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The shortest distance between two points is a straight line
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latest news & products
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Latest Thermal Imagery Technology from thermoteknix
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Condition Monitoring of Intermittent and Short Duration Machine Operations
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MAINTEC 2011 Show Preview
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Dataloggers
editors/contributing: Jon Barret, Christer Idhammar, Alan France
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Energy & Waste Management
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Paul Clappison - Magazine Paul Miles - Online Advertising
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Brembo choose Carl Software to break new barriers in production.
Phone tel: +44(0)1634 731646 Fax: +44(0)1634 631644
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Electrical Safety testing
Address MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ
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Buyers Guide
The shortest distance between two points is a straight line. Christer Idhammar is a world renowned and awarded Reliability and Maintenance Consultant and Guru. He is the founder and executive vice president with IDCON, INC in Raleigh NC, USA; A reliability and maintenance training and consulting company to Industry worldwide since 1972. www.idcon.com Any improvement initiative within reliability and maintenance is a journey towards a state of continuous improvement. You will never reach a final destination. You might state that your goal is 95% planned and scheduled maintenance and 96% reliability. In my opinion these goals are necessary milestones because when you pass these milestones you should not think you are done. What you will notice is that you now have time to go the next step. You must use this time to take actions to generate
continuously better results otherwise your organizations’ performance will weaken. An old but still true statement is “If you do not improve, you are not good anymore”. If we agree on our destination being a state of continuous improvement, the next thing we need to know is where we start. Before you enter into any improvement initiative it is a good idea to ask yourself what best describes your organization’s status:
I don’t know where I am and don’t know where I am going. If you do not know where you are when you start an improvement initiative and you do not know where you are going you might have a nice but very expensive experience. A lot of action but inadequate results.
I know where I am but I don’t know where I am going. If you know where you are, but you do not know where you are going, it will take a very long time to reach any destination. Again a lot of action but inadequate results.
I don’t know where I am but I know where I am going. If you don’t know where you are, but you know where you are going, you might reach your destination, but it will take a lot of unnecessary time and effort to arrive there. Again a lot of action but inadequate or late results.
I know where I am and I know where I am going. If you know where you are and you know where you are going you can reach your destination in the shortest time and the most cost effective manner. engineeringmaintenance.info
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Which statement above best describes your situation?
I have many times said that maintenance managers are in a “Budget Jail�. It is more important for them to stay within the budget than to invest money in improved reliability, because their performance is not measured by reliability, they are measured on cost.
In many cases this situation is caused because they do not have a good measurement on how good their organization is, and they do not have a good picture of how good they can become, and there is no aggressive and quantified plan on how to close this gap. Maintenance management is a very process driven matter. If you document these processes and the elements of each process you can appraise how well each of these elements is executed. You have also created a document that describes what excellence looks like. After you have assessed and rated all elements your organization will discover where your gaps are and you can develop the action plan to close these gaps. We have used this methodology in hundreds of organizations worldwide, and we have proven that a better score on best practices will generate excellent results. The biggest challenge is to get often reactive people to work in a more disciplined way. You need to know where you are and where you are going, and you must have a plan to draw a straight line on how to reach your
destination. Then it is all about long term reinforcement. AS the best practice score increased the number of break downs went down and reliability and production throughput went
up. The value of the increased reliability by 1.9 % is worth about ten times more than the savings in maintenance cost. The data is from several plants over an eight years period.
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ELECTRICAL TESTING
NEW ‘PATBAG’ FOR FAST & SIMPLE APPLIANCE TESTING A new PATBag test-kit concept from Seaward enables organisations of all types and sizes to meet their electrical safety responsibilities in a safe, simple and effective manner.
and a 250V DC insulation test suitable for testing sensitive electrical appliances and surge protected leads. The unique range of tests incorporated in this lightweight and highly versatile
Specially designed to support fast and efficient electrical safety checking and testing routines, each PATBag comprises an easy to operate portable appliance tester with a test guide and training DVD alongside a log book for test results and a supply of ready-made pass/fail labels. The new kits include a choice of manual testers including the handheld PrimeTest 250. The first electrical tester in its class to provide all the electrical tests required for compliance with the IEE Code of Practice for the In-Service Inspection and Testing of Electrical Equipment, the PrimeTest 250 also has a host of other features. These additional test capabilities include an RCD trip time test, a 3-phase leakage test
instrument means that most workplaces appliances can be tested using long life battery power. However the capability of the new tester also extends to powered earth leakage and touch current measurement tests when required. In addition, for those operators that prefer to keep computerised test records, the Seaward PATBag options include a special PATGuard Elements software program providing a simplified database of test results, re-test dates and other data that can be used for the production of test reports and certificates. All the electrical test equipment, accessories, software and supporting documentation is incorporated in a purposedesigned and lightweight carrying bag. The new PATBags form part of a comprehensive range of portable appliance testers and accessories from Seaward to meet all workplace electrical safety testing needs.
For More Information: Visit : www.seaward.co.uk Or Email: sales@seaward.co.uk
Michell Instruments offer solutions for easy maintenance on compressed air systems and much more Michell Instruments’ range of dew-point and relative humidity instruments and their oxygen analyzers are designed to make many routine maintenance and monitoring tasks quick and simple. Michell are exhibiting a range of these products at Maintec, from 29 to 31 March 2011, on stand C23. Included on the stand will be Michell’s smallest and fastest portable dew-point hygrometer, the MDM300. At just 21cm by 17cm, weighing 1.5kg, and with a battery life of up to 48 hours typical usage, it enables the user to take field moisture measurements with the minimum of fuss. The fast response means that many more measurements can be taken each day – allowing for more productivity and also more time free for other tasks. The MDM300 is easy to use: its ergonomic design means that all the buttons are
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easily operated with the thumbs while the instrument is held comfortably in both hands. All measurement parameters are available at the touch of a button and the password-protected set-up menu is simple to navigate and intuitive to use. Both instrument set-up and downloading of logged data are easy with a Bluetooth connection that comes as standard. Michell’s range of Easidew Dew-Point Transmitters are ideal for a host of applications where constant monitoring of moisture levels are key – such as compressed air systems and dessicant dryers. All Easidew Transmitters are available as part of a calibration exchange
program, which enables users to keep upto-date calibration certification with virtually no downtime and at a fraction of the cost of buying new replacement sensors. The Calibration Exchange programme is ideal where periodic re-certification is required to maintain traceability. Before the re-calibration of an instrument is due, the customer orders an Exchange Sensor from Michell Instruments or one of its local representatives. Once received at the customer’s premises the original sensor is removed and replaced with the Exchange Sensor, and the original sensor returned to Michell Instruments. Each calibration exchange sensor comes with a traceable calibration certificate as standard.
INDUSTRY NEWS
STATUS LAUNCHES UNIQUE WIRELESS TEMPERATURE MONITORING SYSTEM Status Instruments, the leading instrumentation manufacturer, has launched a new wireless temperature and transmitter and receiver, ideal for industrial applications where installing hard wired technology can be costly and disruptive. The new WX series consists of the WTX700 wireless temperature transmitter and the WRX 900 DIN rail receiver. Together, they provide an adaptable option for all types of facilities, including the harshest of industrial environments. The WTX700 transmitter accepts RTD and thermocouple sensors as well as slidewire and mV signals. It is powered using a 3.6V Lithium battery with a lifespan of up to 3 years depending on the transmission rate. Two choices of connecting heads allow for maximum flexibility, the aluminium SCH11 is sensor-mounted while the ABS plastic SCH4 can be sensor-mounted or surfacemounted, particularly valuable when used with a flying lead sensor.
Data gathered by up to 16 WTX700 transmitters is sent to the WRX900 DIN Rail receiver. The receiver converts up to four temperature values into isolated current or voltage signals or into two current signals and two relay alarm signals. Any one of the in-head transmitters can be linked to any one of the analogue or relay outputs and all are available via the RS485 digital interface. An optional antenna mounting bracket and extension cable is available for cabinet installations or to optimise signal strength. The WX Series has an open air range of up to 300 metres, making it a valuable resource for large-scale operations. The data signal is transmitted on the ISM band (Industrial Scientific and Medical
Band) of 868,4MHz, a frequency resistant to external interferences, making the WX Series suitable for use in the harshest of industrial environments. For more information contact Status Instruments Tel: 01684 296818 email: sales@status.co.uk www.status.co.uk
Irisys launches first low-cost, high-spec visual/thermal imaging camera Latest handheld system, the IR16DS, makes it easy for engineers to see hot and cold spots when making on-site inspections. The feature-rich, highly affordable, camera brings immensely capable dual imaging technology to engineers everywhere. The handheld, lightweight camera enables engineers to capture and display thermal images, visual images, a fusion of the two, or as picture-in-picture. This makes it much easier to identify hot and cold spots, vital when making electrical inspections, energy efficiency surveys and for mechanical testing. Four moveable cursors allow easy comparison of components and items in the scene. In a 3-phase electrical supply, for example, an engineer can measure the temperature of each cable at the same time on the camera screen, rather than having
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to wait until the information is downloaded onto a computer. A time sequencing function allows unattended monitoring of equipment to observe changes in equipment performance. At five hours, battery life is also unusually long. The camera can be set to alarm when a hot or cold temperature is outside a defined threshold. Over 1000 images can be stored on a micro SD card. Engineers can also add voice notes to each image. The camera also has many applications for buildings maintenance and saving energy, as it quickly spots poor insulation, air leakages, and moisture issues.
