online. A premium version of the game can be purchased by individuals, and schools can purchase a license to cover multiple students for their technology or engineering classes. The premium package includes a series of informative videos showing how to perform basic TIG welding tasks in the real world, plus welding and general workspace safety advice every budding tradesperson needs to know. A quiz is also embedded throughout the premium version of the game to make sure key TIG welding skill and safety messages are being picked up by the player. Students are taught valuable lessons by breaking the rules of the game. For instance, failure to put your helmet’s visor down results in the message “you have been blinded!” – an extremely relevant health and safety concern for a welder in an actual, non-virtual situation. Competenz also supports students’ learning through the Tools4Work mechanical engineering assessment resources it produces. The Tools4Work resources help more than 400 teachers nationwide to prepare students for a rewarding and productive career in industry. Trades attract those interested in hands-on careers, so it’s only logical that the way to learn about these trades takes the same approach. Anyone can go to www. tradesgamer.com now to play TIG Welder for free, and to register or find pricing options

Informative videos show how to perform basic TIG welding tasks in the real world.

for the premium package. Or visit www.competenz.org.nz for more on mechanical engineering trades training, or ‘like’ ‘The Guild – Competenz Alumni Group’ page on Facebook to stay informed. The skills shortage issue is a reality; 64 percent of engineering and metal manufacturers surveyed by Competenz earlier this year said they need at least one more skilled staff member within the next two years. Tahis translates to a potential shortfall

of 4,519 new skilled tradespeople needed by 7,062 companies within these sectors by 2013. Welding is one of the key trades experiencing skill shortages. Currently 444 welding and fabrication apprentices are in training on-the-job nationwide and Competenz hopes its TIG Welder game will help introduce more “new blood” from school to industry, to meet industry’s significant skills gap. Go to www.demm.co.nz/ enquiry quote: D120131

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Think you can weld? Prove it. If you know someone who has potential, get them to check out our welding game at www.tradesgamer.com

> MAINTENANCE MATTERS

National Conference inspires engineers In the tightest conditions for industry since the onset of the global recession, the 2011 Hydac National Maintenance Engineering Conference pulled it out of the hat again, equalling 2010 attendance and providing yet another year of inspiration and networking for maintenance engineers from across the country. The success of events can be judged on a number of factors: attendance, budget, peer review or attendee feedback. While the annual event was a winner on conventional measures, the true judge of success at the Rotorua event was the number

of attendees returning to their workplaces brimming with the inspiration to make a difference. The continuing theme of “lifting your game” reverberated through every paper, presentation and exhibition. A significant number of attendees remarked that they had used the conference time to pick up on the theme challenge, reflect on their own situations and use the networking and peer presentation opportunities to explore concrete changes to take back. In the words of the opening address, “The only thing you need to change is the simplest; your attitude.”

January 2012

By Craig Carlyle

Organisers once again had to turn away exhibitors, unable to accommodate any more in the SKF Exhibition Hall. A welcome feature of the conference was the number of regularly returning exhibitors. These ardent industry supporters wisely ensured their exhibition space by booking up to 12 months early. Hydraulic experts Hydac were back for a record fourth year as the much-appreciated principal event sponsors, while SGS added to their previous involvement by adopting the social “Sheep Tagging” evening. The exhibition side of the conference continues to grow in size, content, relevance and interest for conference attendees, who return every year eager to touch base with the latest technical solutions. Expert and peer presenters ranging from organisations such as IPENZ, Waikato University, Genesis, SGS, EECA and RNZ Navy, to name a few, presented papers grouped around the generic headings of preventative maintenance, technical topics, line management and personal development. All the papers were enthusiastically received, generating intense discussion during the breaks. A regular side feature of the National Conference is the society AGM. Karl Hayward (Orica) was welcomed onto the committee, joining returning members Barry Robinson (Chairman, SAFE Eng.), Craig Carlyle (Secretary, MTL), Christo van Niekirk (Treasurer, ABB), Bill Sole (Competenz), Glenn Pepper (SIRF), Larry Wiechern (MIT) and Dr James Neale (ESM). 2011 MESNZ Scholarship

co-winner Ben Vollebregt (NZ Army, Linton) was on hand to accept his scholarship award, while co-winner Sanjeev Kumar (Manurewa High School, Auckland) enjoyed his presentation amongst his college peers in Auckland. While these young men represented different stages and arenas, the attitude and desire of both applicants impressed the judges and gave heart to the future of engineering in New Zealand. The event management team were pleased with the smoothness of the operation and the enthusiastic response to the event. Buoyed by their success, the team have already released the details for next year’s conference and can confirm that the 2012 National Maintenance Engineering Conference will be held at the Novotel Rotorua Lakeside, Rotorua, on the 7th and 8th of November 2012, with the Field Trip and Trade Expo evening preceding the event on the 6th November. Registration and bookings for exhibitors, sponsors and attendees are open now, so get in early to avoid disappointment next year! Venue, registration and exhibition details are available on the society website (www.mesnz.org.nz), providing an ideal window of opportunity for prospective participants to plan, budget and reserve their places. Craig Carlyle is secretary of MESNZ

> MAINTENANCE MATTERS

Effective preventative maintenance â&#x20AC;&#x201C; questions to ask The purpose of any preventative maintenance routine is to reduce the chance of failure and, in doing so, increase reliability. Much of our time is consumed carrying out Preventative Maintenance (PM) routines but we often do not take time out to question how effective the routines actually are. Preventative maintenance is carried out to preserve the inherent reliability of equipment or to detect failure in sufficient time to plan, schedule and conduct a corrective action. If the PMs do not achieve either of these objectives in a cost-effective way then we have to examine their validity. Firstly, letâ&#x20AC;&#x2122;s look at using

