ems march/april 2008

MAR/APR 2008 BUYERS GUIDE RECRUITMENT STOP PRESS VIBRATION ANALYSIS ISSUE 4

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

Keeping the wheels of industry turning INDUSTRY NEWS

PLANT MAINTENANCE

CMMS

CONDITION MONITORING

- ALL OR NOTHING?

COMPRESSORS

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7

INDUSTRY NEWS Innovations and events shaping the industry

PAGE

LIFE CYCLE COST Simple reliability

by Christer Idhammar

3 PAGE

CONDITION MONITORING All or nothing?

11 PAGE

DRIVES AND CONTROLS

25

Alignment and tensioning of belt drives made easy

PAGE

MAINTEC REVIEW

29

A summary of the UK’s premier maintenance event

PAGE

BOILERS AND BURNERS

36

PUSHING THE

BOAT OUT

You may have noticed the UK economy being buffeted by the beginnings of a strong headwind. Seems the combined might of the global financial services industry, once so keen to lever its profits with a little dubious lending, is suddenly too scared to lend at all. In reality, for the long term, this is a good thing, I just wish it had happened a little earlier in the decade.

Twenty years ago this event would have sent UK manufacturing into a real spin with facilities closing and staff layoffs. Not this time. Those bloated factories, over staffed and slow to react to change are long gone, replaced by lean, rapid reaction forces working with machinery and processes designed to offer inherent flexibility.

Likewise, the low value products in manufacturers’ portfolios are already likely to have been outsourced to far off lands. These will be the facilities first punished by falling orders. Hopefully, sufficient manufacturers will have retained their high value activities (such as R&D, NPI, low to medium volume production and bespoke manufacturing) closer to home.

If so, I see UK manufacturing first off the blocks (exchange rate providing) with an export driven manufacturing recovery as soon as the global economy resurfaces.

However, to make all this happen, our factories need to be operating at maximum efficiency. When times are tight it is so easy to pull the maintenance boat in. I say bite the bullet, push the boat out, and prepare for the orders that will be coming your way given time.

Jon Barrett, EDITOR

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www.atlascopco.co.uk For more information quote EMS Enquiry No. 102 on IBC

Many reliability and maintenance improvement initiatives are successful, but most do not deliver the results that are possible to reach

LCC Life Cycle Cost Christer Idhammar, president Idcon Inc Some common denominators I have observed in very successful organizations include; They are long term focused.

They have stuck to the concepts they believe in for a long period of time.

They have a constancy of leadership.

Their beliefs and missions are well documented and communicated.

Changes in plant leadership do not change their beliefs.

They execute what they believe in.

In a discussion many years ago with the president of a European manufacturer of stainless steel, he told me that Scandinavian industry use five times more stainless steel in their designs then they do in North America. To me it explains the difference in mindset, we are short term focused in USA, and many other countries are more long term focused. This can be driven by taxation rules, climate and other factors.

The concept of Life Cycle Cost (LCC) is not well practiced in many organizations because we are driven by shortsightedness and a focus on short term cost reductions instead of a focus on what drives cost. For example a good preventive maintenance program drives down cost, but it costs money to implement and run. Good returns are produced within a year, but break-through results are seen after three to five years. At that time the same management team that took the cost to implement has moved and can not claim the results.

Selection of equipment based on Life Cycle Cost is another example. The right equipment might cost more, but cost of ownership is lower.

Figure 1

The graph in Figure 1 illustrates this.

The green line illustrates that at the point when 50% of the project phase is used, 5% of cost has been used and decisions that impact 80% of future cost of ownership has been taken. At that point in time equipment and system design is specified and procurement starts with requests for proposals. Much of this has to do with equipment, material, process design etc. Here I like to take an example on technical documentation, which is very important for cost of ownership. If a specification is developed to include all original parts, material, corrective and preventive maintenance descriptions (with pictures), trouble shooting and root cause diagram etc is documented and part of requests for proposals we can assume the cost of

developing this document is 1 if done early in project. If done later the cost is 10. If done when contract is signed as an add on to specifications, the cost escalates to 100 and if it is not done at all the cost to do it five years later will be 1000. If you find that equipment is not performing as expected, modifications can be done to extend technical life and this is also very expensive compared to doing it in the specification phase.