For further information contact: David Smyth Irisys Tel: +44 (0) 1604 594200 E mail: david.smyth@irisys.co.uk Website: www.irisys.co.uk
INDUSTRY NEWS
NEW COMPRESSED GASES SAFETY HANDBOOK FROM WELDABILITY-SIF Weldability-SIF, the UK based “one stop” welding consumable and equipment supplier has published a new 64-page A5 book entitled ‘Compressed Gases Safety Handbook’ for personnel handling and using compressed gases in industrial environments. It is important that operatives using compressed gases understand the properties of the gases and are conversant with the relevant Codes of Practice & Guidance Notes issued by the BCGA (British Compressed Gases Association. This book, which is available Free of Charge, has been written as an educational aid to operatives in that it covers in detail the properties of the most common gases used in industry, the types of regulators used and safety checks required, the importance of using flashback arrestors and why they should be used as well as the handling and use of oxy-fuel cylinders. It also discusses manifold systems, the
storage and transportation of cylinders as well as providing information on cryogenic gases, their properties and the hazards when being used. There is also a chapter on solidified carbon dioxide (CO2) or Dry Ice, its properties, safety precautions required, transportation and disposal. Weldability Sif are also running a series of 1 and 2 day gas safety training courses at their headquarters facility based in Letchworth Hertfordshire which provides practical training and certification of verified achievement in the use, handling, storage and inspection of compressed gas cylinders and associated equipment.
For further information: Alexis Hawkins – Sales Manager Telephone: +44 (0)1462 482200 e-mail: info@weldability-sif.com
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INDUSTRY NEWS
EXPANDED HEADQUARTERS AND SERVICE CENTRE BOOST JOHN CRANE’S SAUDI ARABIA SERVICE CAPABILITIES The opening of a greatly expanded John Crane Saudi Arabia Co. Ltd. HQ and Service Centre in Saudi Arabia illustrates the company’s aim of enhancing the performance, lifespan and efficiency of its customers’ equipment. The move, which also reflects John Crane’s commitment to customers in the Kingdom of Saudi Arabia, highlights the company’s growing service capabilities in this area and underlines the unique combination of technical and operational support which is available. Located in the city of Dammam, the new HQ and Service Centre boasts many impressive features, including separate wet and gas seal reconditioning cells and dynamic test facilities. The facility also incorporates an extended spare parts warehouse, CNC-equipped machine shop, fully-equipped training centre plus a full refurbishment and balancing capability for power transmission couplings. A number of specialist John Crane teams are also based in the new HQ, including the Customer
Service, Logistics, Technical Support, Regional Sales, Projects and Business Development teams. “We have made no secret of our commitment to work in partnership with our Middle East customers and provide them with dedicated support,” comments Paul Cox, President, John Crane Global. “We want to be the number one choice for customers and that means delivering the very best products and service we can in terms of world-class quality, innovation and support. This major expansion project is tangible proof of our commitment being translated into positive action. Our aim is to help those customers enjoy the sort of improvements in efficiency and reductions in downtime that will help them achieve their own targets.” The scale of John Crane’s support to customers in Saudi Arabia is reflected in the fact that the company also operates two other Service Centres in the country. The East Coast facility in Jubail incorporates a
fully-equipped Service Centre with lapping, polishing, machining and pressure testing capabilities, plus a dedicated product and service training centre. Similar capabilities are also available at the recently redeveloped Yanbu Service Centre on the West Coast. Pictured at the official opening of the expanded Super Service Centre are (from left) Mr. David Tallentire, Vice President John Crane Europe, Middle East and Africa, Mr. Tawfiz Al Zamil, Zamil Group Member of the Board, and Mr. Peter Williams – Counsellor, Director of Trade and Industry, Saudi Arabia.
For more details please contact John Crane on +44 (0)161 886 5993, or visit www.johncrane.co.uk
NORBAR LAUNCHES NEW TORQUE APP Norbar Torque Tools is launching a handy torque conversion calculator as a free download on Android and iPhone systems. Similar to the calculator featured at: www.norbar.com, the new app offers instant conversion across a full range of SI, Metric and Imperial Units. Being able to access this information from mobile devices will be invaluable for professionals in engineering and all other sectors requiring accurate torque measurement. Students and apprentices in engineering and technology will also find this app a useful tool to assist in their calculations. Norbar, based in Banbury UK, is the world’s leading torque specialist and has branches in the USA, Australia, New Zealand, China and Singapore. The company’s manufacturing experience and expert knowledge have made this new torque
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measurement app as a truly international tool – easy to access and simple to use by any nationality and useful to engineers, scientists and technologists alike. Philip Brodey, Director of Norbar, maintains that mobility and flexibility of use is vital in many working environments and projects in the field. “The three different systems of measurement are all widely used and this app will make instant calculations between them from the largest to the smallest scales of measurement. The same applies to conversions within a system. This new app is a time saving aid and an ideal way to check your calculations.” The widely used SI measurement of torque is the Newton Metre (N.m), which is the level of torque resulting from the force of
one Newton at a distance of one metre. This approximates to just over 0.1 Kgf.m (kilogram force metre) and 0.7 lbf.ft (pound force foot or foot pound). For further information about Norbar products and services, contact: Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxfordshire OX16 1XJ Tel: 01295 270333 Email: sales@norbar.com
INDUSTRY NEWS
Reduce energy bills with steam system training 2011 Spirax Sarco training prospectus published Plan for steam system training in 2011 with the new Spirax Sarco training prospectus and learn new skills to cut costs and improve the efficiency of steam plant operations. An important new addition for 2011 is the Boiler Plant Regulations and Guidelines course (D8). This provides a broad overview of legislation, guidance and best practice for boiler operators and helps users, or potential users, to understand their legal obligations. Ever popular is Spirax Sarco’s Energy Savings course (E1). Delegates learn about energy saving opportunities in steam systems, how to estimate the energy requirements of a steam plant and how to calculate the payback period. The
application of these skills and energy saving ideas can make a significant impact on an organisation’s energy bills. Also included in the 2011 schedule is the Boiler Operation Accreditation Scheme (BOAS) Refresher course (D6AR). A prerequisite for all BOAS accredited personnel is to complete this refresher course every five years. The course will include the re-assessment examination and an oral interview. The new 2011 training brochure details the full range of courses covering the latest legislation and aspects of the design, operation and maintenance of steam systems. The depth and knowledge of Spirax Sarco’s lecturers ensures a high standard on all the courses, and all lecturers
are fully conversant with the day-to-day issues and practical aspects of steam systems and delegate roles.
Contact Spirax Sarco’s Training Coordinator Kim Mansfield, on: 01242 535211 or email: Training.Centre@uk.SpiraxSarco. com. For a free copy of the 2011 Training Brochure or to fill in a course registration form visit www. SpiraxSarco.com/uk/training.
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INDUSTRY NEWS
ELGA Process Water launches Hydrex eTrend Hydrex eTrend is the latest addition to the Hydrex family. The new service offered by ELGA Process Water, a Veolia Water Solutions & Technologies company, uses latest technology to track and trend plant performance online. Hydrex eTrend electronically records
parameters from cooling and boiler water treatment monitoring programs, allowing for easy data storage and instant access to the latest critical trends. Trend data is stored centrally and securely online and is reviewed by our chemical specialists. This provides an early opportunity to optimise system
performance and to make adjustments in dosing before the system goes out of specification. Additional information such as technical data sheets, site survey reports and certificates, confirming compliance with L8 guidelines and BS 2486, are also stored on the new and secure website. An advanced Hydrex eTrend+ version includes the trending equipment to allow customers to take more frequent readings in addition to the site visits from service engineers.
For more information: ELGA Process Water Marlow International, Parkway, Marlow, Bucks SL7 1YL UK Tel + 44 (0) 1628 897000 Email: sales.uk@veoliawater.com Web: www.elgaprocesswater.co.uk
New Super-Slim Power Supply from PULS UK Saves Space and Reduces Costs Leading manufacturer PULS UK has announced the launch of a new super-slim 24V 30W unit to complement its range of high efficiency DIN Rail power supplies.
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For more information:
The new MiniLine 30 measures a
Moore said, “The new ML30 is one of the
diminutive 22.5x75x91mm: 50% smaller
smallest 30W units on the market and
than PULS’s standard ML30 unit.
with over 89% efficiency it’s also one of
PULS claims efficiency of up to 89.4%
the greenest. Also, using our advanced
with full power operation available from
technology we’ve been able to reduce
a chilly -10°C up to a sizzling +60°C and
production costs without compromising
<0.4W no-load losses.
quality or reliability, so overall the MiniLine
The MiniLine 30’s small size is matched
30 is a very attractive option for our
by its price which is expected to be about
customers.”
30% lower than the standard unit.
First shipments of the new MiniLine 30 are
PULS UK’s Managing Director Harry
due in early January 2011
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January/February 2011
Ellie Jones PULS UK Ltd Unit 10 Ampthill Business Park Station Road Ampthill Bedfordshire MK45 2QW Tel: +44 (0) 330 999 9988 Fax: +44 (0) 1525 841291 Ellie.jones@puls.co.uk www.puls.co.uk
FLOW METERS
Flow meters with local display Bronkhorst offers their MASS-VIEW® thermal mass flow meters with ten preinstalled gases (Air, N2, O2, Ar, CO, CO2, N2O, CH4, C3H8, C4H10 ) eliminating the need to recalibrate. Furthermore the user can switch between
shows the flow unit, gas type, totalised
four flow ranges and adjust alarm and
flow and alarms. The flow meter can
counter settings via a user-friendly menu,
be equipped with a needle valve for
using the 4-way navigation button. The
flow control duties. Mechanical process
instruments are suitable for measuring
connections are fitted for straightforward
flow rates from 0.01 to 200 ln/min with
VA meter replacement. An analog output
MASS-VIEW instruments can be
high accuracies (<2%RD). MASS-VIEW
signal enables data logging; alternatively
features a local readout, indicating the
the instrument can communicate via RS-
ordered online:
actual gas flow, clearly visible from
232 or Modbus.
www.massflow-online.com.
virtually any angle. The display also
CORROSION MONITORING
BAC ENTERS TECHNOLOGY TRANSFER AGREEMENT Cathodic Protection (CP) market leaders, BAC Corrosion Control Ltd (BAC) of Telford, in the UK, is pleased to announce that they have entered into a Technology Transfer Agreement with BGB Projects Ltd (BGB), a well established company specialising in concrete condition monitoring systems. The products to be transferred will include all designs, software and intellectual property relating to the measurement of corrosion rate and associated parameters (corrosion potential, resistance, temperature and relative humidity) of steel reinforcement embedded in concrete.
existing facility at BAC’s premises in Telford.
