emsjanfeb2009

JAN/FEB 2008 OPERATIONS & MAINTENANCE LOOKING FOR TROUBLE GUIDE TO BUYING RECRUITMENT ISSUE 3

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

Industry News

Certification

MAINTEC 2008

Maintenance: In at the deep end

Energy Matters

www.engineeringmaintenance.info

New New Fluke Ti40/Ti50 IR FlexCam® Thermal Imagers with IR-Fusion™ technology IR-Fusion technology on Fluke's IR FlexCams links the thermal image to a corresponding visible light image to show exactly what you are viewing.

And twice as much information makes identifying suspect components easier.

The IR FlexCams are the ideal choice for PdM experts and consultants:

• Choice of 160x120 or 320x240 detector sizes

• Large 5-inch high-resolution displays for extra sharp images

• Thermal sensitivity down to 0.05°C revealing subtle temperate differences

• Handy 180° articulated lenses for a clear reading in every position They join the versatile Fluke Ti20 that brings powerful diagnostic capabilities of thermal imaging within reach of frontline maintenance professionals.

Fluke. Keeping your world up and running.

TM

Visit our web site to request a demo now!

www.fluke.co.uk Email: industrial@uk.fluke.nl

020 7942 0700

Only Fluke gives you double vision For more information quote EMS Enquiry No. 101 on IBC

Fluke Ti20

PAGE

INDUSTRY NEWS Innovations and events shaping the industry

4 PAGE

CERTIFICATION A public demonstration of safe maintenance

7 PAGE

MAINTEC INTRO Your guide to this year’s MAINTEC exhibition

15 PAGE

MAINTEC PRODUCTS Your guide to new show products

19 PAGE

COVER STORY Maintenance dives to new depths

34 PAGE

ENERGY MATTERS

37

TALKING TECHNICAL When ever I see a sign written van including the word ‘engineer’ or ‘technician’ I can’t help but take a closer look.

I am always amazed at the diversity of the engineering community, with each discipline a vital link in the manufacturing chain. No matter how specialised the skill, the next van I see takes the subject to a new extreme.

Recently I caught the word ‘technician’ appearing in my line of sight as another vehicle approached. Imagine how disappointed I was when I saw the full sign: ‘Nail Technician’. I’m not even talking building hardware, these were fingernails.

Don’t get me wrong, I’m sure those working with fingernails can bring great joy when things go right and even greater pain when disaster strikes. I don’t doubt that lengthy training is required before student nail technicians are allowed loose on real people.

However, I just wish they had chosen a different description for their craft. In my book, a technician entrusted with maintaining an aircraft engine, nuclear reactor, blast furnace or other similar system are truly a breed apart.

A technician’s badge has to be earned the hard way: school, college, university or maybe an apprenticeship, followed by years of training and experience. At work, it would not be unusual for a technician to have the lives of hundreds, if not thousands, of people in their hands. The word technician is special, lets keep it that way.

Jon Barrett, EDITOR

A simple guide to boiler selection Web Manager: Oliver Gibbs info@engineeringmaintenance.info

Published six times per year

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Annual subscription: UK FOC Rest of World £90 © 2008 EMS

Articles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every effort is made to ensure the accuracy of information published. No legal responsibility will be accepted by the publishers for loss arising from articles/information contained and published. All rights reserved. No part of this publication may be reproduced or stored in a retrieval system or transmitted in any form without the written consent of the publishers.

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For more information quote EMS Enquiry No. 102 on IBC

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Perfect for industrial maintenance and utilities applications, the new MIT400 series of insulation and continuity testers offers so much

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Can operations manage maintenance?

Christer Idhammar, president Idcon Inc Some of the common measures (besides outsourcing) taken when an organisation decides it needs to improve maintenance performance include moving all maintenance resources to area operations managers. I often get calls from organisations contemplating taking this step towards hopeful improvements.

I always ask why they would do that, what are the perceived benefits?

The answers include the following justifications: Maintenance personnel will develop more ownership to the operations area We will achieve a closer working relationship with operations We will need fewer managers and save money that way Firstly, if your basic maintenance practices are not instituted as a way of life, do not make this move. Why, because instead of having one poorly performing maintenance organisation, you will end up with many. Also, expect several managers (many without experience or interest in managing maintenance) to take the lead. Due to the lack of knowledge, time, interest and willingness, the following are likely to happen within six to nine months: More maintenance people on shift because it feels more secure. As a consequence, operators will request lots of ‘honey do’ jobs and will do less minor maintenance jobs themselves More maintenance people stationed and ready to react to problems because this leads to faster repairs Work requests not entered into the computer system because it is easier to just

call people. This leads to a loss of equipment history and automatic BoM updating More difficult to move people between departments for shut downs Overtime starts increasing even though more people are on shift due to reactive maintenance Contractor hours start increasing due to reactive maintenance Backlog (if still documented) will start to rise Equipment reliability starts declining Total maintenance cost has gone up, but operations managers might not see the whole picture As costs rise the focus will be to cut costs. However, valid maintenance jobs do not go away, they can only be postponed This results in higher costs because cost reduction did not reduce the need for maintenance or execute necessary maintenance more efficiently The organisation is in a circle of despair There are additional phenomena to be observed and sometimes actions to improve the situation. This is often because the manager(s) who initiated the change refuse to see or admit it was a mistake. It can take up to three years (or an earlier change of management) before someone with enough clout realises maintenance is out of control. Many organisations can repeat this cycle many times over a ten to fifteen year period. (Well, it keeps consultants like me in business).

As you can see I am not in favour of handing maintenance to operations. This is because I have seen too many situations as described above and no examples of sustainable improvement. If you institute basic maintenance practices in a central/area organisation, with a strong partnership with operations, there is no reason to change.

Changes are often initiated by consultants because they feel pressured to produce radical change or do not understand maintenance. Both outsourcing maintenance or handing maintenance to operations are frequently shown as acts of desperation.

The graph shows an actual case study (over three years) in an organisation that moved maintenance to operations to reduce employee numbers and costs.

Number of crafts people were reduced by 14.3 per cent first year. After one year, six per cent was hired back and, after two years, another 27 per cent were added as in-house resources. In the same period contractor spending went up 88 per cent and another four per cent before being reduced to 10 per cent of all

maintenance hours. Total maintenance hours including overtime, contractor and inhouse went up three per cent first year and 10.5 per cent second year and is now six per cent higher than three years ago. Total maintenance costs have gone up and are now 22 per cent higher than three years ago. Reliability and production throughput decreased six per cent at its lowest point but is now increasing again. Improved reliability is worth about 10 times more than increased maintenance cost. This plant moved all maintenance resources back to professional maintenance management in the second year and is steadily improving production throughput and costs.

Reader Reply Number: 300 Christer Idhammar is a world renowned expert in reliability and maintenance management best practices. He started the Idhammar group of companies in Sweden in 1972 and Idcon Inc in USA in 1985. In 2002 he received the Euromaintenance Incentive award (EFNMS) for outstanding international contributions to improve reliability and maintenance in industries world wide.

3 www.engineeringmaintenance.info Jan/Feb 2008 EMS

INDUSTRY NEWS Mill refurbishment requires expertise and a focus on safety

Mill refurbishment on the roll Business improvement MCP Consulting and Training is hosting a Business Improvement Seminar on 20 February, at Holiday Inn, Warrington.

The seminar will provide delegates in manufacturing, operations, maintenance, training and HR with a choice of three workshops: reducing costs through effective asset management in a manufacturing environment; improving business performance through people; and maintaining compliance 17th edition electrical regulations. www.mcpworldwide.co.uk Reader Reply Number: 301

Corus Northern Engineering Services has completed an important rolling mill replacement project at Spartan UK’s steel mill in Gateshead, including new roller tables, base and side guide frames.

CNES was asked to replace ingoing and outgoing roller tables that feed the four high reversing roller mills. This work included replacing or refurbishing the side guides, shafts, drives, gearboxes and roll motors.

Prior to installing the new roller tables: the existing runout table frame had to be cut back; the first existing runout roller had to be repositioned; and the existing crossover bridge on the runout side had to be modified. Other work included

Power of two Flir Systems is now the majority shareholder of fellow infrared specialist Cedip Infrared Systems. The acquisition is designed to provide greater R&D capability, enhanced core competence and greater production and distribution ability. Customers of both companies now have access to the widest range of infrared cameras on the market. www.flirthermography.com Reader Reply Number: 302

Cool customer Beko Technologies has appointed Gerry Thorpe as regional service manager covering the north of England. He will be responsible for service and technical support. Gerry has worked on a wide range of compressed air dryers, ancillary equipment, refrigeration and air conditioning systems. He has City and Guilds Electrician qualifications and is a member of the Institute of Refrigeration. www.bekotechnologies.com Reader Reply Number: 303

Stop repeat failures Ramsoft’s one-day workshop (3 April, Jury's Inn, Manchester) will look at what to do when equipment fails and how to stop the failure happening again. Maybe a bearing failed but what are the underlying factors: purchasing policies, repair practices or faulty procedures. Repeat failures cost money and hit the bottom line. www.ramsoftuk.com Reader Reply Number: 304

Only 28mm high, the OvenScope's low profile allows it to pass through most ovens

Oven video inspection system slashes costs McQueen Cairns Technology’s OvenScope video inspection system produces videos of the internal surfaces of continuous ovens as it passes along the conveyor. The system is said to bring huge cost savings by reducing unplanned maintenance and avoiding downtime due to oven fires and other failures.

The battery powered, PC based system can make up to four video recordings simultaneously. When the unit emerges from the (cold) oven, the videos can be immediately viewed by plugging in a keyboard and monitor. They can also be

removing pipework; moving drive systems; removing existing roller tables; cutting back existing pulpit base steelwork; removing existing side guides and foundations; descaling and moving pipework; re-routing mill water feed pipe and existing flush down pipe; and the installation of new civil/structural work.

CNES project manager, Dave Gallagher, said: “Spartan approached CNES because they knew we had the necessary expertise to cope with the job and to ensure that the work was carried out correctly and safely.” www.corusnes.com Reader Reply Number: 305 archived onto DVD in industry standard MP4 format to provide a permanent record for future comparisons.

Only 28mm high, the OvenScope's low profile allows it to pass through most ovens. Fully self contained, it does not require any umbilical cables.

The modular system can be set up with a range of camera and lighting configurations. A laser provides a straight line reference to assist in image interpretation and for comparison between inspections. A tracking system ensures that problems identified can be quickly located.