PMs to preserve the inherent reliability of our equipment. When commissioned, all plant and equipment has a service life and level of reliability that is determined mainly by the quality of the original design, manufacture and installation. If correctly maintained and operated, our equipment will reach that level of inherent reliability. Such a result is achieved through scheduled replacement or restoration of components or through tasks such as cleaning, lubrication and making adjustments. The second purpose of carrying out PM routines is to detect failure in sufficient time in order to plan, schedule and

carry out a corrective action. This usually takes the form of condition monitoring checks such as vibration, temperature or oil analysis. The key to these checks is in understanding the data. For every condition monitoring check, data must be recorded and analysed, as simply writing data on a work order is not sufficient. If it is not recorded, plotted, analysed and used to predict failure to plan corrective action then it may prove a useless exercise. To assess whether our PM routines are as effective as we want them to be, we need to ask ourselves some questions. 1. Does the PM routine

Minimise Downtime

Increase Reliability

preserve the inherent reliability or predict failure in time to plan, schedule and carry out corrective action? We can assess whether a condition monitoring routine identifies failure by simply analysing the data we have available. For example, if we are monitoring vibration on a pump set but are still getting unplanned bearing failures then we need to reassess the exercise. This could be because of the way the reading is taken or the time interval but more often is down to us not recording, plotting and analysing the data well enough. It is not always a simple task to assess whether or not a cleaning

Improve Productivity

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

Course Schedule 2012 5th - 9th March Auckland

26th - 30th March Wellington

Investment $2,100 16th - 20th April Christchurch

9th - 13th July Tauranga

24th - 28th September Auckland

Course Highlights:

Course Content Includes:

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

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

For more information go to www.skills4work.org.nz or contact Phil Hurford

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

> MAINTENANCE MATTERS

or tightening task for instance is preserving the inherent reliability, as often the only method to do this is to stop the task and monitor reliability, which is often not an option. There are still other questions we can ask though to help monitor the effectiveness of these PM routines. 2. Is the time and effort that goes into the PM routine relative to the consequence of the failure of the equipment? It is important to always remember that it isnâ&#x20AC;&#x2122;t the failure itself that we are trying to avoid but the consequence of that failure. Continuing with the pump set example, we may have the same pump in several locations throughout the plant. So a PM routine on one that is crucial to safety or production justifies a higher level of preventative maintenance than one that has little or no consequence if it were to fail. We must ask ourselves whether we are under or over-maintaining each piece of equipment to ensure we are maximising the limited resources we have at our disposal. 3. Are we spending more than 20 percent of our time on scheduled restoration or replacement of components based on hours or cycles run? If so we are undoubtedly carrying out too many of these tasks. Research has shown that only about 20 percent of failures can be predicted based on time run. Failure of these items can often be predicted, but not based on time â&#x20AC;&#x201C; we must look for other indications such as vibration or

January 2012

temperature change. 4. Is the cost of carrying out that PM routine more than the cost of the failure of the equipment? We sometimes continue to carry out these checks simply because we have always done them; we never take time to carry out a cost/benefit analysis. If the PM costs more than the full cost of repair, taking into account all the consequences such as production or quality loss, then it is simply not worth following. Preventative maintenance routines are vital for preserving equipment reliability but they take a large amount of our resources. We need to be sure that our maintenance routine is having a positive impact on plant reliability and we arenâ&#x20AC;&#x2122;t simply following such steps because that is a traditional approach. Perhaps it is time that we took a step back and started analysing the effectiveness of our PM routines. After all, they say one sign of madness is doing the same thing over and over while expecting a different result.

Phil Hurford is the manager of the Skills4Work Maintenance Excellence programme. p.hurford@skills4work.org.nz

> MAINTENANCE MATTERS

Start an engineering career

Open Polytechnic’s Bachelor of Engineering Technology degree (BEngTech) is ideal for people who want an engineering career in New Zealand or Australia. The degree is taught by distance in partnership with the University of Southern Queensland (USQ) and has been designed to let you continue studying while working so you can fit study around your life. The qualification is recognised

by the professional engineering organisations of Australia and New Zealand. You can choose from three majors in mechanical, civil and electrical engineering which will prepare you for employment in consultancies and businesses who work on projects such as constructing and maintaining roads

and testing the environmental effects of buildings and machinery. You will attend practice units at the USQ in Australia (this is not included in your course fees). The units will benefit your study by giving you communication skills, teamwork and knowledge of the environment. If you have the New Zealand

Certificate in Engineering (NZCE) or Level 6 National Diploma you can also apply to cross-credit your study and fasttrack your progress through the degree. You’ll be fully supported during study by experienced tutors, library and learning support staff who are available by freephone and email. You can also access the USQ website to get help from tutors in Australia. Open Polytechnic also offers a range of construction diplomas, trade certificates and mathematics bridging courses. If you want to engineer your future please contact Open Polytechnic on 0508 650 200 or email customerservices@ openpolytechnic.ac.nz.

ENGINEER

YOUR FUTURE Give your engineering career a kick start with a Bachelor of Engineering Technology from Open Polytechnic. This joint Open Polytechnic / University of Southern Queensland degree is designed for those wanting a career in engineering or for those already employed in engineering who want to upgrade their qualifications. The degree has three majors, allowing you to specialise in: • Mechanical Engineering • Civil Engineering • Electrical Engineering Delivered by distance the Bachelor of Engineering Technology has been designed so you can fit your study around your life, letting you choose when and where you study. Right now we’re helping around 29,000 students fit study into their lives. If you’d like to join them we’re here to help. Open Polytechnic also offers related qualifications including construction diplomas and trade certificates, as well as mathematics bridging courses.