The key products are linear polarisation resistance (LPR) probes, which are designed to be either tied into the steel reinforcement and cast into new concrete structures or retrofitted into existing structures. The range of probes and monitoring equipment will be developed and will be manufactured at the
Mr Tony Gerrard, Managing Director of BAC commented “BAC, being a progressive, forward looking company, is always aiming to become even more competitive throughout our product portfolio across the markets in which we operate. This agreement will undoubtedly allow us to
The ongoing development will be aided by corrosion and electronics expert Karel Hladky, as well as the BGB directors and well-known and respected consultants Kevin Davies and John Broomfield.
further our aims in the steel in concrete market and the potential is now there for us to tap into and win new project supply contracts as a result of this extension to our product and service portfolio”. Further information can be obtained from BAC Corrosion Control on: tel: +44 (0) 1952 290321 fax: +44 (0) 1952 290325 email: sales@bacgroup.com or the Website: www.bacgroup.com
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INDUSTRY NEWS
New handheld acoustic emissions monitoring device Schaeffler UK has extended its condition monitoring range of products and services to include a handheld acoustic emission monitoring device, the AE-Check. This device is ideal for monitoring the condition of slow rotating, variable speed and load machinery and components, including mixers, motors, pumps, fans, HVAC systems, bearings and helical gears. Whilst vibration monitoring is fine for high speed machinery, it is much less effective where components are rotating at less than 80rpm, operating under fluctuating load conditions, or only moving through a part revolution. Here, it is much more difficult to collect meaningful data using vibration monitoring. The AE-Check is a route mode acoustic emission monitoring device that is easy to
use and configure. The user can set up to six different routes through the factory, with up to 435 measuring points per route – ideal for patrol monitoring. The device comes with a standard acoustic sensor that simply connects to the handheld device.
Tel: 0121 313 5870 info.uk@schaeffler.com www.schaeffler.co.uk
Hansford Sensors introduce Sensor Modules for Industry For operation with their industrial accelerometers, Hansford Sensors Ltd. has introduced the new HS-556 and HS 557 Series of Sensor Modules.
Both the compact units are DIN rail mounted for easy mounting within industrial enclosures where multi-channel monitoring is required. Both units have internal 2 pole Butterworth filters and operate from a 24V DC supply provided by the additional HS-570 module. Hansford Sensors will be introducing further HS-500 modules in the near future
The HS-556 has been designed
to extend the scope of measurement,
to operate with Hansford industrial
alarm and control facilities.
accelerometers but will also accept inputs from other sensors operating on piezoelectric techniques. The compact unit provides outputs of 4-20mA output for velocity or ‘g’ signals together with a buffered accelerometer output with DC bias.
For more information, please contact:Suzanne Pearl Hansford Sensors Ltd. Tel:0845 680 1957 Fax:0845 680 1958
The HS-557 module offers an additional output, providing a 4-20mA for a temperature measurement range of 0 to 100°C sensed by either a PT100 or 10mV/°C temperature sensor.
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Email: suzanne.pearl@hansfordsensors.com Web: www.hansfordsensors.com
Non Contact Temperature Sensors
Measurement Specialties announces a new generation of thermopiles Thermopile sensors are widely used to detect infrared radiation for contactless temperature measurement. This very fast and precise temperature measurement method is especially suited to measure surface temperatures without thermal errors due to the sensor mass or to measure the temperature of moving parts. Based on 16 years of experience in development and production of thermopile components Measurement Specialties has launched two new thin film sensor chips for the latest thermopile generation in TO5 and TO18 housings. Besides a standard version which offers a good performance in terms of signal strength for all temperature measurement applications, a high end version with advanced signal strength is available. Components utilizing the high signal chip are meant to be used in applications with enhanced accuracy requirements, e.g. detectors with a narrow field of view or in NDIR gas analysis systems. These new components are used in a variety of IR-modules and IR-systems to provide temperature measurements or to detect presence or movement in almost every market segment. The devices are calibrated and provide digital or analog outputs. With in-house capability of design and manufacturing of all key parts Measurement Specialties has full flexibility to provide standard products or customized solutions.
How do you know if things are OK or not? Go and check them is the answer - but obviously you can’t do it all by yourself!
More information:
Measurement Specialties www.meas-spec.com
The answers are stored and uploaded to the included PC trending software that automatically flags up any warnings or alarms. It will even send out emails to anyone who needs to know!
The handheld Pocket Inspection unit is ultra rugged (waterproof and droppable) and has a high resolution colour display with both touchscreen and keypad entry
C-Cubed’s new
capability. The software is incredibly easy
Pocket Inspection
to use and set up. It comes with a set
system allows
of “pre-canned” inspections (e.g. fan inspection, pump inspection, etc) that
absolutely anybody
can easily be edited to create new user
to do it for you by
defined inspections or simply make up
simply answering a
your own. “Is the floor clean?”, “Are the lights working?” and so on….
list of user defined questions on a
Find out more at:
rugged handheld PC.
www.pocketvibra.com
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IR
Latest thermal imaging technology from Thermoteknix Cambridge–based British company Thermoteknix Systems Ltd have launched a new range of fully featured VisIR® thermal imaging cameras which offers the perfect Predictive Maintenance solution for both new and experienced thermographers. The range includes camera models to suit every budget and application and a wealth of powerful software options and other features: Budget entry-level thermal imager joins the Thermoteknix VisIR-P range… New VisIR 160-P camera is Thermoteknix Systems’ new entry-level thermal imager ideal for building inspection, energy audits, detecting electrical/mechanical faults and other anomalies. A fully featured robust, compact and simple to operate thermal imaging camera:
• • • • •
160x120 detector High resolution visible camera x2 zoom High capacity image storage High contrast tiltable touch screen
•
Laser pointer
•
IR/Visible image fusion technology
•
Extensive software options
•
Compact, rugged housing
The handy point and shoot VisIR 160-P model is ideal for a wide range of inspections including buildings, motors, bearings and electrical equipment. VisIR 160-P’s budget price now makes it achievable for electricians and other tradesmen to include it as an essential part of the toolbox. VisIR 320-P and VisIR 640-P The VisIR 320-P and VisIR 640-P are the maintenance professional’s choice of high resolution thermographic tool for detection, diagnosis and analysis:
• • • • • • • 18
High sensitivity 320x240 / 640x480 detector High resolution visible camera Live zoom to x8 Thermal/Visible, PiP, Fused display options High Contrast 5 inch 800x400 touch screen Bayonet fitting interchangeable lenses Articulated central optics pod
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January/February 2011
• • • •
Illuminator/Flash Laser Pointer Voice Recording Rugged IP54 polycarbonate housing
• •
High Speed USB – Real Time
The superior image quality of VisIR 320-P and VisIR 640-P make fault diagnosis faster and more reliable allowing you to cover the same tasks with less images in a fraction of the time. VisIR’s unique Condition RED® assetbased thermography database system guides the camera operator through surveys to ensure consistent, repeatable inspections. Reference images of each asset are displayed alongside the live image at every inspection point to ensure the correct equipment is being inspected. Condition RED then compares the asset’s current condition against its historical data to assess whether any action needs to be taken.