Developed by United Biscuits, where it has already led to six figure savings, the OvenScope is manufactured and marketed

by McQueen Cairns Technology under an exclusive worldwide licence.

UK gas safety and PM manager at United Biscuits, Richard Palmer, said: “The first time we used the OvenScope it more than paid for itself. It enabled us to rectify a problem through an inspection panel, rather than causing major disruption and downtime by dismantling the side of the oven.” www.mcqueen-cairns.com Reader Reply Number: 306

CALIBRATION EXPLAINED

Beamex has released a multimedia CD-ROM that introduces its integrated calibration solution step-by-step. The CD-ROM contains an animated video of the system, demo version of Beamex CMX Light Calibration Software, brochures, customer case stories and technically oriented white papers of various calibration-related subjects. The disk helps calibration professionals understand how Beamex’s calibration solutions can improve the efficiency and quality of the calibration process. www.beamex.com Reader Reply Number: 307

4 EMS Jan/Feb 2008 www.engineeringmaintenance.info

INDUSTRY NEWS GTCE solenoids are rated to EX II 2G EEx em II T4/T5

FOLLOW THE GUIDE Monitran has released a free product selector guide which presents top-level features and benefits of 64 of Monitran’s general and special purpose accelerometers: all in a concise, A4 fold-out booklet.

Products are split into three categories: general purpose analysis (AC); general purpose monitoring (DC); and special purpose; and then further refined into families. The guide also includes selection tips to help users identify the most suitable products for their requirements.

Monitran’s sales manager, Patrick Treherne, said: “Whilst our guide lists 64 of our standard accelerometers, these are just part of our range, which is the largest available from any European manufacturer. We’re appreciative of the fact that different users will have different uses for our sensors, so our guide was designed to aid selection.�

In addition to their presence in the guide, all products can be viewed on Monitran’s website which was re-launched at the beginning of December 2007.

Sensors are initially categorised by use (analysis or monitoring) and then by type (industrial, hazardous, small footprint or waterproof).

Treherne concluded: “If only a few sensors could satisfy most applications you could argue there’d be little need for a product selector guide, but the fact of the matter is that no two applications are ever exactly the same. This is why Monitran has spent 21 years developing the industry’s widest range of fit-for-purpose sensors.� www.monitran.com Reader Reply Number: 308

Safe to pull and push New GTCE series solenoids from Magnet Schulz are designed to meet the new European standards for electrical equipment used in hazardous areas, ATEX Directive RL94/9/EC. Available in body

diameters from 50 to 140mm, the explosion-protection designed, single-acting solenoid is suitable for AC and DC. The GTCE linear solenoid is manufactured to IP54 and rated to EX II 2G EEx em II T4/T5.

Incorporating a pull and push function and suitable for body

or flange mounting, the GTCE provides a stroke up to 40mm and a holding force up to 549N. Applications can be found in chemical, oil and gas, paper, food processing, woodworking and recycling plants. www.magnetschultz.co.uk Reader Reply Number: 309

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%(<21' &203$5( For more information quote EMS Enquiry No. 103 on IBC

www.engineeringmaintenance.info Jan/Feb 2008 EMS

5

Dust and fume extraction hoses from Masterflex

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Temperature range -260°C to +1100°C Size range 38 mm to 900 mm Very flexible, small bend radius Long service life, low operating costs Suitable installation and connecting systems Condensate Systems Ltd.

Masterflex Technical Hoses Ltd GB-Oldham OL1 4ER Tel: 0161 626 8066 www.masterflex-uk.com PU / FABRIC HOSES

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For more information quote EMS Enquiry No. 104 on IBC

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For more information quote EMS Enquiry No. 105 on IBC

SELF-CONTAINED AUTOMATIC LUBRICATORS The World’s Champion Lubricator FOR SINGLE OR MULTI-POINT APPLICATIONS The most powerful self-contained, lubers available!

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SINGLE POINT LUBER Safe, inert nitrogen gas Variable from 14 days to 1 year Remote control option Temperature range -40F to +131F (-40C to +55C) Easy-to-use-simply select the flow rate, install & activate Flashing light confirms operation Approvals: Intrinsically Safe Safe Approvals CSA, UL, Instrinsically ATEX ia E, IICF,T3 Class 1,Certified Groups A, EEX B, C, D, G, MSHA, Energy Mines

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For more information quote EMS Enquiry No. 106 on IBC

For more information quote EMS Enquiry No. 107 on IBC

IECEx

IECEx repair scheme certificate: world first Sira has become the first certification body in the world to issue an IECEx Certificate of Conformity for Service Facilities for the repair and overhaul of hazardous area equipment.

The certificate, awarded to MARC (Thailand), is the first of its kind under the IECEx Service Facility Scheme, of which Sira was also the first organisation to be officially recognised as an Approved IECEx Certification Body.

IECEx secretary, Chris Agius, said: “Considerable interest is being shown in this new program with IECEx receiving enquiries from both equipment users and Ex repair facilities on a regular basis.”

The awarding of this certificate confirms Sira’s position as a world-leading supplier of safety compliance solutions, demonstrating Sira’s continued commitment to safety at every level within the hazardous area industry.

Sira’s general manager, Mike Shearman, added: “This is a great achievement for Sira and the IECEx scheme in general. It clearly demonstrates the dedication, responsiveness and competence of Sira’s employees. I would also like to take this opportunity to congratulate MARC on their achievement and clear commitment to high standards.”

In response to receiving the certificate, MARC’s managing director Wirote Wannasiwaporn, expressed his satisfaction on achieving compliance: “I and my team are very proud of getting a certificate from Sira under IECEx service facilities scheme. I always tell my people how important it is to meet IECEx requirements to reflect our responsibility to our customers. MARC will keep on working hard as per the IECEx requirements and maintain our technical skills and competence to comply with the IEC standard.”

Scheme explained The scheme covers the repair and overhaul of equipment used in potentially explosive atmospheres, providing both OEMs and end-users with the confidence that repair workshops work in accordance with strict technical and quality system requirements laid down within an international (IEC) framework.

Working to IEC 60079-19 (and IECEx scheme documents OD/014 and 015), the service facility is assessed to ensure that essential aspects of the quality management system procedures, the working environment, staff competence, repair methodologies and calibration of test and measurement equipment are satisfactorily operated and maintained.

The end result is the issue of an IECEx Certificate of Conformity, demonstrating that the service facility can carry out repair and overhaul of equipment in accordance with the requirements of the published standards.

Scheme advantages The scheme independently endorses the repair facility’s capability and imparts an international status that gives confidence to its customers and a competitive edge to its services.

It is designed to offer a credible alternative to other, non-accredited schemes and address industry concerns over poor overhaul work standards. Many companies are now insisting they work only with repair and overhaul organisations that are certified by accredited organisations such as Sira.

Successful applicants will also see their certificate posted on the publicly accessible IECEx website. www.siracertification.com Reader Reply Number: 000 The IECEx Service Facility Scheme independently endorses a repair facility’s capability

7 www.engineeringmaintenance.info Jan/Feb 2008 EMS

STOP DUST AT SOURCE Centralised high-vac dust extraction systems for on-tool extraction and general cleaning.

Typical industry customers include: Printing, Manufacturing, Pharmaceutical, Electronics, Aviation and many others with applications such as: • Cutting • Grinding • General Cleaning • Sanding • Machining • Material Transport • Particle Extraction

GRINDING

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CLEANING

Dustcontrol can help in improving product quality, environment and the efficiency of your factory with its high quality modular extraction equipment specifically tailored to meet your needs.

For more information:

CALL 01327 858001 Dustcontrol UK Ltd. Old Barn, Home Farm Business Park, Church Way, Whittlebury, Northants NN12 8XS, England Tel: 01327 858001 Fax: 01327 858002 sales@dustcontrol.co.uk www.dustcontrol.co.uk

For more information quote EMS Enquiry No. 108 on IBC

PLANT MAINTENANCE

Schaeffler UK’s engineering manager, Dr Steve Lacey, discusses the importance of selecting appropriate special coatings or corrosion-resistant material for rolling bearings in harsh environments

Protective materials for harsh environments Salt spray tests put bearing components through their paces

While standard steel bearing materials provide satisfactory corrosion resistance in many applications, for higher performance requirements, nitrogen alloyed martensitic HNS (high nitrogen) steels, such as Schaeffler’s Cronidur and Cronitect, are available.

Cronitect is a new high-grade martensitic hardening steel designed to offer maximum corrosion resistance under extreme conditions, for example dry running applications or when bearings contact aggressive media such as water, acids and cleaning agents. The material is engineered to withstand extreme conditions, including salt spray testing in accordance with DIN 50021 SS, even after 600 hours.

Both Cronidur and Cronitect resist diluted acids, alkalines and salt solutions, with potential applications in clean rooms, electronic component manufacturing plants, pharmaceuticals and food production.

Silicon nitride balls Other special materials include ceramic rolling bearing components. Silicon nitride balls, for example, are light and offer a longer operating life than standard steel ball elements.

High performance plastics such as PEEK can also be used for bearing components in corrosive environments. Depending on load, PEEK is suitable for operating temperatures up to 250°C. Wear resistance is strongly influenced by filler materials and is significantly better than standard

PA66 with glass fibre reinforcement, often used for bearing cages.

Schaeffler offers three coatings to improve surface corrosion/wear resistance.

Corrotect is designed to provide a relatively low cost, 0.5 to 5μm thick zinc alloy coating with cathodic protection, which is effective against condensation, rainwater, contaminated water and weak alkaline/acidic cleaning agents. Under load, the coating is compacted into the surface roughness profile and is partly worn away. The chromate coating and passivation increase anti-corrosion protection and contribute to the component’s optical appearance.

The coating is ideal for small bearings and mating parts such as drawn-cup needle roller bearings with open ends and thin-walled components in large numbers.

Protect A is a matt grey chromium coating with pearly surface structure. The coating is applied by electroplating, so coated parts retain dimensional stability.

Lubricant is retained between the pearls, so anti-wear protection is even achieved under mixed friction or slippage conditions. During running-in, the rolling elements and seals burnish the surface, which leads to reduced friction coefficients.

Protect A resists various chlorides, oils, sulphur compounds, chlorine compounds and weak acidic media.

Ideal for aggressive atmospheres at high temperatures, Protect B comprises two layers: a thin chromium coating covered by a chromium mixed oxide layer, the latter providing corrosion-resistance by supporting the lubricant. The coating is designed to offer high anti-wear and anticorrosion protection. Protect B is ideal for applications where continuous bearing lubrication cannot be guaranteed.