To find out more visit openpolytechnic.ac.nz/bengtech or call us on freephone 0508 650 200

Power at the right place, at the right time

Webster Group’s generators backup and continually supply power in a multitude of applications throughout New Zealand. They can be found in hospitals, rest homes, on air force and naval bases through to cowsheds, and they also travel around the world on board ships. Stefan Richter visited the company to get an inside view of the generator business. We are used to the fact that power comes out of the wall socket, so nobody really cares about generators unless something has happened to the grid and the socket suddenly ceases to provide us with electricity. “We supply generators for power backup or continual supply for shipping lines, farm buildings and a wide range of companies and organisations,” says Tom Webster, “and it is amazing what generators are doing behind the scenes.” The Director of North Shore-based Webster

January 2012

Group illustrates this statement with an example from the meat-producing industry. “Our generators are utilised in milking sheds to power up and backup daily operations. Later, during rail transport of the produce to the seaports, wagon mounted generators supply electricity for the refrigerated containers.” Sometimes there is another generator working on the wharf, when backup energy is required to keep the containers cool. “And then, when the frozen meat starts its journey

to a destination somewhere in the world, our generators not only supply power for the refrigerated containers on deck, but they can also be found connected directly to the ship’s engine room, waiting to provide backup power in case there are problems with the ship’s own generators.” In 1938, Eric Webster, a young electrician, set up an electrical engineering company in Auckland’s suburb of Parnell. Located conveniently close to the harbour, the company,

> gENERATORS

Ralph Leaney (left) and Tom Webster, the two Directors of Webster Group, give an insight into one of their containerised generators.

GE Webster, continually grew, providing specialist services to merchant and naval shipping which included full refits, routine maintenance and also motor winding. Later, lift maintenance and installation were added to the business, and in 1959 the company wired the Auckland Harbour Bridge and also the “Nippon clip-ons” a decade later. Today the Webster Group prides itself on being one of New Zealand’s leading electrical engineering contractors specialising in supplying and repairing marine and land-based electrical and electronic equipment. The services offered include wiring for refrigerated containers, generators, transformers, compressors, and industrial plant and site wiring. “Customers call us to work on electrics for cranes, at cement works, on trains, at desalination plants, at sewage plants and pump stations,” says Ralph Leaney, Director of Webster Group. “But at the moment, about 75 percent of our work is related to generators.” Webster Group runs a fleet of more than 100 hire generators and is also concerned with installation, reconfiguration, operation, repairs and maintenance. A network of branches and agents based in Auckland, Christchurch, Tauranga and Napier provide for 24/7, 365 days availability. And finally customers can also purchase new and used plant (ex-hire fleet) or imported petrol and diesel generator sets, ranging from 2kVA to 2000kVA, and all offered with customised installation if required. How the generator business started “In the late 60s international cargo shipping was strongly transformed by the expansion of refrigerated container fleets. We were probably the first company to service such a refrigerated container,” recalls Tom Webster, who is the son of company founder Eric Webster. “At that time, one of our electricians, who had never seen a refrigerated container before, fixed a problem with one

of the new containers, and we became the agents of that shipping line. Later we serviced all the refrigerated containers of four shipping lines.” By the late 80s the company had to rethink their strategy. “We could see the writing on the wall,” says Tom Webster. “Major shipping lines had consolidated and forced the closure of one of our best customers. And the refrigerated containers became more and more automated and self-diagnosing. Cutting costs was the order of the day, and many shipping lines only authorised necessary repairs and neglected less essential maintenance activities.” At that point the company took advantage of the fact that the expanded worldwide trade with refrigerated containers had left many ships unable to provide additional electricity from their own generators. Tom Webster: “We found a generator somewhere, and leased it to the Shipping Corporation of New Zealand. Later we started to build generators to make them fit for the harsh environment at sea. From there the generator hires have taken off, and our business has become far bigger than we have ever thought possible.” The harsh marine conditions forbid the utilisation of all-purpose generators off the shelf. “We know the requirements of marine applications well, and are aware of the fact that equipment deteriorates quite quickly. Therefore we came up with a specific generator design to meet those demanding requirements, and we have perfected that design over the years,” says Ralph Leaney. Webster Group won an award at the 2010 Westpac Enterprise North Shore Business Excellence Awards for their innovative generator development. Containerised generators on board of ships are important to extend the capacity of the ship’s own power generators. “We have a five-month period of increased exports here in New Zealand with containers full of fruit, meat and dairy products stacked on

Saving space on board a ship is paramount. Webster Group’s containerised generators come with a minimised footprint.

the deck of ships,” explains Ralph Leaney. Many ships are not equipped to cope with the export peaks, and before the utilisation of containerised generators, shipping lines would replace smaller ships with bigger ones in the export season, or they would simply get another ship to complement it. “But the shipping lines have become increasingly comfortable with generators, and in order to cope with the power demands of all the refrigerated containers on deck, generators provide additional electricity.” That way the shipping lines can keep the same ship and avoid the cost of utilising additional or bigger ships and hiring more crew. “It is a financial win for all parties including New Zealand’s exporters.” Minimised footprint as a unique feature “There are many companies who provide generators in containers,” adds Ralph Leaney, “But we try hard to outcompete them by minimising the footprint of our containerised generators.” The side and end-opening doors of a standard ISO 20-foot container and its exhaust make it necessary to allow for some space around the container. And the fuel tank of a containerised generator requires additional space. “Generators on deck and their fuel tanks displace up to 16 export containers off the ship. We try to design our product to be as compact as possible and still maintain all the safety features. At the moment our custom-built containerised generators are only displacing up to six export containers, depending on the ship’s layout. We buy brand new generators, strip them down to the basic core, and then they are built up again to defy the tough conditions of marine applications.” All the containerised generators are surveyed