Above: Condition RED asset-based database system Working seamlessly with Condition RED, VisIR’s patented ThermAlign™ system saves operators time during inspections and gives image to image registration by overlaying a reference onto the live thermal image during repeat inspections. This results in consistent, repeatable inspections, even when performed by different thermographers and ensures that trending and comparisons are accurate and meaningful everytime. ThermAlign automatically sets the same tool and image parameters used during the previous inspections. VisIR 640 cameras work in conjunction with Thermoteknix’ PC based Condition RED software to produce a powerful asset based database, which travels with you to the job. All Thermoteknix products are developed, manufactured and supported from Thermoteknix’ global headquarters in Cambridge, England. For further information contact Thermoteknix:
Video Output
01223 204000
Unique ThermAlign™ image
www.thermoteknix.com
alignment technology
sales@thermoteknzix.com
CONDITION MONITORING
Condition Monitoring of Intermittent and Short Duration Machine Operations Today most engineers and maintenance personnel are familiar with the basic concepts of Condition Monitoring (CM) and are aware of the real benefits it can offer as an input into a Condition Based Maintenance strategy. In fact the Condition Monitoring of rotating machinery is commonplace in world class companies and has a proven ability to detect a wide range of problems in rotating machinery. For this reason established CM techniques and products such as those based on Acoustic Emission (AE) and Vibration Analysis (VA) play a key role in many organisations. The analysis of signals, whether from AE sensors or accelerometers, requires a sufficiently long period of machine running at constant speed so that a statistically meaningful signal characterisation can be made. This is easily achieved on machinery that is continuously running but is on the impossible side of difficult when it comes to machinery that operates only intermittently and for short durations. For example the algorithm used to derive the widely used AE parameters of DistressÂŽ & dB Level in the MHC range of products from Holroyd Instruments requires a 10 second period of running at an approximately constant speed. Similarly it would not be unusual for FFT based VA to require comparable or even longer measurement periods and tighter tolerances on speed variation. In those cases where a hand-held instrument is used to carry out periodic CM it may be possible to interrupt normal machine operation and put it into a special
continuously running mode for the duration of CM measurements. However such disruption is not always possible and is never convenient. Furthermore it is not compatible with the current trend towards CM automation which requires continuous on-line monitoring, with permanently installed sensors inputting CM data or status into SCADA systems or PLCâ&#x20AC;&#x2122;s. On the one hand therefore it is especially challenging to address the automated CM of intermittent and short duration machine operations. However on the other hand it is self-evident that those companies currently benefiting from automated CM on continuously rotating machinery would wish to extend these benefits to their intermittent and short duration machine operations. Examples of such machinery are numerous but include stacker cranes, elevators and indexing drives. Clearly the duration of operation is not the only challenge since their operation inevitably involves periods of run-up and slow-down and may include other effects such as brake and clutch actions. To address these issues it was clear to the Holroyd team that a radically different type of CM capability would be needed and it is this development that has led to the creation of the MHC-Sigma sensor (see photo). MHC-Sigma is an ultra smart CM sensor
which addresses the two key challenges of coping with short signal durations and the rejection of run-up and slow-down periods. Dynamic analysis of detected signal levels enables the sensor to recognise periods of run-up and slow-down and this allows periods of steady state running to be identified. The sensor, which has patent rights reserved, has a special algorithm built-into it which in effect stitches together periods of steady state running of as little as 500 msecs to enable a statistically significant measurement to be made. A typical example of the detected AE envelope waveform from the wheel bearing of a stacker crane as used in automated warehouses is shown in the accompanying figure. This also illustrates the principle of operation of the sensor which is as follows : A suitably set threshold level within the sensor (red dotted line) allows the recognition of machine start and stop. The sensor inhibits its signal processing until the end of the start-up delay. The sensor also ignores signals being processed during the slow-down reject period. Detected signals from the intervening periods (i.e. after the start up delay and before the slow down reject period) from multiple machine operations are processed in terms of DistressÂŽ and dB Level. Tests on both the bench and in the field have shown the effectiveness of this approach in successfully characterising the AE signals from intermittent operations when compared to the same machines operating continuously. The resultant signal characterisations are used as follows : Compared to internally set alarm criteria operating on an alarm status output (e.g. digital input to PLC or LED indicator). Logged internally as a 12 month trend history (e.g. download to PC when the sensor goes into alarm). Fed out as analogue signals for trending purposes (e.g. inputs to SCADA). In addition to monitoring machinery as discussed above, the sensor can be applied to monitoring partial rotations and sliding actions. It should therefore come as no surprise that there is a very broad interest in this new ultra smart sensor which once again illustrates the unique capabilities of Acoustic Emission monitoring as well as consolidating the Holroyd brand at the forefront in this technology. Prepared by : Dr Trevor Holroyd (Holroyd Instruments Limited) www.holroyd-instruments.com
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MAINTEC PREVIEW 2011
Equipment for minimum downtime easyFairs® MAINTEC 2011 gives industry professionals an efficient and highly effective opportunity to meet faceto-face with the sector’s most innovative people in one time efficient visit.
Now in it’s 36th year, easyFairs® MAINTEC attracts senior decision makers from across the spectrum of British processing and manufacturing industries. From automotive to food, and chemicals to utilities, they are looking to invest in maintenance solutions that will help their organisation to improve efficiency and asset performance. At easyFairs® MAINTEC you will discover products and technologies to:
• • • •
Ensure timely intervention to prevent faults and failures Boost plant performance and productivity Reduce CostsImprove safety Ensure environmental compliance
Why Visit? Maintenance skills and know-how are in great demand - but with the speed of technological change a forum is needed for maintenance professionals to discover new ideas and source latest technologies. At easyFairs® MAINTEC discover mechanical, electrical, hydraulic, pneumatic and electronic technologies enabling you to keep abreast of key maintenance developments.
technologies that help improve efficiency, reduce environmental damage and meet government regulations, so visiting the Lions’ Lair offers the perfect opportunity to ‘get up to speed’ with practical solutions. There will be no sign of Theo Paphitis or Peter Jones - instead, Graeme Coyne, Business Manager – IA&DT Service, Support & Training Development at Siemens, Paul Dennis, Technical Facilities Manager at Experian and Richard Wilkins, Centre of Excellence Business Process Owner – Maintenance from MARS will form the Lions’ Lair judging panel and will be casting their critical eye over an array of the most pioneering products put forward by four exhibiting companies. Here are the hopeful Exhibitors taking on the Lions:
VISITOR TESTIMONIALS “As far as technical exhibitions go, this one has to be up there with Europe’s best, from technician to maintenance management, vendor, or condition monitoring specialist, easyFairs Maintec in Birmingham will have something for everybody, it’s also a great chance to learn something new, catch up with similar minded people or even to register with an organisation that can affiliate and educate.” Frank Rawding, Loss Prevention Consultant
“Having recently opened the UK sales office of UWT Level Controls I was looking for an exhibition which would bring people from a wide range of industries together under the one roof. This was my first visit to the easyFairs Maintec and I was impressed with the way it attracted engineers, service personnel and decision makers all with the same goal of discovering new technologies within the maintenance field. The learnShops are a great idea and I gained some insight into the direction of current maintenance programs and more importantly what people want. I will be visiting again in the future.” Graeme Hughes, Sales Manager, UWT (UK) Limited
Flowcrete UK Ltd (stand B18). Product: ‘Floorgraphix’ Idhammar Systems (Stand C15). Product: ‘Andon Signalling and Business Alerts’ MACS Ltd (Stand E9). Product: ‘FAME’ (Facilty and Asset
“easyFairs Maintec 2010 was far better than I expected and I picked up several new contacts, will definitely be visiting next year.” – Stuart Graham, Managing Director, Aerosol Solutions Ltd
Management in one Environment) MAINTEC SOLUTIONS THROWN TO THE LIONS! The latest maintenance ideas will be pitched to industry expert ‘Lions’ at a Dragons’ Den-inspired contest that will be staged at easyFairs® MAINTEC show on the 29th31st March, NEC Birmingham. easyFairs® MAINTEC offers services and
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Siveco group (stand D17). Product: ‘M.tv’ The Lions’ Lair contest will be taking place on 30th March 2011 at 1pm, with all four companies competing. Only one company will be awarded with the Lions Lair Accolade, with results being announced later that afternoon.
“I found the event essential to provide an insight in to available technologies. Face to face interaction with suppliers is always essential to gain knowledge and receive feedback and solutions to a number of problems.” Russell Lamont, William Blythe Ltd
MAINTEC PREVIEW 2011
MAINTEC LEARN SHOPS 2011 Learn Shops 1
Learn Shops 2
29th MARCH
11:00 > 11:30
The Confusion Around Maintenance
11:00 > 11:30
Process Aligned Technical Fault Finding
11:45 > 12:15
Maintenance Strategy Development
11:45 > 12:15
Enhanced Diagnostics through Ultrasound
12:30 > 13:00
Ultrasound – Predictive Maintenance for the Masses
12:30 > 13:00
Understanding Condition Monitoring is as easy as ABC-Protecting key assets to achieve maximum plant efficiency
13:15 > 13:45
Keeping Hydraulics Reliable Mike Retford
13:15 > 13:45
Vibration Analysis
14:00 > 14:30
Case Study - Molnlyke Pharmaceuticals
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Learn Shops 1
30th MARCH
11:00 > 11:30
Improving the performance and efficiency of your equipment, and optimizing maintenance and asset management
Learn Shops 2
30th MARCH
11:00 > 11:30
Key Steps to Implementing ConditionBased Maintenance
11:45 > 12:15
Condition Monitoring of Machine Operations that are Intermittent and Short Duration
11:45 > 12:15
Health Insurance for your plant and machinery-”Prevention is better than cure!”
12:30 > 13:00
Understanding, diagnosing and correcting misalignment
12:30 > 13:00
Getting more for less - A guide to Innovative technologies for energy saving
13:00 > 14:00
LIONS’ LAIR
13:15 > 13:45
Business Transformation through Mobile
14:15 > 14:45
Maintaining Efficiency
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Learn Shops 1
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29th MARCH
31st MARCH
Learn Shops 2
31st MARCH
11:00 > 11:30
Breakthroughs in Food Grade Antimicrobial Lubricants and Greases
11:00 > 11:30
Condition Monitoring of Machine Operations that are Intermittent and Short Duration
11:45 > 12:15
New Generation Proactive Maintenance with Root Cause Analysis.
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12:30 > 13:00
Thermography and Infrared Camera Selection Paul Sacker
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MAINTEC PREVIEW 2011
MAINTEC 2011 Show Features LIONS’ LAIR
see the bravest exhibitors pitch their best products/ services to a panel of industry experts not afraid to speak their minds. For more infomation please visit the LIONS’ LAIR web page: http://www.easyfairs.com/events_216/ maintec-2011_11207/maintec_11208/visitors_11209/ new-lions-lair_20308/
The Leak Detection Challenge
see how quickly you can find the leaks in a compressed air system. Located on stand F4.
BCAS Advice Clinics
get expert advice from compressed air system professionals enabling you to make better qualified delcisions! Located on stand F4.
Health and Safety Surgery
discuss your company’s health and safety issues with Health and Safety Executives offering FREE expert advice. Located on stand A18.
PLUS... WIN £500
worth of health and safety training for your company on the RRC Stop The Hazard Game. Located on stand A18.
C.V. and Interview Clinics
Probe Technical Recruitment are this year providing walk-in clinics over the three days. There will also be a job board where the latest maintenance and engineering job positions are displayed! Located on stand F21.
MAINTEC 2011 SPEAKERS Grant Bailey Sales and Marketing Director Thermal Energy International - suppliers of the GEM Product
Andy Bates - Artesis Improving the performance and efficiency of your equipment, and optimizing maintenance and asset management The capability of systems that simply measure voltage and current drawn by the motor. This will describe the technology, the theory and the practice, drawing on case studies of real examples.