For corrosion and fretting corrosion, Schaeffler has developed a range of coatings including: zinc iron for rolling

mill applications; zinc nickel for automotive; and zinc phosphate for salt or sea water applications.

Black oxidising coatings suit rollers and rings in wind turbines, rail traction motor bearings and applications at risk of minor slippage. Thin dense chromium coatings offer wear protection in mixedfriction conditions for small ball and roller bearings. They also suit raceways on high precision bearings and spindle bearings.

Copper coating A copper coating is also available for emergency lubricant on bearing cages, while silver coatings are used for aerospace bearings. Titanium nitride offers wear protection in jet engine bearings.

As rolling bearings are often used in electric motors they must be electrically insulated. The outside diameters and faces (or bore and faces) are coated with aluminium oxide. Schaeffler offers two different coating thicknesses: thick for high resistance, even in moist environments; and thin with low resistance but sturdier edges.

For food industry applications, flanged, take-up and plummer block designs can also be protected. Housings and insert bearings can be protected using Corrotect, while the housings themselves can also be made from corrosion-resistant (stainless) sheet steel or plastic (glass fibre reinforced PBT). www.schaeffler.co.uk Reader Reply Number: 311

A closer look at seal running surfaces

9 www.engineeringmaintenance.info Jan/Feb 2008 EMS

PLANT MANAGEMENT Mtec 2008 saw Micro-Epsilon showcase a range of sensor products

Boring vision Mtec 2008 saw Micro-Epsilon showcase a range of sensor products. The company states its miniature confocal sensor (optoNCDT 2402) represents a world first in optical sensor miniaturisation. This new range of sensors feature a 4mm diameter, ideal for confined spaces, narrow cavities, drilled holes and bores. The new range includes a 90 degree version, letting users measure the inner surfaces of small bores.

Micro-Epsilon also demonstrated its new simplified user software for the scanCONTROL 2810, the company’s 2D/3D laser line sensor. The sensor can measure up to 256,000 points per second up to 4kHz. The software lets machine builders, systems integrators and end users configure the system for different applications. No special programming skills are required.

Typical applications for the sensor system include: weld seam inspection; glue bead inspection; door edge detection; angle measurement; step and height measurement; planarity and surface control on PCBs; robot guidance and positioning; and groove width and depth measurement.

For fast, high accuracy measurement applications, MicroEpsilon’s new optoNCDT 2220 is claimed to offer unmatched accuracy and a measuring rate up to 20kHz. www.micro-epsilon.co.uk Reader Reply Number: 312

10

For more information quote EMS Enquiry No. 109 on IBC

EMS Jan/Feb 2008 www.engineeringmaintenance.info

CHAIN LOOKS TO THE STARS Costing over Euro 130 million, the La Palma based Gran Telescopio Canarias (GTC) is designed to let scientists observe and analyse the universe from the island’s highest point. Thus, every consideration was made to ensure near perfect performance to achieve uninterrupted operation, while providing high quality images.

Central to these goals is a smooth drive system for manoeuvring the roof (vertically and horizontally) without vibration. Rexnord chain was employed. Four stands of Laschenkette 64-1 (63.5mm pitch) and four stands of Laschenkette 50-1 (50.8mm

Rexnord chain was chosen to drive the Gran Telescopio Canarias roof

pitch) were supplied by Tansmisioines de Potencia. Both sets were matched as groups to provide combined balanced maximum chain pulls of 420,000 and 210,000N respectively. www.rexnord.eu Reader Reply Number: 313

For more information quote EMS Enquiry No. 110 on IBC

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lll#eVg`Zg#Xdb$XbX ÒaigVi^dc^c[d@eVg`Zg#Xdb For more information quote EMS Enquiry No. 111 on IBC

Our chiller range just got wider

ICS are specialists at providing packaged chillers for process and air conditioning applications.

We are therefore pleased to announce the arrival of our new wider range of chillers featuring heat pump, water cooled, free-cooling and closecontrol non-ferrous packages.

These new ranges have been developed to provide the latest energy efficient scroll compressor technology and controls offering remote and BMS web-based (xweb 300) supervisory systems.

When you need to replace your chiller or have plans to expand, please consider our range of units.

We would appreciate the opportunity to recommend to you chillers capable of providing reduced running costs and the latest technology â&#x20AC;&#x201C; all in one package. Call ICS free on 0800 169 3861 or log onto www.industrialcooling.co.uk and email us with your enquiry. Thank you.

Chillers are our business For more information quote EMS Enquiry No. 112 on IBC

ICS chillers and air conditioning â&#x20AC;&#x201C; helping you to create a reliable and efficient cooling system for you and your clients

PLANT MAINTENANCE

Engineering Maintenance Solutions spoke to Hansen Transmissions’ after sales and service manager, Gary Bills, about the role endoscopy has to offer when maintaining transmissions

Looking for trouble There is certainly no lack of options when engineers are tasked with monitoring the health of power transmission systems, with technologies including acoustic, vibration, thermal, oil and visual analysis. Each has their benefits and limitations.

In this article, Gary waves the flag for endoscopy: “Chosen inspection techniques are often governed by the application.

For example, vibration analysis of a fixed speed motor is relatively easy, with anything either side of 50Hz potentially highlighting a problem.

“However, in a multi-reduction gearbox, the combination of gears, bearings and shafts could present frequencies from 1Hz to 350Hz in a single box. Vibration analysis is still possible but then relies on the skills of a trained and experienced engineer to decipher the results. Epicyclic gearboxes just add to the difficulties. Unfortunately, engineers of this pedigree are often difficult to find.

Bearing damage caused by a lightning strike

“Naturally, vibration analysis only highlights a problem when it already exists and with a typical start to failure period of six-weeks for a gearbox, detection can often be too late to prevent expensive damage.

“Endoscopy lets users take a regular, detailed look deep inside a gearbox for early visual indications of a potential problem. In difficult application environments, such as offshore wind turbines, where the gearbox itself might cost £250,000 and replacement a staggering £1M, an endoscopy study is a valuable tool. For example, in one application visual damage revealed a problem caused by arcing during a lightning strike. This damage would have been difficult, if not impossible to detect, using any other inspection method.

“In another plant application, a customer had requested the scheduled refurbishment of a group of gearboxes. However, before starting the refurbishment we conducted a visual internal inspection of all 12 gearboxes in two days and discovered that only three actually required attention. This saved the customer considerable time and cost.

“The bottom line is that endoscopy offers maintenance

managers a simple, quick and cost effective method for the detailed internal inspection of gear units. It can highlight problems early and detect certain issues that other methods would find impossible. If engineers are

Visual inspection systems are designed to cope with tough engineering environments

wondering how detailed the inspection can be, 4mm diameter probes can be used to take digital images inside rolling elements bearings.” www.hansentransmissions.net Reader Reply Number: 314

Maintenance software just got easier

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Tel: 0191 2963816 email: sales@cayman.co.uk Web: www.cayman.co.uk For more information quote EMS Enquiry No. 113 on IBC

www.engineeringmaintenance.info Jan/Feb 2008 EMS

13

™

AIRConnect remote compressor monitoring

Now you can keep informed and efficient Connectivity is the key to continuous remote monitoring of compressed air systems regardless of the number of machines involved - from the smallest unit to multiple compressor installations.

And this can be at a single, or any number of locations.

Few organisations have the resources for this level of supervision, but Atlas Copco’s AIRConnectTM is a unique modular system, tailored to each customer’s requirements, that now makes this a cost-effective reality.

AIRConnectTM continuously monitors compressed air systems, logging performance and immediately sending warning of any irregularities needing attention, by means of an SMS message or e-mail.

AIRConnectTM is constantly on duty. The sophisticated modular packages include complete analysis and management of the system showing status, trends and performance, immediately accessible, in real time, from a customer’s own PC. As a result, problems are identified before they happen.

AIRConnectTM remote monitoring keeps compressors operating at optimum efficiency, improving productivity and reducing operational downtime. It is supported by a team of Atlas Copco trained engineers based at strategically located centres nationwide.

Find out how AIRConnectTM can keep your compressed air system at peak efficiency and keep you fully informed. Call 0800 181 085 today.

Atlas Copco Compressors Ltd Swallowdale Lane Hemel Hempstead Herts HP2 7HA Phone: 01442 261201 Fax: 01442 234791 e-mail: gba.info@uk.atlascopco.com

www.atlascopco.co.uk For more information quote EMS Enquiry No. 114 on IBC

Atlas Copco will be in Hall 8 Stand D6

MAINTEC 2008 11 TO 13 MARCH, BIRMINGHAM, NEC

See the latest innovations in hazard detection and predictive maintenance technology unveiled at Maintec 2008. Minimising down time, breakdown pre-emption, and improved reliability will be hot topics

Maintenance innovations unveiled Some 150 stands will feature an array of innovations from new thermal imaging cameras and condition monitoring systems, to bulk solid measurement sensors and germ-busting floor coverings. There’s also a programme of learnShops seminars, plus a new briefing lunch entitled ‘Improving Plant Productivity & Performance’.

Encompassing the manufacturing and process industries, as well as public sector and plant/asset management organisations, the show is an ideal forum for companies and industry professionals involved in maintenance management, predictive maintenance and CMMS, health and safety and property management.

The show is co-located with Solids 2008 (an event for companies involved in solids processing, handling and storage) and will also feature a new Industrial Environment Forum catering for the growing number of professionals tasked with reducing the environmental impact of operations and facilities.

EasyFairs UK’s managing director, Peter Heath, said: “Bringing these events together will provide an integrated networking and exhibition platform for senior and operational decision makers with a broader remit.

The show also has the support of organisations including: the Society of Operations Engineers; British Compressed Air Society; British Institute of NonDestructive Testing; UK Thermography Association; Society of Diagnostic Engineers; and Health & Safety Executive.

Lunch and learn A new feature for Maintec 2008 is a Lunchtime Briefing, presented by the Process Industries Centre for Manufacturing Excellence (PICME) on ‘Improving Plant Productivity & Performance’.

Scheduled for Tuesday 11 March (12.30 to 13.30pm) the briefing will focus on providing practical solutions. PICME, part funded by the DTI, has been set up to help manufacturers of chemicals, pharmaceuticals,

plastics and rubbers improve their competitiveness and efficiency by reducing manufacturing waste and increasing the efficiency of the manufacturing process in the shortest possible time.

There is also a programme of short, practical learnShops seminars across all three days of the show.

