Engineering Update - November 2013 by Jet Digital Media Ltd

ENGINEERING UPDATE WWW.ENGINEERING-UPDATE.COM

NOVEMBER 2013

Featuring.....

Sensors & Calibration, Fluid Control & Pumps and Sustainability

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Connect with us

November 2013

CONTENTS Publication Manager

|4 Engineering Essentials

Tim Johnston 0800 093 1901 tim@engineering-update.com

|10 Events |12 Sensors

Editor Jenna Burridge 0800 093 1901

|20 Review

Account Executive

|22 Fluid Control

Shaun Phillips 0800 093 1901

|23 Pumps

Publishing House Jet Digital Media Ltd

|24 Sustainability

Spratling Court Farm Manston Kent CT12 5AN

|26 Calibration |28 Editors Choice 速

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November 2013 A corrosive substance is one that will attack, damage or even destroy other substances with which it comes into contact. It may attack a great many materials, including various metals and plastics. Corrosion literally consumes the material, reducing load carrying capability and causing stress concentrations. It is often a major part of maintenance cost meaning corrosion prevention is vital in many applications. Pressure measurement transducers and transmitters are used in a multitude of applications and may be exposed to a number of corrosive chemicals and gases. These chemicals can attack the instruments both internally and externally, typically from leaks or fumes. Electronics and wiring may corrode which will often lead to instrument failure. The product exterior and internal electronics must therefore be protected from chemical exposure through good design and appropriate selection of materials of construction. It is therefore necessary to consider whether the materials used in the construction of your selected pressure transducer or transmitter are suitable for use with the media to be monitored. So where do you begin to choose the correct transmitter for the job? Firstly the constituent elements of the media that the construction of the transmitter is able to resist them, both in the short and long term. It is also important to remember that corrosive media can potentially become more

Engineering Essentials

aggressive as temperatures and pressures increase. Most metals corrode on contact with acids, bases, salts, oils, aggressive metal polishes, detergents and other solid and liquid chemicals. Metals will also corrode when exposed to gaseous materials such as acid vapours, formaldehyde gas, ammonia gas, and gases containing sulphur. The use of notoriously hazardous chemicals such as sulphuric acid and hydrochloric acid are certain to ring the alarm bells, but what if you are measuring seemingly risk free liquids like seawater or fruit juices? Specialised manufacturers of pressure transducers and transmitters such as ESI Technology Ltd offer a comprehensive selection of materials in order to achieve the desired level of corrosion resistance for your ESI can advise you on the best sensor option combined with machined housings and threads in specialised metals and plastics to create a product that will operate safely and reliably at high levels of performance, even in the most corrosive of environments. Standard ESI transducers are manufactured using 316L stainless steel and work effectively with most everyday types of gases and liquids such as nitrogen, oxygen, air systems, lubricants, coolants and hydraulic oils. However the introduction of pressure transducers and transmitters using Silicon-on-Sapphire (SOS) sensing technology presented ESI with a distinct advantage in this area as the pressure diaphragm and threaded pressure port is machined entirely in Titanium. This means the

pressure media is only ever in contact with Titanium leaving the user with no concerns about the possible failure of o rings or seals. This is possible as the sensitive SOS sensing element is bonded to the non-contact side of the pressure diaphragm and therefore isolated from the media. For more information on ESI Technology and their range of products visit www.esi-tec.com or call +44 (0)1978 262255