Greg Bordiak BCAS Technical Officer British Compressed Air Society Ltd Maintaining Efficiency
John Cliff Petro-Canada Lubricants Breakthroughs in Food Grade Antimicrobial Lubricants and Greases
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MAINTEC PREVIEW 2011 John Dacey - Technical Training and Development Adviser Midland Group Training Service Ltd Process Aligned Technical Fault Finding Developing a systematic approach, Benchmarking Performance,Applied Techniques,Reducing Downtime, Reducing stores inventory. We are going to be talking about some quite specialist Maintenance skills
Geoff Dyson - Panasonic EU Business Transformation through Mobile Working
Alan France - OEE Expert - Idhammar Systems Case Study - Molnlyke Pharmaceuticals
Len Gelman - Chairman of Condition Monitoring Technical Committee - British Institute of NDT New Generation Proactive Maintenance with Root Cause Analysis.
Trevor J Holroyd - Holoryd Instruments Limited Condition Monitoring of Machine Operations that are Intermittent and Short Duration
Stan Jackson - Managing Director - SPM Instruments The Confusion Around Maintenance
Simon Mills - Training Services Director - AV Technology Ltd Key Steps to Implementing Condition-Based Maintenance
Gary Mohr - UE Systems - Alpine Components Enhanced Diagnostics through Ultrasound Imaging: How it helps identify problems in electric and mechanical equipment This presentation will examine ultrasound imaging for electrical, mechanical and valve leak diagnostics. The principles of spectral analysis as it relates to ultrasound inspection will be explained
Paul Moxham - Petro-Canada Lubricants Breakthroughs in Food Grade Antimicrobial Lubricants and Greases
Tom Murphy - Director - Reliability Team Ultrasound â&#x20AC;&#x201C; Predictive Maintenance for the Masses
Jit Patel - Technical Sales Manager - Fluke UK Ltd Vibration Analysis
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MAINTEC PREVIEW 2011 Ian Pledger - F’IS Field Service Engineer - Schaffler Health Insurance for your plant and machinery-”Prevention is better than cure!”
Mike Retford - Sales & Engineering Director MGR Fluid Power Ltd
Venue - The NEC Birmingham, England B40 1NT Tel: +44 (0) 121 780 4141 Web: www.thenec.co.uk
BY ROAD
Keeping Hydraulics Reliable
Jim Ross - Petro-Canada Lubricants
Birmingham is at the hub of the UK
Breakthroughs in Food Grade Antimicrobial Lubricants and Greases
motorway network, enabling visitors to travel directly from the M6, M1, M40 and M42. The NEC has its own on-site car parks while
Paul Sacker - Crimson Industrial Vision Thermography and Infrared Camera Selection
the city-centre venues are served by a car park at The NIA and others in the immediate vicinity.
BY RAIL Ian Taylor - Director - Schaffler
The NEC and The NEC Arena are served by
Understanding Condition Monitoring is as easy as ABC-Protecting key assets to achieve maximum plant efficiency
Birmingham International station, connected by a covered bridgelink. London is only 90 minutes away and trains also run direct to
Geoff Walker - Director - Artesis
many regional towns and cities.
Maintenance Strategy Development
BY AIR More than 20 international airlines serve
Dean Whittle - Managing Director Reliability Maintenance Solutions Ltd Understanding, diagnosing and correcting misalignment Misalignment is very common in industry, even where dial indicators and laser alignment systems are utilized. This presentation will begin by explaining why misalignment is so common
• • • • • •
Maintenance or asset engineer/ manager Production, works, manufacturing and technical Engineering manager, chief and senior engineer Buildings/facilities//estates engineer/ manager Development/ design, projects, electrical, electronics,plant, services engineer/manager Chairman/ MD/partner
conveniently situated a few minutes from The NEC. Together they provide scheduled flights from 34 destinations in the UK, Europe and North America. The NEC is also easily accessible from London Heathrow, London Gatwick and other regional airports.
Who visits? The cream of British industrial maintenance The easyFairs® MAINTEC visitor list consists of highly qualified engineering decision makers, representing British manufacturing and process industries, together with public sector, plant and asset management organisations. Here are some typical job titles from last year’s show:
Birmingham International Airport, which is
They are drawn from the following industry sectors:
Accommodation The NEC Group Birmingham Hotels and Accommodation Directory offers the widest possible selection of hotels, guesthouses and bed and breakfast accommodation
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Food & drink
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Petro-chemical
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Pharmaceutical
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Automotive
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Aerospace
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Consumer electronics
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Utilities (water & energy)
entertainment in the area are
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Railways / transport /
available at:
logistics
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Public sector
within easy reach of the NEC and Birmingham International Airport.
Further details, together with information about restaurants, pubs and clubs and
www.necgroup.co.uk/visitor/ directory/hotels/
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MAINTEC PREVIEW 2011
Stand no: E3 FLIR is the world’s largest commercial infrared company. Its R&D spend each year is rarely short of 10% and uniquely it focuses on the continuous and parallel development of both infrared camera hardware and application-specific analysis and reporting software. This is a powerful and highly effective combination. Given its commitment to R&D, upgrades and enhancements are frequently released by the company and naturally the latest generation of all its predictive maintenance infrared cameras will be at this premier event. A typical example is the increased thermal sensitivity of the FLIR P640 and P660 models for expert thermographers. These cameras are now able to detect
temperature differences as small as 0.03°C which equates to a thermal sensitivity of 30mk, a rating that is more common among infrared cameras used for research and development. The benefit of course is that the thermographer can see the smallest thermal anomaly in electrical or mechanical installations. This improvement also allows the infrared camera to be used effectively over a greater distance, a boon for those
involved in high voltage applications. FLIR’s latest cameras also incorporate new features such as IR window correction which automatically adjusts the camera’s sensitivity when inspecting high voltage installation through safety IR windows. Contrast optimisation is another new and unique enhancement. Previously only found in advanced military image processing technology, it automatically optimises the brightness and contrast of an image, making it easier to analyse detailed objects. Applications for a general purpose infrared camera can now also include research and development tasks. This is possible as features that were once solely the preserve of the most expensive cameras are starting to be incorporated into less sophisticated models. For example, image streaming is now available in mid-range cameras. This means, for example, the user can watch a process at start-up and acquire radiometric data at a reasonable speed. In other words a predictive maintenance camera can also be used for some research tasks. Periodic storage is another example. This allows snapshots to be taken at predetermined intervals allowing the camera to act as a watchman for a variety of applications. FLIR infrared has phenomenal application scope and consistently delivers quick return on investment. The company also has broadest range of thermal camera choices on the market to ensure that there is a model to suit every need and budget. See us at MAINTEC 29-31st March 2011, NEC Birmingham, Stand E3” Tel: +44 (0)1732 220011
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MAINTEC PREVIEW 2011
Optris PI - The most portable infrared camera
The optris PI allows measurements from -20 to 900°C with USB 2.0 interface for real time thermography and infrared video recording with a 120 Hz frame rate. It has a very small, water proof and rugged camera sensing head with exchangeable optics of 23°, 6° and 48°. With dimensions of 45 mm x 45 mm x 62 mm and a weight of 250g it fits in narrow spaces, ideal for the use inside machines and test stations. The extensive software package optris PI connect includes a recording function for radiometric videos, snapshots, analysis and post processing of images or videos and a line scan mode.
Fluke introduces new 4-channel ScopeMeters Fluke has introduced two new models, the Fluke 190204 and the Fluke 190-104, to its highly successful range of rugged, handheld portable oscilloscopes.
The new Fluke 190 Series II Colour ScopeMeter® offers 4 channels, designed for the industrial plant maintenance professional servicing, installing and maintaining heavy duty electrical equipment, electro-mechanical machinery and plant automation control systems. They are the first IEC 61010, 1000V CAT III / 600V CAT IV rated portable oscilloscopes designed to be safely used on industrial equipment that is permanently installed on an electrical distribution system. The Fluke 190-204 offers a bandwidth up to 200MHz, while the Fluke 190-104 offers up to 100MHz.
For more information about the whole Fluke ScopeMeter range and other Fluke products, visit www.fluke.co.uk
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INDUSTRY NEWS
COOL FILTRATION SYSTEM Bollfilter installs automatic filter at National Oceanography Centre as part of unique Seawater Cooling System. The National Oceanography Centre, Southampton is the integrated collaboration between the Southampton-based part of the Natural Environment Research Council’s National Oceanography Centre and the University of Southampton’s School of Ocean and Earth Science, at the Waterfront Campus in the docks. One of the world’s top five oceanographic research institutions, NOCS is home to some 520 research scientists, lecturing support and seagoing staff as well as over 700 undergraduate and postgraduate students. NOCS has taken advantage of its dockside location to help reduce energy consumption by means of a unique seawater cooling system (SWC). The cooling system – which is the only one of its kind in the UK – utilises seawater during the winter months to indirectly cool the building via a heat exchanger. The Centre has several
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laboratories and cold stores that require cooling even in winter. The SWC uses raw seawater taken from the dock. A Bollfilter 6.18 automatic self cleaning filter has been fitted prior to the heat exchanger. This operates continually to remove marine detritus, such as seaweed, from the water and helps maintain the efficiency of the system. Although the filter is designed to operate with minimal maintenance, Bollfilter provided on-site training for NOCS’s engineering staff to allow in-house adjustment and cleaning if necessary. Candice Snelling, NOCS Environment & Energy Advisor noted that “The system will reduce annual electricity demand by approximately 5% per year, saving an estimated 117 tonnes in carbon dioxide emissions a year. It also helps maintain a comfortable environment for our staff and students.”