Predictive Maintenance of robots George Thompson, customer services sales manager, FANUC Robotics Infrared inspections for Predictive Maintenance Paul Sacker, sales & marketing manager, Flir Systems Energy efficiency: why is motor testing still important?

Tim Thomas, senior applications engineer, Baker Instruments Condition Monitoring: it doesn’t have to be all or nothing Trevor Holroyd, managing director Holroyd Instruments UK True wireless Condition Monitoring Rockwell Automation Electrical arc flash incidents: risk control and mitigation measures John Maplesden, managing director of TAS Engineering Cost-effective maintenance Simon Mills, training services director, AV Technology Using OEE to create the perfect picture of health Smith & Nephew and Idhammar Systems www.easyfairs.com/maintec Reader Reply Number: 315

15 www.engineeringmaintenance.info Jan/Feb 2008 EMS

Out of sight, but not out of mind

More precision.

Non-contact IR thermometers. thermoMETER CT Very compact inline temperature sensors

Temperature ranges -40 to 900°C One of the smallest sensor designs worldwide Up to 180°C ambient temperature without cooling High speed option available 9 ms

Our data capture capability will identify problems that remain invisible to the naked eye but nevertheless can have a significant detrimental effect on your heavy plant and equipment.

Our highly-skilled employees will use our extensive workshop facilities to do any necessary repair and refurbishment before catastrophic plant failure brings your business to a grinding halt.

And our expert trainers can give your employees the training they need to get the best from any of your equipment – not just that which we’ve refurbished.

To discuss your maintenance and training requirements stop at our stand, E12, at Maintec NEC, 11th-13th March 2008

thermoMETER CThot

Temperature sensors for hot environmental conditions Temperature ranges -40 to 975°C Up to 250°C ambient temperature without cooling Applications in dryers, ovens, metal/glass industry, paper/plastic/textile manufacturing and semiconductor processing

thermoMETER LS

Handheld with patented crosshair laser sighting The new performance standard: user selectable close focus or long-range mode Temperature range -35...+900°C Optical resolution 75:1 (longe range) Spot size from 1 mm (close focus)

www.micro-epsilon.co.uk MICRO-EPSILON UK Ltd. Dorset House · West Derby Road · Liverpool · L6 4BR Phone +44 (0) 151 260 9800 info@micro-epsilon.co.uk

For more information quote EMS Enquiry No. 115 on IBC

For more information contact: David Scatchard Marketing Manager Corus Northern Engineering Services T: +44 (0) 1642 498041 E: info-cnes@corusgroup.com

For more information quote EMS Enquiry No. 116 on IBC

MAINTEC 2008

FIT AND FORGET Xetec is presenting its Micro, Mini, Maxi and MobilMaint CMMS software at Maintec 2008.

The company states that when demonstrating MicroMaint at a show, it never sees some of those visitors ever again because they just buy the software and use it. It is designed to be so easy to use, they never buy training or implementation.

For those needing more than basic WO-WR-PMs, stock management, barcodes, Web access, PDA access, audit trails, integration with other programs such as SAP and accounts packages, they can request an upgrade to MiniMaint, which

uses the same database and program structure. Some customers initially opt for MiniMaint which offers features for larger enterprises.

Adding extra fields and functionalities, such as automatic e-mails from PMs, data access management, multiple warehouses, substitute parts, purchase order, budget control and more, provides a platform on SQL or Oracle for larger maintenance departments.

Customers requiring all the modules can take MaxiMaint. www.xetec.co.uk – STAND G2 Reader Reply Number: 316

Users of MicroMaint can upgrade to MiniMaint

Thermal imaging, the heat is on Mid-range is the focus of Flir’s recent camera developments. Its new ThermaCAM T-Series is designed to be compact, half the weight of its nearest competitor and offer performance normally expected from higher-end cameras.

Engineered for frequent users of infrared, the ThermaCAM T-Series offers a number of time-saving features to make jobs easier and quicker. For example, Thermal Fusion allows the automatic, seamless transition of images from thermal to visual and vice versa, while retaining measurement functions in both view modes.

Images are displayed on a 3.5in touch screen. This opens

the possibility of additional functions such as sketching via stylus and text entry via on-screen QWERTY keyboard. The camera provides a 320 by 240 pixel resolution from a detector specifically developed for this model.

The company’s ThermaCAM P640 is a 640 by 480 infrared camera providing over 707,000 measurement points. This image quality allows use at greater distances from targets, important for the inspection of high voltage installations. Surveys can also be taken quicker as fewer images are required to complete the picture. www.flir.com – STAND F6 Reader Reply Number: 317

RAIL MAINTENANCE ON A ROLL Rail switch plate lubrication is benefiting from the recent development of rapidly biodegradable lubricants which can increase relubrication intervals to two or three times those of previous black switch plate lubricants according to test results.

Kluberrail AL 32-2000 is a fluid grease (free of solvents) which when applied to the surface forms a thin, longlasting film on the slide plates. Service temperature range is -40 to 80°C, suitable for applications worldwide.

Following five years testing, including over 3,500

cycles per test, for over 80 hours with 30 minutes rain simulation using 27 litres of water at 60°C (to simulate an increased wet environment) and a 450N load, the surfaces were consistently covered with sufficient lubricating film with excellent corrosion protection.

SNCF lubrication engineers explained: “The advantages of high-performance points lubricants are obvious, longer maintenance intervals mean cost reductions.” Besides excellent corrosion protection and biodegradability, convenience of application is

another important argument, which is why Kluberrail AL 32-2000 was designed as a sprayable lubricant.

Maintenance engineers no longer have to bend over to brush on the grease.

Kluber states its switch plate lubricants provide cost savings, offer high reliability/safety, extended re-lubrication intervals and lower lubricant consumption.

Approvals and references include: OBB GB Netz, Queensland Rail, Alstom Transportation, RENFE, SNCF, SNCB and Edelstahlwerk Buderus.

New switch plate lubricants are providing cost savings

www.kluber.com – STAND C12 Reader Reply Number: 318

17 www.engineeringmaintenance.info Jan/Feb 2008 EMS

•• Visual Planning for Save money by planning Maintenance and Health work more efficiently & Safety • Spend more time being productive at a glance • Information

• Keep track of parts • Complete system + P&P and VAT • £150 Reduce Paperwork

Tel: 01732 871417 Fax: 01732 840470 sales@tcardsdirect.com

For more information quote EMS Enquiry No. 117 on IBC

For more information quote EMS Enquiry No. 118 on IBC

For more information quote EMS Enquiry No. 119 on IBC

MAINTEC 2008

GOOD DATA, GOOD DECISIONS Proper analysis of good data provides the right basis for cost effective maintenance, which is why Ramsoft will be highlighting ReliaSoft’s RCM++4 reliability centred maintenance (RCM) tool.

This customisable program allows for a mix of classical, streamlined and risk based RCM approaches within a single project, enabling the user to decide the level of detail required. To support this approach, RCM++ incorporates a number of ways to conduct criticality analysis before carrying out detailed analysis.

Guided by clear RCM results, users of RCM++4 can select task frequency for

maintenance action based on optimum costs or by setting risk levels. Getting the frequency wrong for critical failure modes will result in higher operating costs, however there is an optimum time to replace equipment and if maintenance is delayed, costs rise steeply. RCM++4's flexible approach to task frequency is said to be more cost effective than mean time between failure (MTBF) models.

RCM++ follows a structured process, starting with the creation of an equipment hierarchy. Users then conduct an equipment criticality analysis, perform a functional analysis and determine the

IR-fusion supports rapid fault detection Fluke has introduced two new thermal imagers, the Ti25 and Ti10, designed to make thermal imaging affordable and effective for day-to-day troubleshooting and maintenance. Both models incorporate IR fusion technology, which integrates infrared and visible light images in full screen or picture-in-picture views for enhanced problem detection and analysis. Built to withstand harsh work environments and starting at under £3k, the new thermal imagers are ideal for maintenance of electrical installations, electro-mechanical and process equipment, HVAC/R units and other industrial and electrical equipment.

With a widescreen colour LCD display and a temperature range of -20 to 350°C for the Ti25 and -20 to 250°C for the Ti10, the thermal imagers are designed to allow users to operate from a safe distance yet still see small temperature differences. IR-fusion allows users to overlay visual and thermal images, independent of the measurement distance.

This makes it easier to identify details and potential problems as well as improving primary target identification, enhancing issue locating efficiency and improving the clarity of reports.

Ti25 and Ti10 imagers are supplied with SmartView software featuring tools for viewing, annotating, editing and analysing both infrared and IR-fusion images, enabling users to generate customised reports with ease. To further simplify report generation, both models include a 2GB memory card that will store at least 3,000 basic infrared images or 1,200 fully infrared and linked visual images each with 60 seconds of voice annotation on the Ti25.

Units are equipped with a hard carry case and soft transport bag and are tested to withstand a drop of two metres with an IP54 rating against water and dust, making them suitable for use in the field. www.fluke.co.uk – STAND G6 Reader Reply Number: 320 Picture-in-picture presentation of IR and visible light images can facilitate problem detection and analysis

consequence of failure. They can list failure modes and their failure characteristics as well as selecting and defining tasks and assigning frequency.

With the option to enter data in a variety of modes, including import, export, look up tables and bulk add, version 4.0.4 of the software is compatible with existing study data. This makes it easy to hold information in a single database, facilitating analysis for better maintenance decisions www.ramsoftuk.com – STAND H22 Reader Reply Number: 319

CNES engineers will be available to help visitors from every industry sector improve output, efficiency and profitability

MAKE USE OF MAINTENANCE TOOLBOX Engineers from Corus Northern Engineering Services (CNES) will be on hand throughout Maintec to discuss the company’s toolbox of condition monitoring techniques as well as its training, workshop repair and refurbishment services.

With advice from CNES, visitors will be equipped to maximise process efficiency and prevent unforeseen stoppages caused by equipment failure.

For condition monitoring, CNES initially provides a detailed assessment of a customer's plant assets using a range of non-intrusive techniques, such as acoustic monitoring, thermographic imaging, vibration monitoring, laser alignment, lubricant technology and remote visual inspection.

As part of this toolbox, CNES will be exhibiting its inhouse developed acoustic emission monitoring system, Aquilla AE Pro. This fixed system is effective for slow rotational speeds from 80 down to 0.25rpm, or for equipment that moves on bearings through less than a complete revolution.

Typical applications include large tilting vessels used in steel making, bucket wheel excavators, heavy cable reeling or pipe laying machines and carousel machines in production and food packaging environments. CNES will also showcase Aquilla AE Pro IMON, a new semi-portable system for acoustic emission monitoring.