To include maintainability and reliability designs early in the project can be a very good investment.

Why is this not done in majority of organizations? The project manager is driven by budget and time. Someone else will take future costs of ownership. This can be changed, but then we must think long term and reward long term actions.

3 EMS Mar/Apr 2008 www.engineeringmaintenance.info

EMS Mar-Apr pg4

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VIBRATION ISOLATION

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Neoprene Turret Mounts Neoprene Hangers Spring Mounts Spring Hangers Flexible Connectors Floating Floors

- Inertia Bases - Noise & Vibration Surveys - Ex-stock Delivery - Selection Service - Special Design Service

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For more information quote EMS Enquiry No. 104 on IBC

For more information quote EMS Enquiry No. 105 on IBC

There are many examples on very poor LCC designs.

Maintainability which is measured as MTTR – Mean Time To Repair is an important part of LCC. An example of poor maintainability is some cars from the 1960s and 1970s.

In some models it took over two hours to change the headlight bulbs, because it could not be done without taking out the whole headlight unit, in other cars both bulbs could be changed in less than 10 minutes.

American bathrooms are another example. The pipes from toilets are much narrower than in Europe, that is one thing, but there are no drains in bathroom floors. Over time toilets are bound to overflow and then causing severe damages on floors and ceilings in rooms under bathrooms. To install drains as a standard when building a bathroom must make financial sense for owners and insurance companies.

If the demand for a complete bill of all parts and material with original manufacturer’s identification was not included as a part of a contract it will cost up to 1000 times more to create this

Figure 2

Picture courtesy of ABS Pump AB

documentation when equipment have been in use for five years. In addition, the lack of this information creates unnecessary lost production time and wastes 20% of time for a maintenance organization. To include this demand as part of the contract does not cot much if it is done as a company standard.

Good examples on maintainability are Formula 1 cars. Four wheels can be changed in 5 seconds because cars are designed with maintainability in mind.

NASCAR cars take 13 seconds.

The difference between the types of cars are in the

maintainability design. An army tank can replace the whole drive train including engine in 30 minutes. A steel plant can change a pair of rolls in 12 minutes, but most roll changes in a paper machine still takes over four hours.

Figure 2 is an example of how a simple modification in design reduced maintenance costs and increased reliability.

The wheel assembly is a vital part of a winder. In design A it takes eight maintenance hours and six hours of down time to replace wheel assembly. The maintenance cost is $900. Every time this is done axial forces are applied to

bearings when pulling out wheel assembly. Also the seal is very likely to be destroyed.

In design B only the wheel needs to be replaced. It is shrunk on the shaft. With this design the cost of maintenance is $270, it is done by one person in less than two hours and consequently requires only two hours shut down.

Replacement of wheel unit was done eight times in a ten years period so it would pay off to have it done as design B in original design.

The savings in the above example are not too overwhelming, but I hope the example can serve as a catalyst to start thinking maintainability.

The portable lifting arm, jacking bolts for motor alignment, drain valve to drain pump house and fixed pick up points for vibration analysis will cost a little more initially but will save much more during the life of the pump.

Reader Reply Number: 300

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

5 EMS Mar/Apr 2008 www.engineeringmaintenance.info

BOILER PROJECTS WHERE WILL YOUR FOCUS BE?