Engineering Essentials The doomed luxury steamship, RMS Titanic, set sail from Southampton on 10th April 1912 destined for New York. However she never arrived. Her sinking on 15th April 1912 after hitting an iceberg is one of histories most notorious events. Built in the UK; with many of the ships parts, including the famous anchor developed in the Black Country, local residents and councils wanted to honour this iconic ship by recreating an exact copy of her anchor, putting it on display in Netherton; the town the original anchor was forged in. With over 16 tonnes worth of anchor to be displayed, supporting the anchor would not just be a simple task of propping it up. The local council took the decision to mark the occasion of the replica anchor being created, with a public display; with the anchor travelling the reverse route it took in 1911, from Netherton to Dudley. Channel 4 was made aware of the event and it showed great interest and featured the occasion in a documentary. A1 Rentals was contracted the job of moving the anchor from Dudley and then arranging its display in Netherton. This was when Arbil was contacted. Andy Towns, General Manager at A1 Rentals explains, “We have been a customer of Arbil’s ever since our business came into existence, often using them for hire purposes. As initially the anchor was only to be temporarily on display in Netherton we decided to hire 50 tonne jacking stands from Arbil to support and hold the anchor on display. We ourselves only received just over a week’s notice of the details for this job, so we were really up against it in terms of time. This was when we got in touch with Brian at Arbil and he quickly designed and turned around a support to bolt to the jacking stands to hold the anchor in its temporary home” After the initial public display and use in the documentary the council took the decision to store the anchor at the Black Country Museum. However, after reviewing just how much attention this replica anchor had gained; the decision was made that it should be on permanent display. A1 rentals was then contacted again for its services to undertake this. Andy Towns explains, “After discussing the requirements with Arbil we came to the conclusion that a bespoke stand would be more appropriate

November 2013 and also more cost effective in the long-term than the previous this round for us in the limited timeframe we were given.” Due to the turnaround time, Arbil set to work quickly. Initial drawings were produced of the stand design, which had to be approved by the council’s engineering department as they had commissioned this job. Once approved, work then got underway. Brian Timmington, Arbil’s General Manager of Manufacturing and Engineering commented, “As soon as the anchor arrived in Dudley for the initial display and documentary, we went straight to site to take detailed measurements to develop the original support stand for the jacking tools to precision accuracy. As we already had these straight away once the need for a permanent stand arose.’ Timmington continues, ‘The permanent stand was developed out of solid steel with a triangular groove in the top for the anchor head to be placed in. A1 Rentals had inserted a metal support under ground where the anchor was to be displayed and our stand was to be bolted into this. A1 Rentals had also arranged for a mobile crane to lift and place the anchor on the day of the move.’ Brian continues, ‘My grandfather worked at the Noah Hingley & Sons Ironworks back when the original Titanic anchor was forged and so I had a great personal interest in this job, I was more than happy to give up my time, free of charge on the day of both moves, to oversee the transportation to our stands. Witnessing the Andy at A1 Rentals concludes, and was due to be televised; there was no room for error on either the job itself or delivery time. We were impressed by how quickly Arbil turned this around, the quality of workmanship and the professionalism of all those involved. Throughout the whole was promised and the team were a pleasure to work with and we were grateful for them personally giving up their time on the day of the televised event. We would certainly recommend Arbil to others.”

www.arbillifting.co.uk | info@arbil.co.uk 6|

November 2013

Engineering Essentials

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Engineering Essentials

November 2013

Larasian Group Announces â&#x20AC;&#x2DC;Cabinet at Corintech and Lascar with the Managing Directors of its two electronics companies switching roles with immediate effect. Pete Cross, formerly at Lascar, will take the reins at Corintech, whilst Sean Wigmore moves to Lascar from Corintech. Sean Wigmore had been at Corintech for 27 years, working his way up to the top position from a graduate role in Quality Assurance. Pete Cross had spent the last 14 years at Lascar, four of which as MD. Between them they have a considerable range of experience which can now be shared across the whole Group.

a cost effective, easy-to-use method of recording temperature, humidity, voltage, 4-20mA and carbon monoxide. Their extensive range of panel instruments and voltmeters provide display solutions for a wide range of applications within the instrumentation and sensors industries. are looking excellent for 2013 but never one to rest on our laurels we decided that looking forward, a â&#x20AC;&#x2DC;cabinet development of the Group. Having worked with both

In the coming months both companies will be reviewing all aspects of the business so that existing relationships can be built upon, strengths can be encouraged,

invaluable expertise and fresh insight to their respective new companiesâ&#x20AC;?.