CNES also offers a range of repair and refurbishment services. Its workshop and machining facilities are available for the refurbishment of production machinery and the manufacture of spares, or the design and build of new machines. Overhaul projects span all industry sectors and recent refurbishment projects have been carried out on crushers for quarrying; raw mill rollers for cement manufacture and cocoa roasters for food manufacturing. Other refurbishment services include replacing lost metal via weld reclamation techniques. www.corusnes.com – STAND E12 Reader Reply Number: 321

19 www.engineeringmaintenance.info Jan/Feb 2008 EMS

Saving Costs by setting The right routes Kluber Lubrication, the worldwide leading manufacturer of speciality lubricants, offer tailor-made solutions for all lubrication requirements of industry today: whether your requirement is for Pharmaceutical Grade, NSF Food Grade for the food processing related industries or Biodegradable trackside lubricants, lubricants for gears and axlebox bearings, assembly pastes, for the rail industries; No problem, our specialists can develop the correct solution for you however large or small !

Lubrication solutions across industry Visit us at the NEC

MAINTEC 2008 11th—13th March

By harnessing our Asset Care programme & Lubrication Expertise, you can reduce maintenance and engineering costs.

How ? We are proven to extend maintenance intervals, decrease lubricant consumption, arrest or eliminate premature wear, increase operating efficiency or reduce drag torque.

Lifetime lubrication solutions are a real possibility with Kluber technology offering an economical alternative to mineral-oil based products.

11th—13th March

For further information contact our technical department.

Kluber Lubrication GB Ltd. Tel:01422 319149 Fax: 01422 206073 Email: info@uk.klueber.com www.kluber.com

For more information quote EMS Enquiry No. 120 on IBC

A new, versatile and comprehensive handheld machine condition analyser is launched by SPM Instrument

Leonova™ Infinity is lightweight, ergonomic and easy to operate. Under menu guidance, you select Leonova functions via the key pad or the touch screen. The fast processor and very large memory make data logging more efficient than ever. Load Leonova from the PC, then simply measure and save. All input data is pre-programmed.

You get an instant condition evaluation on a green – yellow – red scale

it is fast, light and offers many analysis options.

SPM Instrument UK Ltd Suite 12, Hardman Business Centre New Hall Hey Road, Rawtenstall Lancashire, BB4 6HH Tel: 01706 835331 Fax: 01706 260640 e-mail: info@spminstrument.co.uk www.spminstrument.co.uk

For more information quote EMS Enquiry No. 121 on IBC Untitled-3 1

09/02/2007 12:38:22

MAINTEC 2008

MAKE TIME FOR Asset management on the move CM TRAINING Condition monitoring (CM) consultant, AV Technology, will be running a series of half-day BINDT accredited condition monitoring training courses to coincide with Maintec. Priced at £175 per delegate, the courses will take place near Leamington, 20 minutes from the NEC, on the mornings of the 11, 12 and 13 March. A complimentary shuttle service will be available between the NEC and the venue.

Sessions kick off with an introduction to condition monitoring, where delegates will gain an understanding of all CM techniques and how best to apply them. The second session on maintenance strategy and benchmarking will assist maintenance managers and supervisors select the most appropriate strategies for their operation. The courses finish with a failure modes, effects and criticality analysis workshop where delegates will get a practical introduction to FMECA, leaving with tools and techniques that can be applied in their workplace to identify areas for improvement linked to business needs. Course content is taken from AVT's in-depth BINDT accredited courses.

Managing director, Stephen Mottershead, said: “Our training courses are growing in popularity as more companies see the benefits of adopting a structured condition monitoring approach. Our training services director, Simon Mills, is one of only four BINDT VA level three certified experts in the UK and all of the AVT trainers are trained to level two, as well as being senior consulting engineers for our CM business.”

Designed to offer a single integrated solution for any asset management application across a variety of industry sectors, Miquest products can be used to implement planned maintenance for reduced downtime, as well as increasing staff efficiency and reducing overtime and overruns. Other applications include managing maintenance-related stock levels, tracking information to improve asset visibility and managing work order processes to ensure on-time delivery of stock and schedules.

Miquest is a scaleable solution and will operate from single to multi-sites with many

users. It can also support a custom front end user interface, using ASP.NET forms for simple access. These can be designed to match operating requirements, with further modifications as business develops.

Mobile solutions are available for any module using suitable device and communication options.

RFID and barcode technologies are supported.

Miquest – STAND C30 Reader Reply Number: 323

www.avtechnology.co.uk – STAND B24 Reader Reply Number: 322

AV Technology will be running a series of half-day BINDT accredited condition monitoring training courses to coincide with Maintec For more information quote EMS Enquiry No. 113 on IBC

www.engineeringmaintenance.info Jan/Feb 2008 EMS

21

MAINTEC 2008

ADVICE IMPROVES Hot gossip on MOTOR EFFICIENCY Motor condition monitoring is increasingly seen as a useful tool for improving motor efficiency and energy savings.

To help delegates achieve this goal, UK representative of Baker Instruments, Whitelegg Machines, has invited Baker's senior engineer, Tim Thomas, to be present at Maintec. Tim will be available to answer any condition monitoring queries, which should be emailed in advance of the show to timthomas@bakerinst.com.

Whitelegg will also showcase a host of new products, including Baker’s new power quality testing software, designed to monitor single and three phase systems, looking at harmonic distortion, total

distortion, voltage unbalance, voltage level and harmonics up to the 100th order.

Visitors will also be able to experience the Baker Explorer motor performance tester, offering non-intrusive monitoring of electric motors via their power cables. Ideal for monitoring LV and HV electric motors, the Explorer is particularly suitable for applications where routine inspection access is difficult such as large underwater pumps or rolling mill machinery.

Designed to minimise the risk of catastrophic failure and expensive downtime, the Explorer can look at variables within the motor’s performance profile and torque analysis, which can deliver a mechanical indication of motor and load condition.

Finally, the online motor analyser was developed to conduct complete predictive monitoring with root-cause analysis. www.whitelegg.com – STAND C26 Reader Reply Number: 327

boiler savings Byworth engineers can help visitors tackle the increasing fuel cost of running steam and hot water boilers

Boiler engineers and technical specialists will be available on the Byworth stand to help maintenance and plant engineers across all industries as they address the ever increasing fuel cost of running steam and hot water boilers.

As boiler systems and applications are individual, it is important to gather as much technical information about efficiency improvements as possible. With this in mind, Byworth engineers will be ready to discuss: the latest

technical developments in steam and hot water boilers, waste heat utilisation, fuel saving and efficiency. The company can also provide information on its XiD boiler tube, designed to increase heat transfer, its range of emergency and long term hire boilers, as well as the benefits of operator training, preventive maintenance and energy surveys. www.byworth.co.uk – STAND D18

Reader Reply Number: 325

Take a virtual test drive MONITORING PREDICTS SUCCESS Artesis Technology Systems, an ex-Koc Holding subsidiary, has developed a number of condition monitoring products for plant monitoring, predictive maintenance and process optimisation across multiple industries. The condition monitoring products, Artesis MCM, Artesis PCM, MCMSCADA + Diagnostics and MCMSoC integrated products can be used to tackle applications in the chemical and petrochemical, metal processing, power generation, pulp and paper, water and waste water, gas distribution, cement, food and beverage, automotive, textile and metallurgy sectors and are available through licensable applications and OEM sales. www.artesis.com – STAND F18 Reader Reply Number: 326

22 EMS Jan/Feb 2008 www.engineeringmaintenance.info

Set to harness collective intelligence from online communities, Dassault Systèmes' new product lifecycle management (PLM) tool allows users to share 3D product information. PLM 2.0, supported by the new V6 platform, is a 3D online environment enabling designers, engineering groups and end users to experience products virtually.

V6 enables people to work concurrently in real time via a simple web connection in an environment where all user interactions generate intellectual property (IP). The 3D interface and user experience enable anybody to participate in the

product lifecycle, while the V6 platform with MatrixOne technology gives intelligent access to all IP, no matter the data source location. V6 is an open platform, embracing SOA standards and is said to be rapid to deploy.

Designed to bring together information on the requirements, functional, logical and physical (RFLP) aspects of a product, V6 supports modelling applications in all engineering disciplines.

The platform is also said to unify engineering and enterprise processes. www.3ds.com Reader Reply Number: 324

Unless you’re a Meerkat, it isn’t always possible to stand around watching for danger. And anyway, if you are responsible for heavy duty industrial machinery, you’ll know that the danger signals are usually hidden until it’s too late.

ProCheck

There is, however, an alternative way to maintain constant vigilance.

Proactive preventive condition monitoring from INA FAG – it’s just as sensitive inside an industrial environment as the Meerkat is out in the wild.

DTECT X1

Our condition monitoring products are designed to watch for the tell-tale signs of danger – particularly increased / uneven vibration or rises above temperature norms – in industrial machines. This means you can take corrective action before any real problems occur. Ranging from simple bolt-on monitors to highly sophisticated online systems, our condition monitoring equipment helps you to prevent emergency shut-downs and to plan your maintenance routines more efficiently and cost-effectively.

DETECTOR III

For further details of our condition monitoring products and services call 0121 351 3833 or visit our web site at www.schaeffler.co.uk and click on the Condition Monitoring and Maintenance Products link.

EASY CHECK

Schaeffler (UK) Ltd Tel: 0121 351 3833 Fax: 0121 351 7686 E-mail: info.uk@schaeffler.com Web: www.schaeffler.co.uk

For more information quote EMS Enquiry No. 123 on IBC

MAINTEC 2008

COMPRESSORS FEEL THE SQUEEZE Compressed air specialist, Atlas Copco, will highlight a range of hardware and software products designed to enhance energy optimisation. It will also showcase its aftermarket products and services, including the AIRConnect system, which connects any compressed air system to Atlas Copco's automated 24/7 internetbased monitoring system.

Details of Atlas Copcoâ&#x20AC;&#x2122;s service plans will also be on stand with options for inspection, preventative maintenance or total responsibility, together with information on the latest compressed air energy saving CD. Focussing on hardware, Atlas Copco will exhibit the smallest addition to its

family of variable speed drive (VSD) WorkPlace compressors, the GA11VSD compressor. This 11kW machine produces 10 to 13bar, 50Hz performance, with a flow range from seven to 29l/s. It is said to offer reduced energy costs and precise pressure control for the smaller compressed air user.