> ELECTRICAL TECHNOLOgy

The company’s hire generator fleet encompasses more than 100 units.

by Germanischer Lloyd representatives in New Zealand to meet International Safety Convention requirements. Ralph Leaney points out that generators designed for marine applications come equipped as standard as “silent packs” to eminently suit residential and commercial placement, while at the same time retaining a very rugged construction for other applications such as mines and oil rigs. One of Webster Group’s generator sites, for example, is offshore on Maui B, a production platform located 35 km off the Taranaki coastline. All the major ports in New Zealand – Tauranga, Lyttelton, Auckland, and Napier – frequently utilise Webster Group’s generators to run extra power on the port’s grid. Quite often

New Zealand Electrical Institute Incorporated – change of National Secretary Allan Hill has accepted the role of National Secretary to ease the load on Alan Cuthbert who has done a tremendous job as National Secretary for the Institute since September 2008. Alan Cuthbert will continue to work on electrical standards with Standards NZ. Profile of Allan Hill, MIMC, MNZEI Allan Hill is a Registered Electrical Inspector with many years of experience with electrical, instrumentation and control systems. He has provided E,I&C expertise

January 2012

refrigerated containers are stacked on the wharf to wait for their respective ships to arrive and take them on board. To keep their content cool, extra energy needs to be provided. The company’s generators can also be found in hospitals (e.g. the Mercy hospital in Dunedin), universities, rest homes, on air force and naval bases and on board trains that transport refrigerated containers. “And after the devastating earthquake in Christchurch, we had a number of generators in use, backing up buildings, cool stores, and telecommunication infrastructure.” Due to the fact that Webster Group’s services include electrical contracting, there are always a sufficient number of trained and experienced electricians available to set up, service or maintain a generator – even when there is an emergency. “In 1998, during the Auckland power crisis, we were busy delivering generators to many companies,” recalls Tom Webster. Webster Group is proud to be a familyowned, wholly New Zealand business, where things are still done on a personal level. “Since my father founded the company in 1938, we must have trained at least 130

apprentices,” says Tom Webster. “All of them have been fully-trained and qualified on the job and have become highly-skilled, motivated and cherished team members. We have always adhered to the belief that the best tradesmen come from in-house training.” Tom Webster thinks it is a shame that many competitors do not train promising young people, but rather want to hire already trained staff. “There are many kids who would relish a chance to get hands-on experience and training in the wide and varied areas of marine electrical contracting, not just wiring a house. The future is certainly fertile for resourceful thinking in this area. And the future of generators as an alternative to an extension of the grid is going to be an interesting one too, given that there are more power sources available than just petrol and diesel, such as solar, wind and micro-hydro schemes. We just need to keep our minds open and be on the lookout for these opportunities.” Go to www.demm. co.nz/enquiry quote: D120138

both nationally and internationally to a vast array of continuous process industries. Together with his wife Evelyn they have been running their NZ-based electrical consulting company since 1999, after closing their Australian company in 1996 and returning to New Zealand after a three-year contract with the engineered wood panel division of CSR in Australia. Allan is passionate about safety and has carried out machine safety assessments and undertaken the electrical engineering to bring machinery up to the required standard. His strong people management skills ensure that project programs, irrespective of size or duration, are achieved and all stakeholder requirements are realised. Allan has the electrical engineering expertise to identify, justify, design and implement improvements to any continuous industrial process. He

prides himself on being a systems person, having personally set up instrumentation documentation systems for ISO9002 and several preventative and predictive maintenance systems. Alan is currently employed by Brightwater Engineering, in the Birkenhead office as a Senior Project Engineer. The new contact details for the National Secretary are as follows: National Secretary New Zealand Electrical Institute Inc. PO Box 64-258 Botany Manukau, Auckland, 2163 Phone: (09) 271 1901 Mobile: (021) 613 448 Email: NZEI@xtra.co.nz

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> ELECTRICAL TECHNOLOgy

Electricity Regulations and Wiring Rules amendments published The Electricity (Safety) Regulations 2010 Amendment 1 has now come into force on the 10th of November 2011. A copy of the Electricity (Safety) Regulations 2010 including Amendment 1 is available from the website www.legislation.govt. nz – look for the “Electricity (Safety) Regulations 2010 as reprinted on 10th November 2011.” The amendment of the Electricity (Safety) Regulations 2010 and Amendment 1 also brought into force changes to the Wiring Rules (AS/NZS 3000 + amendment s No. 1 and A). One of the major changes of the Wiring Rules will bring into force changes to the provision of 10mA RCD in school classrooms, up to school year eight. The other major change is when carrying, work in a domestic residence, the fixed wiring in ceilings walls and under floors must be such that if thermal insulation is not initially being installed to the NZ Building Code, the fixed wiring installed must be designed to be able to operate safely when the thermal insulation is fitted later to comply with NZ Building Code requirements. This will require all electrical workers to review the “rules to thumb” used when designing and installing the fixed wiring in the domestic installations. It will be necessary to check the permitted maximum current ratings of cables used in domestic installation and the overcurrent devices MCB ratings. It should also be noted that any distance exceeding