There will also be some restructuring to allow the

Corintech Ltd. offers a complete, experienced contract electronics manufacturing service covering everything from printed circuit board design and assembly, to full product build. Their product design service takes projects from concept through to manufacture and their range of thermometers and sensors specialise in touch Lascar Electronics is a leading provider of digital panel instruments, data loggers and custom design and

strong logistical operations and supply chain skills to deliver both high volume long term commitments and rapid turnaround assembly of products. For more information about Corintech Ltd. please visit www.corintech.com contact pete.cross@corintech.com or the Sales team on 01425 655655. For more information about Lascar Electronics please visit www.lascarelectronics.com contact sean. wigmore@lascar.co.uk or the Sales team on 01794 884567.

November 2013

Engineering Essentials

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Breaking through

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growth

#UKmfg has turned a corner in 2013 with real signs of a sustained recovery. #TMDC2013 brings together like-minded manufacturing leaders for growth in 2014 and beyond.

Hear from Leading Senior Manufacturers including: Dr Phil Lewis

John Howie Managing Director Babcock Marine

Steve Dalton OBE Managing Director Sony UK

Gardner Aerospace

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Tony Wallis Director Toyota

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Events

November 2013

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For more information on exhibiting and sponsorship opportunities contact North and Midlands: Paul Fitzgerald, Sales Manager, +44 (0)151 3841589, South and Overseas: or visit www.nemex.co.uk SuPPorteD by:

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|11

High Precision MEMS Inertial Sensors and Systems

Recent developments mean that Silicon Sensing can now provide high precision MEMS gyroscopes and accelerometers with low output noise and bias instability able to meet the accuracy requirements for all marine applications. High accuracy

Excellent bias stability

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Sensors

November 2013

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Sensor-Technik UK Ltd.

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Sensor-Technik UK Ltd. Unit 21M, Bedford Heights Business Centre Manton Lane, Bedford, MK41 7PH, UK Tel. +44 (0) 1234-270770

-£ än Pioneering new technologies

Pioneering new technologies

www.sensor-technik.co.uk |13

Sensors

November 2013 www.gillmetstream.com 01590 613500

Gill Instruments Limited Stream, bridge, process, store and link with MetStream Gill Instruments Limited, a leading worldwide design and manufacturer of meteorological and environmental instruments, is proud to launch the ground-breaking new data solutions platform ‘MetStream’.

existing technologies, MetStream takes it one step further and provides an end-to-end solution for those who would like to bridge, link, store and stream their data in real time through to different devices.”

Comprised of a hub and supporting software, MetStream enables users to obtain multi-channel data via one single unit streaming it across to different outputs. Users can access data via tablets, smartphones and PCs, whenever and wherever they are. The idea behind MetStream originated from a gap in the market, based on limitations of using dataloggers or personal computers for data management. To guarantee a high quality end product, all development was kept in-house by using sister company Gill Research & Development Limited to develop the hardware and software.

A completely new solution to an age old problem, MetStream is unmatched in the marketplace. The MetStream hub is compact and hard wearing, designed to enable users to browse a dashboard style interface and adapt it to meet their needs, depending on the sensor equipment linked to the hub. Furthermore, sensors are not limited to work only with Gill Instruments own branded products. Gill Instruments will be showcasing MetStream, alongside other products from the world’s largest range of ultrasonic anemometers currently on the market, at the Meteorological Technology World Expo in Brussels, October – stand number 2030.

Richard McKay, Product Manager for Gill Instruments says “MetStream is a unique product in the marketplace. Building on the positive attributes of

To find out more, visit www.gillmetstream.com or call +44 (0) 1590 613500 and speak to one of the friendly sales team.