For more information about Bollfilter Filtration Systems for Building Services applications, please contact: Terry Watts Sales Co-ordinator Bollfilter UK Ltd Unit 9 Station Road Tolleshunt D’arcy Essex CM9 8TY Tel: 01621 862180, Fax: 01621 869257 E-mail: sales@bollfilter.co.uk web: www.bollfilter.co.uk
DATA LOGGERS
Grant targets industrial market with dataTaker DT82i data logger The dataTaker DT82i is a low cost but sophisticated data logger designed for a wide variety of industrial applications CAMBRIDGE, England, January 17, 2011 Grant Instruments (www.grant.co.uk), a worldwide developer and supplier of data acquisition, scientific and life sciences products, has introduced the dataTaker DT82i, a low cost but sophisticated data logger designed for a wide variety of general industrial applications. These include R&D, process or energy monitoring, fault identification, machine down time and vehicle testing. Based on the highly successful DT80 range of data loggers, the DT82i is an
intelligent, robust, stand alone, low power and extremely cost-effective data logger featuring 2 analogue input channels, 4 digital inputs and 4 low speed counters. The unit supports temperature, voltage, current, 4-20mA loops, resistance, bridges, strain gauges and frequency measurements. The DT82iâ&#x20AC;&#x2122;s Dual Channel Isolation Technology allows up to 4 isolated or 6 common referenced analogue inputs. The DT82i also supports Modbus sensors and SCADA systems, features switchable 12V and 5V regulated outputs to power
sensors, and has extensive communications capabilities including RS232 and Ethernet. The DT82i has a built-in web interface called dEX which allows users to configure the unit, access logged data and see current measurements as mimics or in a list using a web browser. With dEX, no special PC software is required as the software loads in the web browser so there is no need for users to load cumbersome applications on their computer. The DT82i can store up to 10 million data points in a secure, non-volatile internal 128MB memory with user control available for multiple data files, overwrite modes, alarm histories and automatically archived event records. The unit also features USB memory stick support for easy data and programme transfer. The dataTaker DT82i is the latest in a range of data acquisition products on offer from Grant Instruments designed to satisfy the most demanding data collection requirements across industrial, scientific, R&D and environmental applications. The Grant data acquisition product range extends from high specification, portable data logging systems (Squirrel family) through to fully integrated customconfigurable acquisition and control systems (dataTaker family), while Eltek, the Cambridge-based Grant affiliate, produces Squirrel variants primarily for remote logging. All products come with a 3 year warranty. OEM versions of most products are available on request.
For more information about Grant Instrumentsâ&#x20AC;&#x2122; wide range of data acquisition products, please visit:
www.grant.co.uk. Alternatively, telephone: +44 (0) 1763 260811 or email: acquisitionsales@grant.co.uk
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WATER PROOFING
Belzona Boat Race Kick Starts 2011 On Thursday 6th January 2011, leading protective coating and polymer repair composite solution provider Belzona Polymerics demonstrated the outstanding performance of their waterproofing products. Belzona Polymerics displayed their confidence by coating a ‘Belzona Cardboard Boat’ in their water based, weather proofing products and despite the wintery conditions set it a sail across the lake at Ripley Castle, Harrogate. Belzona’s highly trained engineers designed
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and created the ‘Belzona Cardboard Boat’ to prove that the water based roofing membrane was completely waterproof and would not breakdown under immersion in water. The frame was built using cardboard boxes; the joints were then bandaged over using Belzona SuperWrap resins and reinforcing sheet to give the boat some rigidity. The boat was then fully coated using Belzona 3111 (Flexible Membrane), a solvent free microporous coating primarily used for the long term repair and protection of all types of roofs. The ‘Belzona Cardboard Boat’ successfully sailed across the lake leaving its competitor (an uncoated replica) to completely collapse and sink to the bed of the lake. The Belzona water based products were selected to demonstrate the products versatility and ability to resist water whilst offering a ‘breathable’ coating. The system
is not only suitable for use on pitched and sloped roofs but is also effective on roofs subject to ponding. Belzona is not just a product manufacturer but can provide a complete supply and apply package through its contracting network specifically created to provide clients with direct access to Belzona quality products, specialist application services, inspection services and supervision from a single source. It is Belzona’s mission to meet specialist repair and maintenance needs in its target industries and markets worldwide.
Belzona Polymerics Limited Telephone: 01423 567641 Website: www.belzona.co.uk
INDUSTRY NEWS
NEW REMOTE FROM HBCradiomatic KEEPS EQUIPMENT OPERATORS ON THE MOVE New from leading industrial remote control manufacturer HBC-radiomatic is a multi-equipment remote that offers operators maximum mobility and safety. Wireless technology means that the keynote can be used to operate a wide range of equipment remotely without the need for pendant cables or static control panels. The hand-held device is robustly designed with 12-one-step buttons sized and spaced to enable use while wearing safety gloves. It offers complete freedom of movement which greatly improves safety and with an instant ‘stop’ impact button, operators can react immediately in emergency situations. The keynote offers a complete package of features and functions, including a
transmitter that allows the output of 21 single-step commands and comes complete with radiomatic iLOG which enables the quick activation of a spare transmitter in the event of an out of action radio control. Keynote operates with a wide range of HBC’s radio receivers and is suited for applications with AC or DC power supply. It is compatible with interfaces such as CANBus, Profibus-DP, RS232 and RS 485 and it operates on a wide range of frequencies. Other features include a re-chargeable
NiMH battery which has 30 hours of continuous operating time and can be changed in a matter of seconds without any effect on memory. LEDs indicate operation, battery status, feedback information and warning messages. An extended range of functions is available via bank switch to a second control level with LED showing the selected control level. Complete with battery, the keynote weighs just 360g (0.8lb) and its casing incorporates a belt clip for convenience. The keynote is available from HBCradiomatic UK, the newly established UK division of one of the world’s leading manufacturers and suppliers of radio controls for industrial applications.
Hydratight Takes NASA to Great Heights HYDRATIGHT engineers have helped NASA’s rocket launches fly straight and true. Machining services specialists at Hydratight were asked to help prepare launch facilities for NASA operations. Technicians were asked to undertake critical milling and boringwork to keep two giant launch pads precisely horizontal — to tolerances of no
more than 0.015in across six mounting points. A laser system was deployed to maintain the exact level across the pads, with the final level being achieved through highprecision milling.
In all, 19 field technicians employed seven DL Ricci milling machines, heat-treating equipment and a line-boring machine for three weeks to complete the work — within the precise NASA specification. “When you are dealing with such massive structures involving objects with huge potential for destruction if things go wrong, you have to be ultra-precise,” said Hydratight’s southeast regional sales leader, Rick Neurohr. “Our technicians are used to working with that kind of precision, so we were very proud to assist.” Visit: www.hydratight.com
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INDUSTRY NEWS
Nederman Reduce ‘TCO’ Nederman has reduced prices across the board on service and spare parts to further improve value for customers purchasing their systems.
Nederman’s UK projects division not only offers upfront design and commissioning support but also service contracts, extended warranty, COSHH certification and national fast response service and breakdown cover through an in-house aftersales team. The reduction in service part pricing, combined with a service contract, can help save money, offer budget transparency and provide a true one stop shop the company claim.
The reductions, typically as high as 20%, come with advice to those looking at investing in extraction systems, industrial filtration or other Nederman solutions to evaluate ‘Total Cost of Ownership’ (TCO) alongside purchase price. “Nederman quality means we’re seen as a top end solution provider,” said Mark Hodgens, Managing Director of Nederman Ltd. “But excellent reliability and expert UK aftersales support means overall cost of ownership is extremely competitive too.”
Further information is at: www.nederman.co.uk or telephone Nederman on: 08452 743434
SENTRY G3 - ONLINE MACHINE MONITORING WITH ROBUSTNESS The established Sentry G3 machinery protection monitor is a high performance signal conditioning unit with a universal sensor interface developed by condition monitoring specialists SENSONICS. The latest Sentry G3 systems encompass vibration, position and speed measurements, the hardware fault tolerance of which has recently been independently verified through a recent study. Channel hardware independence is important for machinery protection applications where a failure of any hardware assembly should have a minimal effect on the overall system measurement integrity and in this respect Sentry G3 offers the ‘best-in-class’. The four channel G3 module has been specifically designed with an independent digital signal processor (DSP) for each channel of measurement. The DSP can be loaded with the specific measurement algorithm which not only controls the sensor selection, but also the protection relay status and analogue output levels. This provides complete hardware autonomy from sensor through to the protection relay combined with high channel density (24
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channels in a 3U format). The rack based system operates on a dual +24V power supply backplane which can be connected externally or derived from the optional G3 dual redundant rack based power supplies. When a high integrity protection function is required, the IEC61508 international standard for functional safety can be applied to ensure that sufficient integrity is designed into the electrical / electronic systems employed for the safety function. A failure mode and effects analysis is carried out on the overall measurement control loop, from sensor to shutdown actuator. This determines not only the Mean Time between Failure (MTBF) of the protection equipment but also the diagnostic coverage and the safe failure fraction (SFF). The diagnostic coverage illustrates the percentage of failure modes of the equipment that are detectable from an operator perspective and the SFF determines the percentage of failures which result in a safe process condition.