150mm of TPS cable through a hole in a thermal insulation blanket has to be treated as “completely surrounded in insulation”. Reference AS/NZS 3008.1.2:2010 Clause 3.5.7. In general, twin + E 2.5mm2 TPS copper cable will have a maximum rating of 15amps when completely surrounded by thermal insulation, and this does NOT include any de-rating for bunching or ambient temperatures exceeding 30 degrees Celsius, or, the increase of cable size necessary due to voltage drop. Thus it will be seen that a 20amp MCB will not be able to protect a 2.5mm2 TPS cable. Clipping the TPS cable to roof or ceiling timber may qualify for increased current rating using “partially surrounded by thermal insulation” values but any increase in current rating would require the TPS cable to be in continuous contact with timber. In practice, this fixing method is never achieved. If the TPS cable diverts from being fixed to timber thermal insulation, it comes in contact with the TPS cable and the completely surround values must be used. The types of recessed luminaires have been increased and for some small wattage lamps, mainly of the CLF type. Some luminaires will be able to be completely covered by thermal insulation, but always check that the fitting is marked with the internal marking of a capital F in a delta triangle and covered by a horizontal line over the delta triangle before doing so, or alternatively, consult the

fitting written manufacturer’s instructions. An upcoming amendment, No.2, for the Wiring Rules, is nearing completion and is being considered at a meeting of the joint EL-001 committee

in Sydney on the 5, 6 and 7th December 2011. Details of the changes being made will be given in the next issue. Alan Cuthbert

New Zealand Electrical Institute Inc, c/o 68 Melrose Road, Island Bay, Wellington, 6023. www.nzei.co.nz

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> FEATURE

Don’t let unqualified “experts” risk tenants’ lives and building safety We have all watched the US troopers with their ‘nightvision’ /infrared capability enjoying an advantage over insurgents in Iraq and Afghanistan, or firemen able to see through smoke and find victims in a blaze. The spin-off of a $US 500 million US Defence Department investment is now also being applied to improve preventive electrical maintenance in New Zealand commercial properties. Kevin Kevany reports. Bill Mitchell, a qualified, highly-experienced electrician, an ITC-certified infrared thermographer, and accredited user professional infrared cameras, is a man with a double mission – to convert building owners and managers to the value of this costefficient, effective preventive maintenance, using a specialist camera, and to eliminate “the cowboy users of infrared technology”. As a seasoned electrician, Mitchell is passionate about how the latest generation of infrared cameras enhances his ability to deliver highlyaccurate preventive maintenance, quickly and unobtrusively, during office hours. Being a qualified electrician too, he is uniquely capable of fixing the problem there and then – what he calls his “we need to do something NOW” moment. “Basically, nearly everything gets hot before it fails, making infrared cameras extremely cost-effective, valuable diagnostic tools in many diverse applications in the electrical industry,” he says. Jeff Mclaren, CEO of the Singer Group, has welcomed the infrared capability and Mitchell’s professional skills package to the company, particular to building maintenance, which is managed by long-serving manager Kevin Dunbar. “Kevin has been on about us adding a thermographic capability to our maintenance services for some time now. I’ve seen a few demonstrations of it, of varying standards and application. But I was bothered by the fact that the operators involved seemed to be totally reliant on the cameras and had to then brief an electrician to fix any problem. “That seemed like too many links in the chain. When Kevin introduced, Bill, a longstanding friend, and made the point that he

January 2012

was fully-qualified to both diagnose and fix, I was sold. And that has been the case with our customers, who have to a man, welcomed the combination of leading-edge technology, an operator trained to the international standard, and a qualified and experienced electrician. “Technology for technology’s sake has never done anything for Singer. But this is the only way to go. I’m very supportive of the New Zealand Association of Professional Thermographers looking to enforce standards and lobbying the insurance industry to recognise the difference through premiums. “We don’t need a ‘towering inferno’ experience in a New Zealand CBD before we recognise the dangers of having unskilled and unsupervised operators passing off incomplete information. The last time we allowed that to happen, New Zealand ended up with the leaky houses disaster – something we are all still paying for,” Mclaren adds. Mitchell is Secretary of the professional association and is working to support the efforts of its president, Ken Jackson, who is the country’s top professional trainer of certified thermographers, delivering courses approved by The Infrared Training Center (ITC), the world’s largest thermography training organisation, which last year trained more than 7000 infrared users worldwide. “Finding a problem with an infrared camera is sometimes not enough. In fact, an infrared camera image alone, without accurate temperature measurements, says very little about the condition of an electrical connection or worn mechanical part. Many electrical components are operating properly at temperatures that are significantly above ambient. An infrared

image without measurement can be misleading because it may visually suggest a problem that does not exist,” Mitchell says. That can lead to unqualified or inexperienced operators with very basic gear and knowledge bringing a building to a standstill, only to find that a switchboard component was functioning within the correct parameters, and that an outside factor like a setting sun was to blame. “There is constantly a fine line that we have to tread between being officious (and mistaken) and erring on the wrong side, when safety could be compromised. The operator/electrician, not the camera, makes the call, based on the information accumulated. “At all times, you have to be using your own brain and skills in conjunction with this superb equipment. You and the camera need to analyse what is being emitted by the ‘target’; what is coming off you as the operator and being reflected back; and what is being reflected in from the outside. Getting a proper reading is the first step. You also have to understand what is in that calculation. You must be able to ‘contextualise’ the information from the camera, the environment and your electrical training and experience to really get the correct answer,” says Mitchell, who was trained in the Royal New Zealand Navy, where the environment is the primary consideration – every time. Your first thought, as a layperson, is that the camera looks ominously like a cop’s radar gun. But it is far more sophisticated. Mitchell explains, “Take the camera I use. It’s a Flir – ‘forward looking infrared’ – which delivers two images. The first is a digital

> FEATURE

Thermography Infrared light or thermography is the use of an infrared imaging and measurement camera to “see” and “measure” thermal energy emitted from an object. Thermal, or infrared energy, is light that is not visible because its wavelength is too long to be detected by the human eye; it’s the part of the electromagnetic spectrum that we perceive as heat. Unlike visible light, in the infrared world, everything with a temperature above absolute zero emits heat. Even very cold objects, like ice cubes, emit infrared. The higher the object’s temperature, the greater the IR radiation emitted. Infrared allows us to see what our eyes cannot. Infrared thermography cameras produce images of invisible infrared or “heat” radiation and provide precise non-contact temperature measurement capabilities.