CAPITAL COST

LIFETIME RUNNING COSTS

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INDUSTRY NEWS

Structural bearings help maintain silence at convention centre One of the prime design criteria for the International Convention Centre (ICC) in Birmingham, UK was perfect acoustics despite a main rail-line running beneath it. Andre laminated natural rubber bearings from Trelleborg Engineered Systems were used to support and isolate the eleven auditoriums. Recent tests on these revealed virtually no signs of creep or aging after more than 15 years in situ. Once inside, the noise stops and within the Symphony Hall silence is absolute. In fact, you have to be careful what you say, as everything is clearly audible in the far corners of

the hall. To achieve this the design team - including Over Arup, architects Percy Thomas Partnership and the Artec acoustic consultancy - faced a variety of challenges, notably the fact that a rail tunnel runs directly under part of the site. The solution was to isolate the building raft on Andre rubber laminated bearings from Trelleborg Bakker, an operating unit of Trelleborg Engineered Systems, a business area of Trelleborg Group. www.trelleborg.com Reader Reply Number: 301

HELPING TO SUPPLY GREEN ENERGY FOR BEIJING’S OLYMPIC GAMES When the leading Chinese wind turbine company Goldwind was awarded the contract to supply 33 turbines for the 2008 Beijing Olympic Games the company selected SKF as the bearing supplier for this prestigious project.

In choosing SKF the Goldwind company based it’s decision on a good history of cooperation with SKF on smaller turbines, but also the fact that SKF had supplied to many bigger turbines around the world, including the biggest in the world at that time; Repower’s new 5 MW turbine that was designed for the extremely tough environment of offshore wind energy generation.

The 1.5 MW design is a direct drive turbine requiring no gearbox but the turbine mainshaft, to which the blades and rotor are connected, must be supported by bearings to allow the blades and rotor to rotate in order to produce electricity.

Critical components, like bearings, have to

be able to withstand a broad range of forces that are continually changing; in magnitude and direction, and also have to be resistant to, or protected from, rain in order to run reliably according to design and application expectations.

While almost all machinery is expected to have some form of ‘running attention’ and maintenance, unexpected stoppages in wind turbines can be extremely expensive because usually cranes have to be hired for some days to dismantle and repair the turbine. And of course, the turbine is not producing electricity while in repair. So reliability of critical components is a very high priority for turbine designers, builders and users. www.skf.com Reader Reply Number: 302

Launch of Dunphy’s new digital control touchscreen Dunphy has launched their new, in-house designed touchscreen for the Ratiotronic TM 6000 digital burner/boiler management system. The panel has all the functionality of a standard PC including IP addressable web access. The touchscreen offers manufacturing and production engineers the facility for multiple set points as well as a unique timer features which enable burners to fire at specific temperatures and pressures preset for any time of the day or night. The Windows style interface makes the system easy to navigate. On screen documentation is also available for datasheets and manuals of all system components. www.dunphy.co.uk Reader Reply Number: 303

Tata invests up to £1billion Tata is expected to invest up to £1 billion in Jaguar and Land Rover over the next four or five years as it takes charge of its first major Western brands. The investment is virtually the same as the £1.15 billion that the Indian conglomerate paid yesterday to take control of the two renowned British marques.

Reader Reply Number: 304

British Energy boosts share holdings British Energy Group (BGY.L: Quote, Profile, Research) said on Monday it was in talks which could lead to a tie-up or an offer for the 6.7 billion pound company, boosting its shares.

British Energy has been talking to several international power firms in recent months about partnerships to build new reactors after the UK government gave the go-ahead to a nuclear renaissance.

Reader Reply Number: 305

15,000-tonne press – one of the world’s largest A 200-year-old Sheffield metal- basher is considering building a 15,000-tonne press - one of the world's biggest - to satisfy the demand for parts arising from the global renaissance in nuclear power. Sheffield Forgemasters (SFI), which was on the verge of bankruptcy two years ago before it was rescued by a management buyout, has placed an order for one 4,000- tonne press and is weeks away from ordering a 15,000-tonne device as governments worldwide look to nuclear power as a source of non-carbon-emitting energy.

Reader Reply Number: 306

7 EMS Mar/Apr 2008 www.engineeringmaintenance.info

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INDUSTRY NEWS

Safe and Raising alarms and protecting equipment efficient oil-platform removal Aker Marine Contractors (AMC) has developed a new method of removing offshore platforms to meet international decommissioning guidelines.