Not only does VSD control produce energy savings of up to 35 per cent, but with air treatment equipment such as refrigeration dryer, air filters and condensate management built into the compressor package, Atlas claims a further 10 per cent saving from reduced installation costs and the elimination of pipework leakage and pressure drops. A sound level

!LPHA?-ONTAGE?(ALF0AGE PDF

24

The 11kW GA11VSD compressor is Atlas Copco's smallest workplace compressor, reducing energy costs with precise pressure control

below 69dB(A) also facilitates installation at the point of use, eliminating the need for a separate compressor room. www.atlascopco.com â&#x20AC;&#x201C; STAND D6 Reader Reply Number: 328

For more information quote EMS Enquiry No. 124 on IBC

EMS Jan/Feb 2008 www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 125 on IBC

THERMOGRAPHY

ThermaScope® is the state of the art camera system from Thermoteknix Systems Ltd designed for monitoring and viewing processes in very high temperature environments such as furnaces, incinerators, boilers, cement and steel plants.

Biomass Boiler Burner Grate ThermaScope® SLK

Stunning Video Imagery showing the Burner in a Cement Kiln captured with ThermaScope® HTV

Furnace Cooler Zone Imagery from ThermaScope® HTV

Footage from heavy fuel fired boiler at Power Station (Puerto Rico) from ThermaScope® SLK

ThermaScope® SLK - Steel Reheat Furnace

ThermaScope® SLK - Cement Kiln and Refractory Temperature Measurement

ThermaScope® High Temperature Camera keeps tabs on your hot property With a water cooled stainless steel protective camera housing, automatic fail-safe pneumatic camera insert/retract mechanism and camera interface, signal processing circuitry and services control unit, ThermaScope is available both as a low cost high resolution CCTV video system or as a fully radiometric temperature measuring model either as a stand-alone unit or integrated into Process: ThermaScope® SLK displays bright clear real time thermal images of high temperature processes and measures temperature at every point in the field of view. A key factor in efficient and safe operation is the ability to accurately monitor the combustion process and ThermaScope SLK sends real time thermal images and unlimited temperature data of the process to the control room PC. As fuel flow, operating conditions or fuel quality changes, ThermaScope gives operators and control engineers a clear image and instantaneous temperatures at any spot or within any area of interest.

Alarming warns of unwanted temperature extremes and process variation whilst direct external outputs enable interfacing and automated control.

High temperature kiln, furnace or oven operating conditions are continuously monitored by the ThermaScope SLK. Abnormal conditions such as over or under temperature,

26

poor temperature distribution or irregular flame shape is instantly shown. These can be alarmed and interpreted by the Operator or Process Engineer with user-friendly analysis tools and temperature displays.

ThermaScope® HTV (High Temperature Video) is a nonradiometric high temperature video camera which displays high resolution real time imagery and is a lower cost option for those wishing to view clear images of their combustion processes without the need for measuring temperature.

Both ThermaScope systems will help to improve pyroprocessing efficiency, increase combustion control, save energy and reduce pollution in your high temperature processes. www.thermoteknix.com Reader Reply Number: 329

see us at MAINTEC 2008

ThermaScope Kiln Installation

An Engineer installs one of four ThermaScope SLK units at PREPA Power Plant, Puerto Rico (2007)

The ThermaScope System

For more information quote EMS Enquiry No. 150 on IBC

EMS Jan/Feb 2008 www.engineeringmaintenance.info

DURA TREAD

Anti-slip Fibreglass Floor Grating

Range includes: - Standard Grating - Covered Grating - Pultruded Grating - Structural Stair Treads - Tread Covers - Solid Fibreglass Plate

Prevents trips, slips and falls in the workplace Applications: Benefits: - Stairs - Industrial Flooring - Walkways - Platforms - Assembly Lines - Wash Bays - Work Stations

Tel: +44 (0) 1255 423601 Fax: +44 (0) 1255 435426 duratread@fibreglassgrating.co.uk www.fibreglassgrating.co.uk

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CALIBRATION

The benefits of integrating calibration software to a computerised maintenance management system (CMMS) For process manufacturers today, having a reliable, seamlessly integrated set of IT systems across the plant, or across multiple sites, is critical to business efficiency, profitability and growth. Maintaining plant assets – whether that includes production line equipment, boilers, furnaces, special purpose machines, conveyor systems or hydraulic pumps – is equally critical for these companies. This is particularly true if the company is part of an asset-intensive industry, where equipment and plant infrastructure is large, complex and expensive. Also, if stoppages to production lines due to equipment breakdowns are costly, implementing the latest computerised maintenance management (CMM) systems can help save precious time and money.

In the process industries, a small but critical part of a company’s asset management strategy should be the calibration of process instrumentation. For this, Beamex’s calibration management software, Beamex CMX, has proved itself time and time again across many industry sectors, including pharmaceuticals, chemicals, nuclear, metal processing, paper, oil and gas. Manufacturing plants need to be sure that their instrumentation products – temperature sensors, pressure transducers, flow meters and the like – are performing and measuring to specified tolerances. If sensors drift out of their specification range, the consequences can be disastrous, perhaps resulting in costly production downtime, safety issues or batches of inferior quality goods being produced, which then have to be scrapped.

Beamex CMX helps companies document, schedule, plan, analyse and optimise their calibration work. Seamless communication between CMX and ‘smart’ calibrators means that companies have the ability to automate pre-defined calibration procedures. As well as retrieving and storing calibration data, CMX can also download detailed instructions for operation before and after calibrating. The most common types of download include procedures, reminders and safety-related information.

Today, most process manufacturers use some sort of CMM system that sits alongside their calibration management system.

Seamless communication with calibrators also provides many practical benefits such as

a reduction in paperwork, elimination of human error associated with manual recording, and the ability to speed up the calibration task. CMX also stores the complete calibration history of process instruments and produces fully traceable calibration records.

Today, most process manufacturers use some sort of CMM system that sits alongside their calibration management system. Common CMM systems available include SAP, Maximo and Datastream, otherwise the company may have developed its own, in-house software for maintenance management.

Whilst Beamex CMX Calibration Software functions very well as a standalone calibration management system, customers using the software in this way are not reaping all the rewards they could if they were to integrate CMX with their CMM system. The CMM system is also likely to have been implemented before the calibration management software and so will normally be the first port of call for maintenance staff and for generating all work orders.

But the good news for customers of Beamex CMX Professional or Beamex CMX Enterprise software is that CMX can now easily be integrated to CMM systems, whether it is a Maximo, SAP or Datastream CMM system. Beamex offers a ‘standard’ integration package, although most customers will require a customized version that suits their existing software and maintenance strategy.

Integrating CMX with a CMM system means that plant hierarchy and all work orders for process instruments can be generated and maintained in the customer’s CMM system. Calibration work orders can easily be transferred to CMX Calibration Software. Then, once the calibration work order has been executed, CMX sends an acknowledgement order of this work back to the customer’s CMM system. All detailed calibration results are stored and available on the CMX database.

The integration project normally involves three parties: the customer, the CMM system software partner and Beamex.

Jarmo Hyvärinen, Sales Manager at Beamex comments: “Beamex’s customers have been asking us for some time whether we can integrate our CMX software with their

28 EMS Jan/Feb 2008 www.engineeringmaintenance.info

maintenance management systems. Our integration services were introduced recently, and it has generated high interest among the customers. Many customers are currently going through the integration process.”

These customers are in the food and beverage, oil and gas, energy, steel processing and pharmaceuticals industries and, according to Hyvärinen, use a SAP or Maximo CMM system. “The integration project normally involves three parties: the customer, the CMM system software partner and Beamex. With our customers, Beamex’s part of the integration has been successful.

However, the customer may have a large CMM system and a considerable amount of data keying to perform before the integration is complete. However, once finished, the integration should save these companies time, reduce costs and increase productivity by preventing unnecessary double effort and re-keying of work orders in separate systems.

When there is no need to manually re-key the data, typing errors are eliminated. This improves the quality of the entire system.

Integration will also enable these companies to automate their calibration management with smart calibrators.”

Beamex’s standard integration interface uses the XML (Extensible Markup Language) data file format, which enables the sharing of structured data across different information systems. Data fields such as position ID, device ID, location, serial number and work order number can be transferred from the customer’s CMM system to CMX.Similarly, data can be transferred the other way, including work order numbers; position ID; maximum error; pass/fail notifications; calibration date and time; and who carried out the calibration task.

“Of course, in reality, the customer will require more data fields to be transferred, but our standard package is the first building block on the bridge between the two systems,” explains Hyvärinen. “Often, a data exchange module or interface is required that sits between the two systems and so the customer’s CMM system specialist will need to be involved here.”

Although there’s certainly a growing number of manufacturing companies today, at boardroom level, that are beginning to realise that maintenance management is

CALIBRATION

now an issue which deserves enterprise-wide, perhaps multisite, attention, in general, most plant or maintenance managers still donâ&#x20AC;&#x2122;t get a voice in the higher echelons of the boardroom. Maintenance is simply viewed as a necessary cost to the business and no more.

Once finished, the integration should save these companies time, reduce costs and increase productivity by preventing unnecessary double effort and re-keying of work orders in separate systems.

But the fact is, any initiatives (including software integration) that can support an asset management strategy are likely to help save costs from a companyâ&#x20AC;&#x2122;s balance sheet. Hence, the software communityâ&#x20AC;&#x2122;s latest buzzword, â&#x20AC;&#x2DC;EAMâ&#x20AC;&#x2122;, or enterprise asset management. EAM is more than just maintenance management software. Itâ&#x20AC;&#x2122;s all

The benefits of integration Plant hierarchy and all work orders for process instruments can be generated and maintained in the customerâ&#x20AC;&#x2122;s CMM system.

Calibration work orders can easily be transferred to CMX calibration management software.

Companies save time, reduce costs and increase productivity by preventing unnecessary double effort and re-keying of work orders in separate systems Integration also enables companies to automate their calibration management process with â&#x20AC;&#x2DC;smartâ&#x20AC;&#x2122; calibrators.

The limitations of using a standalone maintenance management system Plant hierarchy and work orders can be stored in CMM system, but the calibration cannot be automated because the system cannot communicate with â&#x20AC;&#x2DC;smartâ&#x20AC;&#x2122; calibrators.

Duplicated effort and re-keying the same data into multiple databases.

Factors driving companies towards integration Seamless integration of IT systems across plants and remote sites.

Sharing of critical plant and process information.