shot of the item being assessed. The second is an image which is, if you like, the top of a massive ‘mathematical box’, which contains, in my case, an image resolution of some 320 x 240 (a whopping 76,800 pixels) or individual temperature detectors, generating a seemingly-static surface snapshot of all those simultaneous calculations. And those 70-odd thousand detectors get calibrated into a calculated narrow range, to bring the detail on a potentially faulty cable coupling or circuit-breaker into a macro-range where nothing can escape the probing eye. Remember, thermal imaging doesn’t see through walls or cabinets or equipment’, it measures what is on the surface, which in turn is a

Thermal imaging cameras are able to produce a crisp image in the darkest of nights. Thanks to special calibration, some thermal imaging cameras are also able to measure temperatures in a non-contact mode. Infrared cameras which incorporate temperature measurement allow predictive maintenance professionals to make wellinformed judgments about the operating condition of electrical and mechanical targets. Temperature measurements can be compared with historical operating temperatures, or with infrared readings of similar equipment at the same time, to determine if a significant temperature rise will compromise component reliability or plant safety. (Adapted from Flir sources)

product of what is beneath it,” he notes. Being a qualified and experienced electrician, Mitchell adopts a belt-and-braces approach, keeping a thermocouple handy for when he wants to check a reading which he thinks might be misleading. He describes it as a thermoelectric temperature sensor which consists of two dissimilar metallic wires, e.g. one chromel – an alloy made of approximately 90 percent nickel and 10 percent chromium – and one constantan – an alloy, also known as Eureka, usually consisting of 55 percent copper and 45 percent nickel – coupled at the measurement-junction or probe-tip and extended to the reference junction or “known temperature”.

0800 474 643 www.singergroup.co.nz

> WHAT’S HOT

Infrared energy detection An infrared camera is a noncontact device that detects infrared energy (heat) and converts it into an electronic signal, which is then processed to produce a thermal image on a video monitor and perform temperature calculations. Heat sensed by an infrared camera can be very precisely quantified or measured and allows you to not only monitor thermal performance, but also identify and evaluate the relative severity of heat-related problems.

The temperature difference between the probe tip and the reference junction is detected by measuring the change in voltage or electromotive force at the reference junction. The absolute temperature reading can then be obtained by combining the information of the known reference temperature and the difference of temperature between probe tip and the reference. The final thought from Mitchell, “I believe there are three critical variables which have to lineup in applying thermography to ensure that it delivers for the customer. One: the quality of the camera. A 60 x 60 pixel camera only gives you 3,600 temperature detectors

versus say 50,000 and upwards. “Two: the competence of the ‘driver’. The training and the other qualifications and experience of that person are as critical as the technology. You’d prefer a trained astronaut to a bus driver to fly your rocket, most times. “Three: look at the company and the resources it has to stand behind the individual using the technology. If you suddenly find yourself facing a major problem, you want to be able to draw on as many qualified electricians and even engineers that might be needed – seamlessly. That’s why I brought my skills and training to Singer.”

Real-time power quality enhancement The Equalizer is a power factor correction unit from Elspec. It switches capacitor groups on and off using state-of-the-art electronic switches. The connection and disconnection of capacitors occur precisely at zero-current crossing. This smooth connection avoids transient effects typically created by electromechanically switched power factor correction (PFC) systems, extending the life expectancy of the Equalizer dramatically. Using exclusive automatic control algorithms and rapid electronic switching, total acquisition time (complete compensa-

tion of reactive current) is achieved in 2/3 cycle typical (50Hz = 13.3ms; 60Hz = 11.1ms), irrespective of the number of steps required. The power factor is controlled very accurately through an advanced open and closed loop control and measuring system that uses information from all three phases, as well as accounts for the effect of harmonics (1 through 63). Minimum, maximum and average power factor modes, as well as threshold levels, can be selected for perfect compliance with specific network requirements. The Equalizer includes a unique

solution for line-to-line loads, in which it calculates a transformer’s internal currents and compensates accordingly. Third party measurements have proven the Equalizer to be the ultimate solution to offer precise compensation. Go to www.demm.co.nz/ enquiry quote: D120142

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> WHAT’S HOT

PowerSave Light Company has been supplying PowerSave lights to New Zealand business for seven years and the results are real and measurable. Factory and warehouse lights that run at less than half the power, improve the light quality, start instantly and are paid for out of the power savings in eight to 18 months. . There are models to replace or retrofit highbays, lowbays or floodlights which run at 200 watts compared to more than 400 watts for conventional light fittings. A business running 24/7 will save more than $300 per year per light. Take advantage of the ability to start lights instantly and use sensor controls to reduce running times and savings will be even more. Tim Roberts, Fonterra Research site electrician, says, “PowerSave were right about the savings we would get, and staff say the daylight colour has made a world of difference to the light clarity. Retrofitting our lowbays took only 15 minutes each, the results were immediate and there was no disruption to staff.” Martin Bliss, AHI Roofing project engineer, commented, “We installed some PowerSave highbays a few years ago as part of a lighting upgrade. We have progressively changed all our factory, warehouse and floodlighting to PowerSave fittings

and although we are operating at reduced hours, savings are over $35,000 annually. The installation in the export warehouse included the redesigned highbay reflectors which have proven very effective in increasing the light output over the original models. The rapid start function makes it easy to switch areas on and off without having to wait ten minutes for normal light levels to return.” Huge savings are also reported by Keith Morris, NZ Post national asset manager. “A lighting upgrade at a large Courier Post site not only won over staff who said the lighting is brighter and more comfortable to work under, but the savings were verified independently and they exceeded forecasts. As a result there has been a roll-out across the depots countrywide. Lighting is the area where savings could be achieved most cost-effectively and the bonus has been with staff saying label reading and sorting is now a lot easier.” And Metal Skills director Graeme Bartlett reports, “We used PowerSave lights in our previous building four years ago and electricity is one of our biggest overheads as we run 24 hours a day. By using PowerSave lighting we can redirect the $30,000 we save per year in to other areas that add value to the company.” Go to www.demm. co.nz/enquiry quote: D120143