Trelleborg Viking supplied rubber elements for the AMC buoyancy tank assemblies. The method involves attaching buoyancy tanks to the four corner legs of the jacket, so that when the legs are cut, the jacket will float in the water. It can then be towed to land. It sounds simple, but in practice it is not, according to AMC purchaser Bjørn Andre Jarli. The BTAs are large structures, standing 67 meters high and weighing over 1,200 tons.

Rubber elements delivered by Trelleborg Viking, more than 750 of them in different shapes and sizes with a total weight of more than 38 tons, are fitted to the BTAs where they will be in contact with the jacket legs.

Within the clamps mounted at the top and bottom of the assemblies and at places along the length of the assemblies, they act as deflection elements absorbing any impacts. The rubber elements in the jaws of the clamps also have to be able to tolerate the very high forces generated during refloating – jackets are heavy structures, some weighing more than 20,000 tons. www.akersolutions.com Reader Reply Number: 309

Monitran, a world leader in the development and manufacture of sensors for the measurement of vibration and displacement, has launched the VS0004, a complete condition monitoring and alarm module.

Fixed to a piece of plant machinery, the VS0004 can respond to a rise in vibration levels in a number of user definable ways. The unit has two alarm levels, with the user able to set Alarm 1 between 1

and 50mm/s and with Alarm 2 capable of being set as a multiple of Alarm 1, either 1.5, 2, 3 or 5x. Also, the unit has a 4-20mA output scaled to Alarm 2, and so can be interfaced with PLCs or other control circuitry. The VS0004 contains a double-pole double-throw relay for each Alarm Level, and the user effectively wires to the normally open (NO) or normally closed (NC) contacts depending on what action is to

be taken when an alarm limit is reached. The switching capability of each relay is The switch module also features a 10 second Alarm ON time constant and a 30 second start-up delay. www.monitran.co.uk Reader Reply Number: 308

SPACIOTEMPO UNIT SIGNALS GO AHEAD FOR TUBE LINES UPGRADE

Tube Lines’ major investment in upgrading the Jubilee line is timetabled for completion with the help of a temporary workshop supplied by space solutions specialist, Spaciotempo. Responsible for the maintenance and upgrade of the infrastructure on the Jubilee, Northern and Piccadilly lines, Tube Lines is investing £4.4 billion in a programme to rebuild the London Underground’s busiest lines.

This includes a new signalling

system, which will allow trains to safely run faster and more frequently. Based at Stratford Market Depot, the 140m x 14m (1,960m2) temporary workshop enables Tube Lines to take trains out of service on the Jubilee line for a short period and modify them for the new signalling system, whilst allowing service on the London Underground to continue uninterrupted. Erected within three weeks, the temporary workshop complies with the

WORLDWIDE APPROVAL Monitran, a world leader in the development and manufacture of sensors for the measurement of vibration and displacement, has been awarded IECEx certification on all 18 of its intrinsically safe vibration sensors.

IECEx is an international

standard under which a product’s certification approves its suitability for use in hazardous atmospheres, where flammable liquids, vapours, gases or combustible dusts are likely to occur and risk fire or explosion through sparks or contact with hot surfaces.

necessary standards required by London underground. Based on a heavy-duty aluminium extruded section, offering a clean, modern look with remarkable solidity and strength, the unit comes complete with a 10-year guarantee. To facilitate the project, the workshop was subsequently fitted with specialist operational equipment comprising of high lighting levels, a compressed air system for the use of air-powered tools and 28 train-lifting jacks.

Trains are rolled into and out of the facility on a high voltage overhead DC power system where they are fitted with computers and antennae wiring. This enables them to communicate with cables on the track and thus obtain precise details about each train’s location and speed to ensure a faster, more frequent service. www.spaciotempo.co.uk Reader Reply Number: 310 Submitting our wellestablished intrinsically safe sensors for IECEx approval, in addition to their long standing European ATEX certification, now brings Monitran the ability to satisfy the needs of an even wider range of potential users. www.monitran.co.uk Reader Reply Number: 311

9 EMS Mar/Apr 2008 www.engineeringmaintenance.info

EMS Mar-Apr pg10

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PLANT MAINTENANCE

CONDITION MONITORING

- ALL OR NOTHING? If you can predict the failure of a machine early enough you have an opportunity to do something about it, so as to minimise downtime and disruption to production. Often a simple remedial action such as re-greasing at the right time can prevent not only failure but also any permanent damage.