MetStream 100 14|

Sensors

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November 2013

Sensors

November 2013

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Profile Technology

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Fluid Control

November 2013

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Sustainability

October 2013

EcoCooling evaporative cooling can be used as an alternative to air conditioning in most industrial buildings providing 90% energy savings at 25% of the capital cost of a traditional air conditioning or ventilation system. A carefully sized ventilation system is of fresh air into the building. evaporative cooling is used to cool the air before it click here One EcoCooler can cover an area of 250sqm or a 15m

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Calibration

November 2013

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Beamex introduces new calibration pumps Beamex has expanded its pump range with two new pumps: PGL and PGPH. The PGL pump is a low-pressure calibration pump with excellent possibilities for very fine adjustments. The pump is ideal in industries where accurate, low-pressure generation is needed, such as the pharmaceutical industry. The PGHP pump is a pneumatic, high-pressure generator with air as the pressure medium. This pump is a practical, high-quality solution in calibrations where using liquids is forbidden, such as the gas industry. The new pumps complete Beamex’s range of pressure generation equipment. “Beamex is now able to supply a complete range of user-friendly calibration pumps for a broader range of pressure calibration applications,” Beamex’s Product Manager, Heikki Laurila, describes. The PGPH is a hand-operated, pneumatic, (uses air as the pressure medium) high-pressure calibration pump for table-top use. The pump is extremely efficient in generating pressure up to 140 bar (2,000 psi) quickly and effortlessly. It takes far less than a minute to reach the maximum pressure. The PGPH is also able to generate vacuum. It is equipped with a fine-adjustment control providing excellent fine-tuning of generated pressure, and two handtightened connectors allowing fast and easy connections without the need for any tools. The PGL is a hand-operated calibration pump for low pressure using air as its pressure medium. The pressure range of the PGL is ±400 mbar / ±160 iwc. The pump is equipped with an isothermal bellows chamber for reducing possible environmental temperature changes during the calibration process. With the screw-operated volume control and fine adjustment, an extremely accurate and stable pressure adjustment is possible, enabling attunement to 0.1 Pa.

26|

www.beamex.com beamex.ltd@beamex.com

www.isotech.co.uk Isotech: The Source for Temperature Calibration

Why Calibrate Temperature Sensors? The requirement to measure temperature is enormous, pause to think of the devices around us, in many cases there is an obvious need to measure temperature, from the central heating control, the refrigerator, the kitchen oven, the heating system in the car. Perhaps you have a thermometer in a green house or a desktop weather station. If you are say on a chair, the materials from the plastic cover to the steel legs are processed at particular temperatures to ensure the quality and to avoid wasting energy. The milk in our coffee has to be pasteurised at a particular temperature. For many areas it is not critical what the temperature is, if the display in the car reports 19C but in reality the temperature is 21C the difference, life goes on, no great trust is required and the error may never be noticed. In other areas good quality measurements may be critical, consider the cost and long term business damage if a supplier of refrigerated food discovered the goods had not been transported within agreed limits. In power generation being able to make accurate measurements can save energy, and energy savings brought about by even a small improvement in measurement might save hundreds of thousands of pounds a year. In a medical setting, be it a thermometer being used for diagnosed or a sensor controlling an MRI scanner, poor measurements could have disastrous consequences. So whilst some sensors may never be calibrated others may need calibration to ensure quality, make cost savings from increased

devices capable of accommodating large sensors. Types of Heat Sources For on-site calibration “Dry Block” calibrators are usually most convenient, a metal block is heated or cooled to the required temperature and the sensor or sensors to be tested are placed into the block. There are also multi-function calibrators that can be used both as a Dry Block and also Stirred Liquid Baths. With this type of device the thermometers are placed into a suitable liquid, usually silicon oil rather than a drilled metal block. A Portable Fast Response Calibrator Some Dry Blocks are used in a way that the sensor being tested is compared to the displayed temperature value, for greater a separate higher accuracy thermometer is placed into the heat source to which the sensor is compared against. How often? Calibration

brings

How to Calibrate A complete measuring system will compromise of both a sensor and a measuring instrument. Instruments can be calibrated by disconnecting the sensor and connecting a temperature simulator, for example a thermocouple can be replaced with a voltage source that injects voltages equivalent to the thermocouple signal over a range of temperatures.

measurements being made. The frequency of calibration needs to be determined to suit the application. Let us consider a sensor being used with an instrument to verify that a specialist adhesive it stored below -80C, failure to observe this impacts the bond strength of the adhesive.