Productivity improvement, cost reduction and improving quality by eliminating manual errors in re-keying data.

about companies taking a business-wide view of all their plant equipment and coordinating maintenance activities and resources with other departments and sites, particularly with production teams. Integrating a CMM system with calibration

management software is an important step in the right direction here, particularly if the company has a high volume of process instruments that need calibrating regularly.

Savings from EAM are reasonably well-documented and come in various guises, the

most common benefits being: less equipment breakdowns (leading to a reduction in overall plant downtime); a corresponding increase in asset utilisation or plant uptime; better management of spare parts and equipment stocks; more efficient use of maintenance staff; and optimised scheduling of maintenance tasks and resources. â&#x20AC;&#x153;The key to success is really the quality of information you input to the software. Part of this relates to the success of the up-front review process, as well as the ongoing discipline of your maintenance team that uses the system. The data has to be as close to 100% accurate as possible to get maximum benefit from the system,â&#x20AC;? concludes Hyvärinen.

Beamex www.beamex.com Reader Reply Number: 330

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For more information quote EMS Enquiry No. 128 on IBC

www.engineeringmaintenance.info Jan/Feb 2008 EMS

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PLANT MAINTENANCE

In this extract from a technical article written by SPM Instrument’s Louis Morando, EMS explores shock pulse

Shocking results Condition monitoring should always start with a list of machine faults, specific for each machine. Only if you know exactly what you expect from the monitoring method, can you apply it efficiently and correctly. Otherwise, there is a danger that you will simply be collecting data, and data is of no use unless it is converted to useful information that you can act upon to realise your true goal of maintaining plant equipment in good working order.

When we look at the rotating component that gives us the most concern, it usually comes down to the bearing. I think it’s fair to say that 70 to 80 per cent of rotational problems are bearing related. Whether the causes are due to under or over lubrication, contamination, installation faults, secondary forces or just plain fatigue, we need to know the operating condition of bearings most frequently. So it’s very important to determine the best technique for identifying your particular bearing problems. The other rotational problems certainly need to be identified as well, so again, choose the most cost effective, efficient technique to accomplish that.

How do you run a cost efficient, effective condition based monitoring program? Start by selecting the appropriate technique for the application and for the type of answers needed. As a general rule, you can apply the 80/20 rule in many facilities. That is, around 80 per cent of equipment needs to be monitored

without the need of spectral data and large amounts of data collection.

You could then utilise spectrum analysing only on the equipment that needs it. For those pieces of equipment that are so critical that periodic monitoring is not enough, then continuous monitoring needs to be considered.

The Shock Pulse Method (SPM) is the front line technique the Hallsta paper mill chose to quickly manage input from its 800 rolls, with 4,000 machines and 16,000 measurement points. With eight inspectors, they need a quick method to know whether bearings need to be greased or not, or that damage is present and needs to be monitored more frequently.

What is shock pulse?

What we loosely call ‘machine vibration’ is a very complex form of movement that has many different causes and that can be described and measured in many different ways. Vibration exists in all machines with moving parts, because some of the force, which makes the machine work, is directed against the machine structure and tries to shift it from its position. Thus, vibration is normal up to a degree, and all machines are constructed to withstand a certain amount of vibration without malfunctions. In order to use vibration monitoring to diagnose machine condition, we have to: Find a suitable way of measuring vibration, and

Decide what normal vibration is and what excessive vibration is for any particular machine All vibration measurement starts with a time record, a registration of vibration over a length of time. A transducer converts the movement into an electric signal, which an instrument quantifies, displays and stores. The signal can then be evaluated in terms of ‘good’ or ‘bad’.

One way of looking at vibrations is to define the type of force, which causes it.

Most industrial machines are rotating, so the main force is rotational, operating on masses which are imperfectly balanced.

This accounts for approximately 99% of the total vibration energy. Rotational forces are continuous and cyclic. The force does not stop (while the machine is running under power) and the movement is repeated once per revolution of a part.

About 1% of machine vibration is due to shock. Shock forces are not continuous but can be repeated, either at regular or irregular intervals. The remaining small amount of vibration, about 0.1%, is attributed to frictional forces.

Even bearing damage can be detected through vibration analysis. A bearing produces a group of peaks in the vibration spectrum, caused by the rolling elements passing, at different speeds, over the inner race and the outer race, and by spinning around their axis. A further peak is caused by cage rotation.

Given the small mass of the bearing in

31 www.engineeringmaintenance.info Jan/Feb 2008 EMS

PLANT MANAGEMENT

Figure 1 â&#x20AC;&#x201C; Transients superimposed on wave from shaft rotation

relation to the large mass of the machine, these peaks normally have very low amplitudes and many times are difficult to pick up with a spectrum before there is severe damage.

A shock pulse transducer contains a reference mass (m) and responds with a dampened oscillation when hit by a shock wave. Attached to the reference mass is a piezoelectric crystal which produces a voltage when compressed by the movement of the reference mass. This voltage is proportional to the amplitude of the oscillation and thus to the energy of the shock wave. The principle is the same as used in accelerometers for vibration measurement. There is, however, an important difference.

When a mass is excited at its resonance frequency, it will oscillate with much greater amplitude than at any other frequency. For vibration measurement, one normally stops measuring far below the resonance frequency of the transducer.

On the other hand, shock pulse meters are mechanically and electrically tuned to operate exclusively at their resonance frequency of 32 kHz (fm), where the resulting signal is strongest. This gives us a very sensitive transducer for shocks only, but which will not react to normal machine vibration frequencies.

When a ball hits a damaged area in the raceway, it produces a shock wave. Shock waves are transients or short-lived waves starting with relatively high amplitude that quickly dampen out. In a time record displayed by an oscilloscope, these transients are often clearly seen, superimposed on the

continuous wave produced by shaft rotation (see Figure 1). When the distance between transients is constant and corresponds to the ball pass frequency, this is clear evidence of bearing damage.

In the spectrum, however, peak amplitude is determined by the energy contents of the vibration at any given frequency. In relation to the energy at the

Figure 2 â&#x20AC;&#x201C; Ball Pass Frequency lost in spectrum noise

Figure 3 â&#x20AC;&#x201C; Illustration of effects on signal after band pass, rectifying and enveloping

32 EMS Jan/Feb 2008 www.engineeringmaintenance.info

shaft frequency, the energy of the shocks produced by the damaged bearing can be negligible. Thus, the ball pass frequency line has low amplitude and is easily lost among the noise, as shown in Figure 2. In the area around the resonance frequency, we can record a time signal, which clearly shows the transients produced by the damaged bearing. Each shock is a single event, but is also repeated at a regular rate, the interval being the time between one ball passing the damage and the next.

The signal is treated by rectifying (which cuts off the negative amplitudes) and by enveloping (which produces well-defined peaks). Figure 3 illustrates this process.

The enveloping technique used by vibration analysis attempts, by manipulating the signal, to make shocks visible and measurable in the frequency domain, simply because frequency analysis is the general technique used to detect machine faults. The main strength of the shock pulse method is its specialisation on shock detection. The transducer and measuring instrument are designed to measure the magnitude of shocks directly in the time domain. All generations of shock pulse meters give readouts of both the magnitude of the peaks (maximum value dBm) and of the signal level between peaks (carpet value dBc). Together, these two values can be directly translated into bearing condition information by utilising the bearing bore diameter and rpm. www.spminstrument.co.uk Reader Reply Number: 331

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COVER STORY

Is this the most dangerous maintenance job in the World?

MAINTENANCE: In at the deep end Neil Cole has spent the past 20 years diving in treacherous conditions in the North Sea. Yet it isn't the rough weather, freezing temperatures or the eight-hour dives carrying out installation and maintenance work on oilrigs, which are the most gruelling aspects â&#x20AC;&#x201C; it's the experience of living in the infamous saturation chamber for a month at a time.

These chambers, situated on support vessels, are the size of a small room, housing six men and allowing them to live under pressure so they are able to undertake multiple dives, at greater depths, over longer periods, with one Decompression period of up to six days at the end of a 20-day period.

It means more work can be done more economically, and safely.

The chambers, says Cole, are about 4.5m long by 2m wide, with bunk beds, a toilet and shower and a communal table squeezed into the space. Meals, cooked on the vessel, are provided through a special compartment and inmates are cut off from the outside world, with no phones and only a port hole to look through. The main form of entertainment is a 12in television. Cole, 50, from Southport on Merseyside, says it takes a very special person to live in these conditions.

"It's not everyone's cup of tea," he says. "Some guys can deal with it, others can't. It depends on your psychological make-up. You need a good sense of humour and you need to be a bit of an extrovert and get on with your team members.

"You've actually got less space than

the minimum requirement that Amnesty International lays down for prisoners. Their rule is two-and-halfcubic metres per man and ours is less than that. We had a chap working with us recently from Canada and once he was locked in (to the saturation chamber) he couldn't handle it and had to come out.

"North Sea diving is safer than it was in what Cole describes as the "Klondyke" years of the early oil industry, in the sixties and seventies, when things were fairly unregulated.

Yet Cole, whose work involves highly prized welding and metallurgy testing skills, says diving still carries huge risks.

Thirty years ago the main attraction was money, but the rewards have now fallen behind those of other offshore workers. It is this disparity that recently brought 900 divers into a pay dispute with employers, one of the most serious in the industry's history.

"In the past, some employers considered us to be oil-field trash. But we've managed to get the message across that we're experienced and skilled workers," he says. But some of the danger elements of the job and general working conditions still need to be addressed, adds Cole. "The danger lies in the fact you're working in an alien environment, diving sometimes down to 600ft. If anything goes wrong, you can't just take your hat off and breathe water.

"You're attached by an umbilical cord.

Your umbilical could be squashed by a piece of equipment, or it could burst.

You're reliant on mechanical means for

34 EMS Jan/Feb 2008 www.engineeringmaintenance.info

support to keep you alive. We haven't had a death since 1999 but there are still injuries occurring because of failures in safety procedures. "It's dark. It's cold.

It's 600ft down in the North Sea. It's possibly the most dangerous working conditions on the planet. So why do deep sea divers do it? Cole says he's lucky never to have been involved in a serious incident himself, apart from when the hot water supply to his suit malfunctioned and he had to return to the bell. This incident could have resulted in death had he not been able to return to the bell, because the water temperature in the North Sea is 5°C. One experienced operator is retired ex-North Sea diver Jim Limbrick. Born in Kent, he spent 26 years as a diver, first in the Royal Navy, later in the Middle East on private contracts, then four years in the North Sea in the late sixties and early seventies. "The money then was the attraction of the job. The industry was up and coming and offshore diving was a real adventure for me.