•

TESTING & MEASURING

Instruments

When you're looking for Testers and Measuring Instruments you want practical design with an emphasis on reliability and a range of features to meet your needs. Then you need Benning testers and measuring instruments. One of Europe's leading instrument manufacturers, Benning offer a wide range of affordable quality testing and measuring instruments. The range includes the proven DUSPOL voltage testers, DigitalMultimeters, Logging Multimeters and Clampmeters, Appliance Testers and Installation Testing Equipment. Benning measuring instruments not only meet today's exacting standards but carry features to ensure they will continue to set the standard in the future. Benning DUSPOL Voltage Testers comply with the new European standard IEC/ EN 61243-3 For further information on the Benning range contact your local electrical wholesaler.

EUROTEC

ET/BENN/2011

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> EVENTS

Coming events

www.pacific.org.nz

Introduction to Oil & Gas Production for Technical Managers

05-06 March 2012 Quality Hotel, New Plymouth This intensive two-day training course provides a technical overview of oil and gas production process. The course will use process engineering fundamentals to explain the operation of each process unit. All attendees will be provided with a workbook and a certificate of completion. For more information: www. conferenz.co.nz/training/introduction-oil-gas-production-technical-managers

ous Areas Industry? IDC Technologies are currently looking for a number of speakers to submit an abstract and present their papers at this upcoming conference. This conference will combine papers on Safety Control and Instrumentation Systems, Machine Safety and Hazardous Areas. For more information contact conferences@idc-online.com Or check out the full Call for Papers online: http://www.idc-online.com/ newsletters/brochures/1205_CFP_SafetyNZ.pdf Abstracts due ASAP – topics are approved on a suitability and first-come basis.

7th Planning4Reliability National Forum

National Manufacturing Week 2012

Engineering Machinery & Electronics Exhibition New Zealand

Austech 2012

21-22 March 2012 Melbourne, Australia The forum will provide two days of presentations, encompassing things such as shutdowns and turnarounds, CMMS utilisation, cost reduction and reliability improvement through defect elimination. By attending the forum you will have the opportunity to learn from amongst the country’s best industry practitioners and interact with peers with similar problems and challenges. Visit www.sirfrt.com.au for more information.

01-03 May 2012 ASB Showgrounds, Greenlane, Auckland EMEX is the most comprehensive engineering, machinery, electronics and manufacturing industry event in the country and is seen by many as the prime professional and business tool for anyone working in industrial engineering and maintenance, control and instrumentation, machine technology, plant automation and monitoring, welding, forming and cutting, and software and computerisation. For more information: phone: + 64 9 976 8300, email: info@emex.co.nz, http://emex.co.nz/

Call for Papers Safety Control Systems & Hazardous Areas Conference

02-03 May 2012, Auckland Are you an Engineering Professional in the New Zealand Safety & Hazard-

08-11 May 2012 Sydney Showground, Sydney Olympic Park, Australia NMW 2012 will house a record 12 product zones, including two new zones: Sustainable Manufacturing and Metals & Composites. The Sustainable Manufacturing zone will focus on opportunities for reducing industry’s environmental footprint; while Metals & Composites presents new developments in industry’s quest to develop reliable, lightweight, easily moulded manufacturing materials. More info: www.nationalmanufacturingweek.com.au 08-11 May 2012 Sydney Showground, Sydney Olympic Park, Australia Austech is Australia’s premier advanced precision manufacturing and machine tool exhibition. It covers the key areas of machine tool and sheet metal working and runs alongside other affiliated manufacturing industry exhibitions, making it the premier event of its type in Australia. Go to www.austechexpo.com.au to find out more.

CIVENEX 2012

16-17 May 2012 Western Sydney Dragway at Eastern Creek, Sydney, Australia Exhibitors include suppliers of earthmoving equipment, landscaping needs, pipes and precast products, paving products, street and park furniture, traffic control, survey and GPS, trucks, trenchless technology, power equipment and more. Visit www.civenex.com for more information.

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

www.demm.co.nz/enquiry or email frank@adrenalin.co.nz reader reply form Reader enquiry number:________________________________________________________ Name:_____________________________________________________________________ Your business name:__________________________________________________________ Position:___________________________________________________________________

LOOKINg FOR NEW BUSINESS AND SALES ENQUIRIES?

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January 2012

Contact Frank Atkinson Email / frank@adrenalin.co.nz DDI / (09) 477 0362

7- 8 NOVEMBER ing The forum-based open network gineers. conference for maintenance en Novotel Rotorua Lakeside

Principal Sponsor

Happy New Year!