All these factors, in combination with protection system channel redundancy, are used to calculate the overall SIL (Safety Integrity Level). A recent SIL analysis has demonstrated a single Sentry G3 measurement channel is suitable for use in a SIL-2 low demand safety function and when combined in a suitable voted redundant channel arrangement the system could be utilised for SIL-3 applications. Sentry G3 provides state-of-the-art protection for vibration, position and speed measurements, turbine specialist algorithms to cover shaft eccentricity and large differential expansion measurements are also included within the equipment scope. Further details on Sentry G3: Tel: +44 (0) 1442 876833. Fax: +44 (0) 1442 876477 Email: sales@sensonics.co.uk www.sensonics.co.uk
NEW CDA REFRIGERANT AIR DRYERS FROM HI-LINE A new range of refrigerant air dryers has been introduced by Hi-line Industries Ltd. This is their CDA (Clean Dry Air) range which provides air that has been filtered and dehumidified to remove both particulates and moisture for safe use in pneumatic devices or systems. Rather than being manufactured to meet a commercial capital cost, these products have been designed for reliability, coupled with economic cost of ownership. Nevertheless, these products
are claimed to represent the best value money for comparable units currently available in the UK. Any non-essential lights or electronic circuitry have been eliminated to minimise the potential ‘weakest links’ which are common in most budget dryer ranges. A range of 15 standard models offering flow rates from 21 to 775 cfm are currently available ex-stock, with larger dryers up to 9680 cfm capacity manufactured to
INDUSTRY NEWS order on short delivery. All products offer performance in accordance with ISO 7183. The dewpoint is displayed directly from the refrigerant circuit via a manometer which indicates both dewpoint and pressure as exact, real time readings. Operating pressures from 2 to 16 barg can be accommodated, with a maximum inlet air temperature of 55°C. The standard ambient temperature range is 0° to 43°C with a 47°C option also available. A full range of high performance oil and particle removal filters are also available to suit the full range of dryers. Approved R134a or R404a refrigerants are used throughout, with the ex-stock dryers operating off a 230v single phase 50-60Hz power supply. Connections range from 1/2” BSP up to an 8” flanged outlet over the range. All these high quality dryers, which are available in a standard finish of compressed air blue (RAL 5015), are also fitted with HTD autodrains, with a ball valve strainer for protection. High pressure and thermal mass dryers are also available to order, with nationwide back-up and service support by our own engineers also available for the full range of Hi-line products. For More information:
Typical examples of the new CDA range of refrigerant air dryers available ex-stock from Hi-line Industries Ltd
Telephone: 01283 533377 Email: enquiries@hilineindustries.com Website: www.hilineindustries.com
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ENERGY & WASTE MANAGEMENT
shentongroup LAUNCHES DUAL FUEL WASTE TO ENERGY SYSTEM
compared to single-fuel solutions. Duplo reduces engine wear and produces far lower emissions than a normal diesel only system and has an enhanced ability to cope with variations in gas quality and pressure. An option to provide hot water via
Pioneering, power solutions
the Hexpac™ heat exchanger at the
company, shentongroup, is
turns Duplo into a combined heat &
launching a state-of-the-art dual
the option of an integrated approach
fuel waste to energy system called Duplo™.
same time as generating electricity power (CHP) system. This provides commercial or industrial premises with to delivering both prime power and hot water. Duplo can also be fitted with control system that enables any excess electricity to be exported to the National Grid. This lets users take advantage of the Feed in Tariff Scheme
As well as being a prime power
Biodiesel, Natural Gas, Biogas or a
(FITS), which pays businesses to
source, Duplo™ can also provide hot
combination of any of these using
generate their own electricity from
water via an optional heat exchanger
the very latest dual fuel technology.
renewable or low carbon sources.
and be fitted with a control system
Having multiple fuel sources not only
The scheme guarantees a minimum
that enables excess electricity to be
significantly improves the generator’s
payment for all electricity generated
exported to the National Grid.
resilience for continuous operation but
by renewable sources as well as a
Duplo runs on standard Diesel,
also appreciably reduces running costs
separate payment for any electricity exported to the grid. Duplo is suitable for any commercial or industrial site with insufficient or no mains power. Systems are available in a wide range of sizes from 50kwe up to 2Mwe and more if require. Smaller Duplo systems are modular, fully integrated systems assembled into ISO containers for increased flexibility and ease of use. All Duplo systems are supported by shentongroup’s Infinium™ service and maintenance programme. This is a perpetual renewal, maintenance and warranty programme that provides for fixed cost on site service and
shentongroup, is launching a state-of-the-art dual fuel waste to energy system called Duplo™
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maintenance for the working life of the system (excluding fuel).
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PUMPS & VALVES
SCA Hygiene achieves payback three times over within six months Spirax SafeBloc™ Double Block and Bleed valves have helped SCA Hygiene in Prudhoe, in Northumberland, to eliminate unscheduled boiler shutdowns costing up to £20,000 each in lost production. SCA Hygiene runs a 24/7 process, producing branded tissue. It is the company’s practice to only carry out maintenance work on a live steam system behind double block and bleed isolation. The company frequently suffered minor problems with blocked level gauge glasses on its boilers. However, because only single isolation valves were fitted to the gauge glasses, the boiler had to be shut down and depressurised to enable maintenance engineers to fix the problem safely, halving production output for up to 10 hours. “We replaced the existing single isolation valves with four SafeBloc valves on each of our boilers, so that any future maintenance work on our gauge levels can be done without having to shut down a boiler, enabling us to maintain production,” explains Mr. Neil Carroll, Area Engineering Leader at SCA Hygiene, Prudhoe Mill. “Previously a boiler shutdown could cost us up to £20,000 in production downtime. The last four valves paid for themselves three times over within the first six months.” Double block and bleed (DBB) is the industry’s best practice for double isolation for safe maintenance without having to shut down the entire system. Double isolation is achieved by closing two isolation valves, with the intermediate bleed valve being left open to provide a sealing integrity check to ensure the downstream pipeline remains safely isolated during maintenance work. The innovative, patented design of Spirax SafeBloc incorporates two isolation valves and a bleed port in a compact assembly, making it easy to install into the space left by an existing single isolation valve. No other commercially available product provides double block and bleed isolation in such an integrated, compact unit. This was one of the main advantages for SCA Hygiene: “Spirax SafeBloc is basically two valves with a bleed port in the space left by one valve, giving it the face-to-face
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dimensions of a single valve.” Mr. Carroll continues, “We would never have been able to install a DBB system in the past as other designs take up too much space,
often sticking two to three feet out from the boiler.” An added advantage of Spirax SafeBloc is that a retrofit can be undertaken quickly, eliminating the time-consuming and expensive pipe cutting, welding and pressure testing needed to engineer a conventional double block and bleed arrangement from separate isolation and bleed valves. This high quality, UK manufactured and easy-to-fit unit is robust enough for industrial environments. It uses proven technology from the Spirax Sarco range of bellows sealed globe valves that offer zero gland leakage, while ensuring tight shut-off conforming to DIN 3230 BO1 and ISO 5208 Rate A specifications.
OEE
OEE Basics I gave a 3 hour workshop on OEE to a mixed audience last week; most people know quite a bit about the measure, but are often surprised when they spend just a small amount of time thinking through the different ways that OEE can be applied. I guess it’s the same with continuous improvement - performance can go up, but only if we spend enough time on properly examining the losses, and making the actual improvements. So here is a little theory, with an exercise, and answers at the end. (Don’t be tempted to read those first, that’s as bad as fixing the OEE score!) The basics are easy, we take availability, a performance rate, and a quality value, multiply them together, and that’s the OEE score. Here are the calculations:
The important point to remember is that only availability is a measure of time, the others are both measures of quantity. If 60 minutes of performance is lost because the operator kept slowing down a single asset due to a build up of heat; that information is the reason for the performance loss, not part of the calculation. We have to consider, if we ran slowly for an hour, did we operate at 5% speed for the first 5 minutes, then 15% for 10 minutes, then 50% for 15 minutes and so on, or did we speed up and down constantly for the entire hour. We could calculate the varying speed with a real-time speed signal, but the OEE calculation means if we have made 750 units, but should have made 1,000 in the time, the performance measure is 75% The reason for slow running is still valuable information, it’s just not part of the OEE calculation.
An Example We lose an hour on a changeover and a further hour on a breakdown. The important value is the target performance (3,600). The calculation is not 200 units times 20 hours, it has to be the 200 units times the actual run time (18 hours) making the 3,600. The rest of the calculation needs little comment.
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Alan France, Operations Director of Idhammar Systems, has extensive experience in lean manufacturing with a background that includes several years as Engineering Systems Manager for the largest food company in Europe. A systems specialist, he now consults on the importance of underpinning lean initiatives with realistic targets and sound metrics. Contact him by e-mail: alan.france@ idhammarsystems.com or visit: www.idhammarsystems.com for more on CMMS and OEE software.
OEE
What’s the difference between a Performance and Availability Loss? If we have two filling machines feeding a single tray packer, and the tray machine stops and the line stops - we lose availability. However, if one of the two fillers stops but the other can continue to produce, we lose 50% of our performance capability. Of course, we do lose 100% of the availability for the broken filler, but OEE for the line remains at 50%. In this case the first example shows a 30 minute breakdown, but then perfect performance. The second shows no breakdowns, but an hour of slow running, where we only make half the quantity expected. In either case the OEE remains at 50%. The difference between choosing availability or performance does not affect the OEE score, but the reasons for choosing are important in deciding how to resolve the losses.
What about the difference between Planned and Unplanned? It’s important to remember that all events classed as planned will be excluded from the OEE score. That means to calculate a true OEE value only periods of no sales, or times when the plant is not crewed for production should be regarded as planned. Other events, such as product changeovers might be planned to take place at 3pm but should always be treated as an unplanned opportunity for improvement. The reason is simple; let’s say the Dead Duck Corporation produces products across three shifts, but loses an hour in every eight hours on changeovers. What if a new company - the Yumimoto Duck Corporation - opens a new plant
next door? They invest in state of the art equipment with a ‘magic’ sensor on the first conveyor. As this sensor ‘sees’ a different product shape travelling down the line it automatically changes the line equipment to this new product. No changeover is lost. The Dead Duck Corporation loses more than 1,000 hours per year on changeovers whilst Yumimoto gains that time for extra production. Viewing ‘changeovers’ as planned events will limit your opportunity for improvement; consider them unplanned and work hard to make them slicker and quicker.