"Limbrick believes North Sea divers deserve a substantial pay rise but have less cause to complain about conditions, saying they're probably as good as they can be, given all the limitations, and better than they were in those maverick years when he was diving.

"In those days, you had what you called 'tool pushers', guys who directed the drilling on rigs who pushed divers into the water in adverse conditions," he says. "Many were killed. Back then, companies took shortcuts with safety and equipment. I quit the North Sea

COVER STORY

because of that. I was sent down once in more than 150ft of water with a camera to take a photo (of part of the rig). I was just in scuba gear, which is now banned in the North Sea, with no line attached to the surface. I came up with absolutely no decompression whatsoever. It wasn't offered to me. My life was in my own hands so I made sure I didn't come up too fast.

"Limbrick knows only too well what happens with lack of decompression, having suffered once from "the bends" on a dive in the English Channel. The bends, or decompression sickness, is caused by ascending too quickly, when a diver moves from a high-pressure environment into one of low pressure. Bubbles form in the

bloodstream as gases in pressurised form revert to their normal state, like lemonade fizzing out a shaken bottle. Limbrick suffered a temporary paralysis and was saved only by prompt medical treatment, but the condition

could have been fatal.

Although conditions are better now than in the sixties and seventies, one thing that never changes is the difficulty dealing with the isolation of the saturation chamber and also the disruption the job causes to family life.

Cole, who is married with three children, says: "Sometimes you get a couple of days' notice for a job, sometimes they might ring you at four in the morning and ask you to be there the next day. You can be planning something special with your family and then you'll have to drop everything. And I miss my family when I'm away.

"He also says men can never take their family or personal problems to work. "We don't talk about these things in the saturation chamber. It's too difficult. We prefer just to tell dirty jokes," he says.

Cole is at an age when most divers retire, and although the oldest diver in the North Sea is 61,he says he might have a few years left in him for diving.

Reader Reply Number: 332

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For more information quote EMS Enquiry No. 132 on IBC

www.engineeringmaintenance.info Jan/Feb 2008 EMS

For more information quote EMS Enquiry No. 133 on IBC

For more information quote EMS Enquiry No. 134 on IBC

For more information quote EMS Enquiry No. 135 on IBC

ENERGY MATTERS

Wellman Robey’s managing director, Tajinder Heer, guides readers through boiler choice

Specifiers of commercial and industrial boilers do not have an easy life. There are many alternative methods and suppliers available, thus the selection path is not always clear. However, the selection criteria can be made on five basic questions, explains Wellman Robey’s managing director, Tajinder Heer.

Servicing heating and hot water needs 1) Will the chosen plant be fit for purpose and provide the exact requirements, taking into consideration that no two installations are the same?

2) Since the boiler(s) may last up to 30-years, can you be sure that maximum trouble free operation will extend throughout the life span?

3) As fossil fuel costs escalate into the future, will you still get maximum efficiency?

4) Will all foreseeable legislation on carbon emissions be met by the new plant?

5) What assurances should you expect from the boiler supplier, including aftercare for full life expectancy?

An example of savings achievable from working in partnership is that of the Wellman Robey plant at Kellogg’s, which provides both steam and hot water for heating and hygiene purposes.

Kellogg’s of Wrexham recently undertook a refurbishment of its boiler house. The revitalised plant is now set to recuperate its capital costs with fuel savings over the next eight months.

The plant produces cereal, 24-hours a day, 352-days a year. With virtually continuous high volume output, energy costs are correspondingly high. However, a recent upgrade of the boiler house is set to considerably reduce energy consumption in fuel oil and natural gas, at the same time meeting all foreseeable emissions legislation.

When the Kellogg’s plant opened in the late 1970s, FKI Babock (now incorporated within Wellman Robey) supplied two of the three steam raising

boilers that are still in operation. However, in 1987 production increased and a fourth Wellman Robey twin furnace unit was installed. This boiler, rated at 46,000lbs/hr, 150psi working pressure, fitted economiser and firing on heavy fuel oil, then became the main steam supplier.

Although there have been several fuel saving innovations incorporated into the boiler-house refurbishment, the main contribution comes from the new Economizers fitted within the existing boiler shell. The Economizer tubes have 236 serrated fins per metre, which increase the nett efficiency from 89.92 to 93.26 per cent when firing on natural gas, with light oil now being the secondary fuel.

The projected life expectancy for this twenty-year old boiler is a minimum of ten years, yielding a saving in excess of £100,000 per annum for a capital outlay of less than £63,000.

In the 1 to 4MW range of hot water boilers, the Wellman Robey Ygnette has been well proven over several decades. A recent application for the Ygnette range has been nine like-for-like replacement boilers following 30-years of service at RAF Marham in East Anglia.

The boilers replace and upgrade existing Wellman Robey Ygnette boilers originally installed in 1977. The new hot water boilers are due to be commissioned and consist of three 2,500kW LPHW (4.5barg) and six 800kW LPHW (10barg) boilers, all fitted with dual fuel modulating burners supplied by Wellman’s own burner company, GP Burners.

The Ygnette is a horizontal, three pass, wetback, reverse flame design incorporating a large furnace. www.wellman-robey.com Reader Reply Number: 333

Five questions are all it takes to get boiler specification on the move

37 www.engineeringmaintenance.info Jan/Feb 2008 EMS

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www.engineeringmaintenance.info CONTROL INSTRUMENTATION ENGINEERS MARINE DEFENCE Location: : SOUTH WEST - South West Rate: £Neg (Permanent) Based in the southwest, our client is a world leader offering a complete range of design, build and support solutions across both defence and commercial sectors. Opportunities have now developed for C&I Engineers and Technicians to become part of their Engineering team. These positions are both permanent and contract.

You will be using and supporting mechanical handling equipment for the purpose of fuel handling as well as working with cranes and lifting equipment for both nuclear and non-nuclear operations. You will be a problem solving engineer with related experience in faultfinding and you will be required to liaise with operational personnel.

Educated to HNC/degree level or equivalent experience, you will ideally come from a design or operational background and have excellent leadership and communication skills.

PLEASE EMAIL CV’S TO: jobs@mslrecruitment.com or to receive further information please fill in the enquiry card on the inside back cover and quote MSL400

PROJECT ENGINEER/ MANAGER Location: : BRISTOL - South West Rate: to £ 32 K (Permanent) + Bonus Scheme plus Benefits Package The Project Engineer/Manager will assist in the project management of high value contracts both in the UK and worldwide. The Project Engineer/ Manager will be involved in the negotiation of terms and conditions appropriate to each contract, producing a programme, attending regular reviews and ensuring the contract comes in on time and on budget.

Our client is a global supplier of solutions, equipment and services for rock and minerals processing. The Bulk Materials Handling Division covers, amongst others, the design and provision of machinery used in the crushing and separation of minerals; rail tippers, ship un-loaders, etc.

The successful Project Engineer/ Manager will hold a relevant engineering qualification and will have previous experience of project planning, budgeting and procurement. An important part of the Project Engineer/ Manager’s role is the ability to clearly communicate technical concepts with regard to heavy machinery.

Some foreign travel will be required and previous experience of international business would be useful although not essential.

PLEASE EMAIL CV’S TO: jobs@mslrecruitment.com or to receive further information please fill in the enquiry card on the inside back cover and quote MSL401

SENIOR VACUUM ENGINEERS & TECHNICIANS Location: : OXFORDSHIRE - South East Rate: £Neg (Permanent) As Senior Vacuum Engineer/Technician, you will be responsible for the availability and operation of specific technical systems, and will contribute as part of a multi-disciplinary team to the successful operation of all vacuum related systems. You will install new equipment, and participate in the design, procurement, inspection and testing of such equipment. You will act as project Manager for procurement contracts and mange staff performing installation work.

You will be working as part of the vacuum system section which is responsible for many of the systems including vacuum vessel integrity, plasma fuelling, vessel conditioning and vacuum pumping.

You will be working on a machine which incorporates a 200 m? ultra high vacuum vessel in which surface conditions and gas purity are critical to performance.

To succeed as Senior Vacuum Engineer or Technician, you should be qualified to degree level or equivalent in engineering, with some experience in a high technology environment. You will have a good working knowledge of high vacuum technology, and experience in staff supervision. Effective working in a multidisciplinary team, you will be able to write and follow procedural documentation and be computer literate. Experience of mechanical design, gas distribution systems, cryogenics, control or software engineering would be an advantage.

At the forefront of research into nuclear fusion with its exciting potential as a long term, environmentally friendly energy source for future generations, excellent opportunities now exist for Technicians to join them at their site in Oxfordshire. Operating Europe's flagship fusion experiment and other research facilities, these will support the next generation of fusion machines.

PLEASE EMAIL CV’S TO: jobs@mslrecruitment.com or to receive further information please fill in the enquiry card on the inside back cover and quote MSL403

39 www.engineeringmaintenance.info Jan/Feb 2008 EMS

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01494 816569

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0121 351 3833

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01706 835331

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01732 221245

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020 7942 0700

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01642 497000

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01909 504700

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0845 6801957

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40 EMS Jan/Feb 2008 www.engineeringmaintenance.info

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Artesis MCM – Advanced Technology for Simple, Effective Condition Monitoring

Every now and then, a new solution comes along and changes your thinking.

Artesis MCM is a new approach to condition monitoring, providing all the benefits without the complication and costs of traditional systems.

Artesis MCM monitors the condition of equipment driven by electric motors, using the motor itself as a sophisticated transducer. It requires only connection into the motor’s electrical supply, avoiding the need to attach specialised sensors to the plant. Because Artesis MCM is permanently installed, it provides continuous fault monitoring and doesn’t require the manual data collection that represents a major cost of using walkaround systems. So Artesis MCM is especially applicable to situations where the plant is not easily accessible, either because it is remote or because the local environment is hazardous.

DEVELO

P

NA

ED TECHNO

L

O

Artesis MCM uses advanced technology developed for NASA to bring you a selflearning capability in a compact, panel-mounted instrument. Over the initial period of operation, it teaches itself about the normal operation environment of your equipment so that it can accurately identify and diagnose faults when they start to occur. Artesis MCM doesn’t demand specialist setup or operating expertise, it just tells you what you need to know, when you need to know it. If you want all A S the benefits of condition monitoring but think it’s too difficult or expensive for you, Artesis MCM will make you think again.

GY

simple, effective

condition monitoring “...it simply works” tel 0845 634 3854 info@artesis.com

www.artesis.com For more information quote EMS Enquiry No. 138 on IBC