The problem with this approach is that it only checks the instrument – not the sensor. In many cases sensors undergo wide changes in operating temperature and can be used in hostile conditions.

How can Calibration be Trusted? Isotech heat sources and instruments can be provided with UKAS

electronic technology and being located away from extremes of temperature. To calibrate the whole measuring loop a portable heat source can be used in situ. Now the sensor can be placed into a heat source and temperature cycled so that the whole loop, sensor Portable and transportable heat sources are now available to cover the range from -100C to 1300C. Isothermal Technology Ltd (Isotech) can provide small handheld sources through to large

is a “is a formal, third party recognition of competence to perform How Isotech Can Help Isotech has 30 years’ experience of temperature calibration, from calibrating low cost temperature sensors to providing Primary Temperature Standards for National Metrology Institutes. We are happy to share our knowledge and experience. In addition to individual enquiries we have technical articles on the website and can provide in house and on site temperature training courses. Isothermal Technology Ltd www.isotech.co.uk

Health & Safety – Business Cost or Commercial Opportunity? There are very few businesses that would put health and safety compliance at the top of the corporate agenda. Yet for any organisation with a significant asset base, failure to consider the financial and business implications of safety procedures is a mistake – a potentially extremely costly mistake. As the Health & Safety Executive’s Fee for Intervention begins to make its mark, there is growing awareness that minimising reactive maintenance through effective planned, preventative maintenance can drastically reduce accidents – as well as improving uptime and reducing asset maintenance costs. So how can a business turn health and safety compliance from a grudging tick box exercise to a culture of proactive maintenance that delivers measurable business value? Karen Conneely, Group Commercial Manager, Real Asset Management outlines the value of embedding safety and compliance within the maintenance system. Fee for Intervention

schedule reduces equipment failure, minimises downtime and optimises asset cost. These figures also underline the importance of good PPM in improving safety and cutting injury. With the right, approach PPM will lower the number of reactive events and hence the risk of accidents. It is also a fundamental component of ensuring compliance with regulatory requirements – such as the routine PATs. But PPM on its own is not quite enough. Organisations need also to embrace a safety aware attitude within the overall maintenance process. Making safety a business Key Performance Indicator, for example, is a key component in changing culture and attitudes. And this is important: to be truly effective, compliance requirements and safety awareness need to be embedded within the PPM. By tracking and publishing maintenance performance on a weekly, monthly and annual basis, organisations raise awareness and reinforce a safe culture. Indeed, those organisations that proactively display ‘number of days since last safety incident’ completely change attitudes both towards ensuring compliance and undertaking every maintenance activity, both planned and reactive, with a safety first approach. Embedded Model

As the first anniversary of the Health and Safety Executive’s Fee for Intervention (FFI) approaches, a growing number of businesses are discovering first-hand the cost of failing to take a more robust approach to compliance. Facing a budget reduction of 35%, the HSE had a target of at least £37 million in fines in the first year and after a slow start, feedback from HSE is that the money is beginning to flow.*

Entrenching safety within the maintenance system is fundamental to improving performance without adding any administrative overhead. At the most basic level, organisations must ensure that manufacturers’ service requirements for each piece of equipment are recorded and automatically included with the PPM schedule. This guarantees that warranties remain valid as well as minimising the risk of unscheduled downtime.

Yet while the HSE’s FFI has raised the bar in terms of the cost of investigating non-compliance, the associated fines are still minimal when compared to the longer term business implications. From the bad publicity associated with injuries at work to the business upheaval and disruption associated with both investigation and the introduction of new processes, failure to put procedures in place can be highly damaging.

In addition, any legislative compliance requirements must be recorded and included within the schedule. Any failure in the PPM routine – due to staff absence or emergency – that may affect these required events must be automatically flagged to the maintenance manager for urgent action. With this approach, the company can minimise risk and demonstrate its buy-in to duty of care obligations.