What about the difference between Utilisation and OEE? ‘Utilisation’ is a very different measure to the OEE calculation. OEE is an exceptional measure for the factory operations team to help them view true performance and begin the loss management process. Utilisation is a measure of the whole operation to see how well have it has ‘worked assets.’ For example, let’s say an operation is not crewed to produce over an extended weekend break, say for 68 hours. Calculating Utilisation in this example, you can see the availability has gone up; we still had the same amount of breakdowns but in theory the plant was now available over the weekend, although we had not crewed to operate. The performance has dropped way down to 43% because we only made 64,325 products in 151 hours when we should really have made 151,000 units. The key issue is that the difference between the 63% OEE and 38% Utilisation figures is that utilisation cannot be controlled by the factory operations. So it’s a good measure for the whole operation, including the sales department, but not a good measure for factory staff and continuous improvement teams.
A Short Exercise... Here is a quick exercise. Fill in the A, P, Q and calculate the OEE Values. Good luck. If you need a hand or get stuck, please feel to contact me. Answers: Availability = 83/100 hours making 83% Performance = 64,325 / 83,000 units, making 78% Quality = 63,000 / 64,325 units, making 98% OEE = 63% Two possible errors: Including the Planned Safety Briefing as a loss - that’s a trap. It should be excluded from the calculation. Making the target quantity 100,000 units instead of (1,000 units times 83 hours) 83,000 units. I did include an awful lot of clues!
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CMMS
Brembo choose Carl Software to break new barriers in production. THE BREMBO GROUP Brembo is a world leader in the design, development and production of braking systems and components for cars, motorbikes, industrial vehicles and machinery, for the OE market, aftermarket and racing. The Group has recently branched out into the design and production of passive safety systems. Brembo guarantees the utmost safety and comfort and improved product performance thanks to process integration and optimisation of the entire production cycle, from the initial design and castiron or aluminium casting to assembly, testing and simulations on the bench, track and road. Brembo’s constant quest for innovation calls for new technologies, new materials, new shapes and new markets; product performance is accompanied by the search for a unique style in line with the design of the equipped vehicles. Research at Brembo is conducted at the Research & Development Centre, which has also been involved since 2002 in mechatronics, a border science that combines mechanics, electronics and
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informatics. The increasing application of ecocompatible technologies, recycling of all materials used in the production process and systematic prevention of all forms of pollution all bear witness to Brembo’s commitment to safeguarding the environment. For Brembo the workforce is considered an invaluable asset, providing the thrust and drive that lead to any breakthrough – Brembo works as one great team. Brembo sells its products in 70 different countries and has production sites in Italy, Poland, Slovakia, Spain, Great Britain, Germany, Brazil, the USA, Mexico, China, Japan and India. The products are marketed by companies located in the main outlet markets, with headquarters in Great Britain, Sweden, France, the USA and Japan. The Group has over 5,400 collaborators, close on 10% of whom are engineers and
product specialists involved in research and development. In 2009 the Group’s turnover is 825,9 million euros. Brembo have long been advocates of preventive maintenance Within the foundry 60% of works are anticipated and planned. The maintenance department performs 35% of corrective maintenance on the equipment and 5%of other works are performed by predictive maintenance. As purveyors of maintenance and asset management Brembo are always looking to achieve further gains through maintenance procedures. In 2008 the maintenance team from Brembo Italy visited one of the European maintenance exhibitions where they met the Carl Software Team. Brembo were looking to introduce standardisation for the maintenance department and confirm best practices and optimisation of the management of spare parts and inventory. In addition the team were looking for a target inventory cost reduction of 10% of the total value of the car unit’s spare parts stock. Brembo conducted an in depth study of the CMMS products available and further to the study chose Carl Software as the best tool for their requirements. On implementation the software soon integrated the control and supervision of the production processes and is now set to dramatically reduce costs. A new EAM / CMMS generation
“Brembo conducted an in depth study of the CMMS products available and further to the study chose Carl Software as the best tool for their requirements.”
MORE ON NEXT PAGE
CMMS
Building on 25 years of experience in asset management and maintenance management systems, CARL Source is CARL Software’s most recent application. Available since the start of 2008, CARL Source has been completely overhauled to suit today’s new maintenance and asset management requirements.
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A solution tailored to your organisation In addition to conventional maintenance management, CARL Source aims to take care of all financial, technical, regulatory, quality or property processes related to your company’s assets. For this reason CARL Source is tailored to the specific needs of your industry and the scale of your company. CARL Source is available in a number of industry-specific versions: Factory: production equipment, handling equipment, special or technical equipment (meters, measuring or controlling devices, research centre, etc.). As well as industry-specific versions, CARL Source offers 4 configuration levels: Smart, Expert, Enterprise and Corporate: The Smart version puts the emphasis on ease of use, speedy deployments and is very competitively priced. The Expert version covers the requirements of medium sized maintenance departments: this version provides a wealth of functions, and meets the standard needs of maintenance departments, and more. The Enterprise version suits projects with a large number of users, requiring significant customization or imposing a complex hardware and software architecture. The Corporate version is designed for large-scale projects (national or international centralized deployment), in contexts that can be multilingual (multiple nationalities exploiting the same database). All the versions are based on a common technical core guaranteeing easy changes
â&#x20AC;&#x153;The most advanced software technology Based around a web-native architecture, CARL Source meets the latest technological requirements (Web 2.0, Java, XML, Web Services, SOA, etc.) and the needs of users in the field.â&#x20AC;?
from one version to another. CARL Source is available in many languages (Arabic, English, German, French, Italian, Spanish, etc.). The most advanced software technology Based around a web-native architecture, CARL Source meets the latest technological requirements (Web 2.0, Java, XML, Web Services, SOA, etc.) and the needs of users in the field. Particular attention has been paid to ensure that its interface is user-friendly, powerful and simple, whilst remaining fully compliant with web user standards. In addition, it is highly customisable and extendable (additional fields, tailored report workflow,
custom main screen and dashboards, modifiable data-entry screens and printed reports, etc.). CARL Source leaves you a great degree of freedom in your chosen technology. It provides a solution tailored for all types of architecture (from standalone workstations to highly sophisticated network configurations). A major aspect that sets CARL Source apart from its competitors is that users are not bound to proprietary solutions, in that open source products can be used for all components of the architecture. It can also operate with leading proprietary solutions (BEA, Microsoft, Oracle, etc.).
CARL Source is also inherently open to other IS applications via integrated web services (SOA). Lastly, CARL Source can be deployed without installing any programs on the client workstation, reducing deployment costs.
For further information please contact: Carl Software: o +33 426 29 49 49 www.carl-software.com
ELECTRICAL SAFETY TESTING
EFFECTIVE ELECTRICAL TESTING AT AIRBUS SITE Versatile electrical safety testing technology is helping a specialist facilities management and building services company, Inviron, to maintain safe working conditions at one of the UK’s largest manufacturing sites. As part of its responsibility for providing planned preventative and reactive maintenance for the mechanical and electrical systems at the Airbus Broughton site in North Wales‚ technical facilities management specialist Inviron undertakes all of the plant’s portable appliance testing (PAT) requirements using Seaward test equipment. Airbus’ Broughton facility includes two large industrial manufacturing units‚ with supporting administration and staff service areas. The largest of the engineering areas‚ at over 83‚500 sq metres‚ houses the manufacturing and wing assembly for the A380 airliner. Around 6‚000 people work on the site. Inviron’s PAT services include the scheduled and reactive testing of all electrical equipment and appliances‚ alongside test data records management and electrical repairs. Given the variety of working environments and activities present on the site – including engineering‚ construction‚ office‚ kitchen‚ shop and public areas – there is an extremely wide variety of electrical equipment in use. These include both 230V and 110V hand held tools and portable equipment‚ 3-phase equipment‚ IT and
office equipment and catering appliances. As a result‚ Inviron’s team of engineers based at Broughton use different Seaward safety testers to meet the electrical test needs of different types of appliances. Hand held electrical tools and portable appliances used in production areas are monitored‚ tested and repaired on a daily basis using a Seaward Supernova Plus. The Supernova Plus is a comprehensive dual voltage electrical safety tester that is ideal for use in engineering workshop locations. The robust tester includes a flash test capability, accurate earth bond and leakage measurements when multiple earth paths exist, multiple 250V/500V insulation testing and an internal storage capacity of up to 5,000 appliances. Electrical equipment used in office and other non-manufacturing locations at Broughton are tested in periodic phases by Inviron engineers using the Seaward PrimeTest 350. This lightweight‚ handheld tester is battery powered and specifically designed for maximum portability – enabling engineers to carry out all required electrical tests quickly and effectively. All PAT procedures adopted by Inviron at the Airbus Broughton facility are in keeping with the 3rd edition of IEE Code of Practice
for In-service Inspection and Testing of electrical equipment. Any electrical equipment that fails any of the safety tests is immediately removed from service and retained in a ‘quarantine’ compound until it is repaired or disposed of appropriately. All safe appliances are marked with a distinctive ‘pass’ label. All test results‚ records and data gathered from the inspection and testing programmes are retained in a dedicated PATGuard Elite database. This enables full and easy access to equipment safety records‚ the production of test certificates for all electrical items and the scheduling of future test dates. In this way‚ with such a large site to cover and so many electrical appliances in use‚ the key to managing electrical safety at the Airbus Broughton site is the effective integration of equipment records‚ test procedures and future test scheduling. Steve Salter‚ Inviron Engineer ‚ said: “Portable appliance testing is an important part of the health and safety and equipment maintenance policies. “To meet this need‚ comprehensive testing‚ traceability of results and unambiguous test records are all vital to demonstrate compliance. The use of Seaward PAT test technology helps us to achieve this and enables us to prove a proactive electrical safety testing service to Airbus.”
COMPANY DETAILS: Seaward Electronic Ltd Bracken Hill, South West Industrial Estate, Peterlee, County Durham, SR8 2SW Website: www.seaward.co.uk Tel. (0191) 586 3511 Fax. (0191) 586 0227 E-mail: sales@seaward.co.uk
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BUYERS GUIDE 2011
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BUYERS GUIDE 2011
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