EB-260A SWIVEL HEAD BAND SAW EB-280DS SWIVEL HEAD BAND SAW BS-10S SWIVEL HEAD BAND SAW • 1.5hp 240V motor with 1-speed of 90mpm • 245 x 180mm (WxH) rectangular capacity • Heavy-duty gear drive system • Quick-action lock/release vice • Swivel head mitre cut to 60˚ right • Coolant system • Adjustable hydraulic cylinder for auto feed

• 1.5hp 415V motor • 245 x 180mm rectangular capacity • 2-speed motor enabling blade speeds of 45 & 90mpm • Coolant system for cutting efﬁciency & blade life • User friendly blade tension system with gauge

2,500 (B062)

3,800 (B063)

• 1.5kW / 2hp 415V motor • 400 x 230mm (W x H) rectangle capacity • Mitre cuts to 45º using swivel head • 4-speed cutting (24-38-53-81mpm) • Large easy to read mitre scale • Built-in coolant system • Adjustable length stop for repetition cutting

6,000 (B028)

BS-13DS SWIVEL HEAD BAND SAW • 2hp 415V motor • 458 x 235mm capacity • Dual mitre semi-automatic operation • Adjustable hydraulic vice pressure regulator • 19-102 M/min Variable speed drive • Auto blade breakage sensor • Mitre cuts to +45º, -60º • Laser guide

9,500 (B030)

AL-340A CENTRE LATHE

CL-38A CENTRE LATHE

CL-60B CENTRE LATHE

CL-75 CENTRE LATHE

• 1.5kW / 2hp, 240V motor • 39mm spindle bore • 178mm centre height • 1000mm between centres • 8 spindle speeds (70-2000rpm) • Includes: 3 & 4 Jaw chucks, faceplate, ﬁxed & travelling steadies, change gears, dead centre, thread-chasing dial, safety chuck & rear splash gurad, work light, stand, foot brake, swarf tray, tool box & instruction booklet

• 5.5hp 415V motor • 16 spindle speeds (45-1800rpm) • 52mm spindle bore • 205mm centre height • 1000mm between centres • Includes: 2 Axis digital readout, quick change toolpost, 3 & 4 jaw chucks, faceplate, steadies, dead centre, thread chasing dial, footbrake, coolant system, work light, rear splash guard & spindle reducing bush

• 7.5hp 415V motor • 1500mm between centres • 80mm spindle bore • 230mm centre height • 12 spindle speeds (25-1700rpm) • Includes: 2 Axis digital readout, taper turning attachment, quick change toolpost, 3 & 4 jaw chucks, faceplate, steadies, dead centre, thread chasing dial, footbrake, coolant system, work light, rear splash guard & spindle reducing bush

• 10hp 415V motor • 80mm spindle bore • 12 spindle speeds (25-1600rpm) • 280mm centre height • 560 x 2000mm • Includes: 2 Axis digital readout, taper turning attachment, quick change toolpost, 3 & 4 jaw chucks, faceplate, steadies, dead centre, thread chasing dial, footbrake, coolant system, work light, rear splash guard & spindle reducing bush

4,850 (L179)

10,500 (L191D)

15,700 (L605D)

17,500 (L626D)

HM-52 MILLING MACHINE

BM-52VE MILLING MACHINE

BM-65VE MILLING MACHINE

BM-90HV MILLING MACHINE

• 1.5kW / 2hp 240V motor • Swivel table & two arbors for the horizontal spindle • 1000 x 240mm table size • Includes: X-Axis power feed, safety cutter guard, swarf tray, coolant system, halogen lamp, drill chuck & arbor 2 & 3 MT adapators, 8 peice metric collet chuck set (4-16mm) & machine vice

• 3-Axis digital readout system • 5hp 415V motor, dial variable speed system • 1370 x 254mm work table • NT40 Spindle • X-Axis power feed • Coolant system, halogen light, 150mm machine vice & swarf tray • Travels: (X) 865mm (Y) 420mm (Z) 400mm

• 5hp 415V motor • 1500 x 300mm worktable • NT40 spindle • Variable 60-3600rpm • Includes: 3 axis digital readout, automatic oil, lubrication pump & reservoir, pneumatic drawbar system M16 thread, coolant system, slideway covers, Z axis powered elevating motor X & Y-Axis power-feed, halogen light, safety cutter guard & swarf tray • Travels: (X) 925mm (Y) 420mm (Z) 480mm

• 5hp 415V motor • NT40 horizontal & vertical spindle • 1470mm x 370mm work table • Includes: 3-Axis digital readout ﬁtted, ball screw X & Y-Axis, automatic oil lubrication pump and reservoir, pneumatic drawbar system M16 thread, coolant system steel slide-way cover, Z axis powered elevating motor, X & Y-Axis servo controlled power-feed, halogen light, safety cutter guard & Swarf tray • Travels: (X) 1120mm (Y) 520mm (Z) 440mm

12,300 (M596D)

IW-60H PUNCH & SHEAR • 60T • 7.5hp 415V motor • Power inching for easy job set up • Adjustable stroke for faster punching • Punch table and shear table both ﬁtted with guides as standard • Adjustable length stop with rule • All work stations guarded • Five work stations, including notcher • 2 year warranty

12,500 (P173)

18,000 (M629D)

38,000 (M633D)

IW-80S PUNCH & SHEAR

PB-422A MANUAL PANBRAKE

PB-820 MANUAL PANBRAKE

• 10hp 415V motor • 80T punch pressure • Punch capacity ø26 x 22mm • Flat bar shearing 460 x 15mm • Angle shearing 152 x 152 x 13mm

• 1250mm x 2mm capacity • Extended ﬁngers allows bending of pans or boxes to a depth of 230mm • Ground segmented ﬁngers can be repositioned to suit many applications

• Heavy duty steel fabricated construction • Removable ﬁngers • 2440 x 2mm capacity

$19,900 (P175)

$3,550 (S262)

$4,500 (S564)

L STIMIT OC ED K

4,800 (M161)

(09) 2717 234

Unit D/38 Highbrook Dr, East Tamaki 46

January 2012

www.machineryhouse.co.nz

1_DEMM_010112

Specifications & Prices are subject to change without notification. All prices exlude G.S.T. and valid until 31-01-12