Of course, asset safety encompasses an extraordinary range of requirements from the Control of Substances Hazardous to Health (COSHH) to the dangers of an employee getting injured opening an unmaintained window or the need for routine Portable Appliance Testing (PAT). Given the wide extent of these demands, it is perhaps little wonder that most organisations have a somewhat tick box approach to health and safety.

Even day to day activity must be conducted with safety awareness – such as ensuring any work order includes relevant information. This may be nothing more complicated than a list of required safety clothing or equipment, advice on how to clear an area of employees or the public before commencing any activity or include vital information that the location has been flagged as one with asbestos, which could make even the changing of a light switch a hazardous activity.

Minimising Risk

Conclusion

However, there are significant positives that can be gained, not only from ensuring compliance to a raft of health and safety legislation but actually embedding a ‘safety first’ culture into the entire asset maintenance strategy. Not least the fact that minimising reactive maintenance through effective PPM can drastically reduce accidents – as well as improve uptime and reduce asset maintenance costs.

With poor implementation proven to lead to a significant proportion of equipment failure, a ‘safety aware’ attitude needs to start from the installation of equipment. By embedding safety

According to international giant DuPont, when it comes to maintenance processes, the most likely person to be injured is a maintenance technician with less than two years’ experience doing reactive work. Similarly, Exxon Mobil reported that accidents are five times more likely in maintenance when doing breakdown work than when doing planned and scheduled work; and in 66% of companies more than 60% of injuries occur when doing reactive maintenance according to Idcom.**

and compliance within every aspect of the maintenance process, from reactive to planned, from equipment to skills and education, companies achieve far more than avoiding HSE’s FFI. Changing attitudes and achieving that much vaunted shift from reactive to preventative maintenance is proven to reduce costs and improve uptime. By adding a safety led KPI to the PPM model, organisations can improve overall performance and operator safety.

Improving Safety It is clear that prevention is always better than cure. Maintenance managers know that a good proactive, preventative maintenance

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www.realassetmgt.co.uk

November 2013

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Visual Checking of Liquid Flow Helps Ensure Operational Safety Titan Enterprises has launched a new range of stainless steel and aluminium oval gear flow meters with a clear acrylic top enabling users to visually check the flow as well as monitoring the flow output. The ability to visually check flowing liquid, from the visible rotation of the gears, has particular safety of operation benefits with viscous fluids such as lubricating oils. Titan Enterprises oval gear (OG) flowmeters with acrylic top are available in sizes from 1/4-inch to 1-inch diameter, for flows between 1ml/min and 100l/min. Compact in design - Titan rugged oval gear flowmeters are proven to give high performance with a low cost of ownership. High accuracy with excellent levels of repeatability is further benefits of this flowmeter range. These meters are as happy measuring simple aqueous solutions as they are measuring more viscous fluids such as lubricating oils and greases. Unlike other flowmeters, measurement accuracy with Titan oval gear meters improves as the liquid viscosity increases, from a nominal one per cent to around 0.1 per cent of flow rate at higher viscosities. All Titan OG flowmeters are individually flow calibrated and are supplied with a traceable flow test certificate, for flows both in forward and reverse directions, if necessary. For further information on oval gear flowmeters please visit www.flowmeters.co.uk/oval_gear_meters.htm or contact Titan Enterprises on +44-1935-812790 / sales@flowmeters.com

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After For over twenty-five years, JML Hardware has been supplying high quality maintenance hardware for local authorities. Based in Wigan, JML Hardware combines skill and expertise with years of experience to ensure that each and every product is produced to the highest standards, providing top quality solutions for a whole host of maintenance-related issues. JML now stock a full range of gas and electric meter repair boxes and lids. All boxes and lids are made from aluminium and come complete with two quarter turn budget locks and full length 316 rust proof stainless steel piano hinge. We are offering a solution to the never ending problem of gas and electric meter box doors falling off or being damaged or vandalised. No need to remove meters as boxes will cover existing box saving money in labour costs and utility services.