Unfortunately neither past experience nor MTBF (Mean Time Between Failure) can predict the failure of any particular machine. Some machines will fail much earlier and some much later than expected. The only approach to achieving such machine specific details is to utilise Condition Monitoring.

However Condition Monitoring is only part of the solution since once you have identified a faulty machine and gained some insight into its

seriousness the next and crucial step is to do something about it and this is usually referred to as Condition Based Maintenance (CBM). It is CBM that gives the benefits but these can only be gained by implementing CM with its associated costs (see Table 1).

A wide range of Condition Monitoring techniques are available, each of which has its own strengths and weaknesses and it is fair to say that no single technology can provide information on all machine faults. Even within one area of CM technology the range of instrumentation available can be bewildering.

Therefore, for the newcomer wishing to get started on CM it can be a daunting prospect and two commonly encountered approaches are as follows:

TABLE 1 CBM Benefits :

CM Costs :

Increase Machine Life & Availability

Purchase New Equipment

Reduce Secondary Damage

Learn New Skills

Reduce Unplanned Stoppages

On-going Implementation

Focus Maintenance Effort Improve Product Quality

Picture curtesy of Elyo Systems Ltd

When we purchase a machine we accept that it will not last forever. The problem isn’t that it will eventually fail but the consequences of it failing unexpectedly.

In fact a machine is more likely to fail just when you need it

Some companies approach the task in a proactive and systematic way whereby each machine is analysed in terms of possible failure modes, likelihood and consequences. The capabilities of appropriate CM techniques are then matched to each of the failure modes and a cost benefit analysis for each can then be performed. In an ideal world every company would follow such a procedure but in the real world few have the luxury of financial and manpower resources to pursue it. As a result, some companies leave CM on the back burner from one year to the next.

At the other extreme some companies get bounced into CM in response to an unexpected and serious machine failure which has had a major adverse impact on production/operations. This often results in a panic to get CM implemented so that “It never happens again”.

Needless to say hasty decisions made by newcomers to CM, often with blank cheque books, are a recipe for later regrets. In the absence of knowledge and under extreme pressure human nature is to buy the most expensive as it must be the best!

11 EMS Mar/Apr 2008 www.engineeringmaintenance.info

PLANT MAINTENANCE

However there is another approach to implementing CM between the two extremes of all or nothing. Why not start with those machines where past experience tells you that the consequences are most serious such as : where there is no spare capacity to meet production demands machinery for which spare parts are on long delivery times old machinery for which spare parts are no longer available machinery that has awkward access making repairs difficult machinery whose failure would have knock-on consequences In short start with those machines where people will jump up & down if it suddenly fails! You don’t need a consultant to tell you which these are.

Next its important to consider what information is needed from CM. You will want to identify at an early stage : which machines have a problem how serious the problem is how long before failure (or secondary damage) occurs what the fault is No matter what CM technique(s) you choose its going to require skill, experience and sophisticated instrumentation to diagnose what the fault is. In the first instance the time to failure can be estimated from the trend of readings as a function time (i.e. from a trend plot) which does not require great skill. The difficulty of recognising which machines have a problem and ranking the relative severity of the problems is different for different CM techniques (as is the sensitivity of the different CM techniques).

For example an increase in temperature is very easy to recognise and trend but it is insensitive to the early stages of a problem and very difficult to interpret in terms of the problem, giving rise to it. Similar comments apply to an overall vibration reading. In contrast, frequency domain vibration analysis starts with the difficult task of diagnosis and follows on from this to identify whether or not there is a fault and if so how rapidly it is developing.

As an alternative to getting bogged down in assessing the relative merits and capabilities of the various CM techniques to provide all the answers why not instead simply ask “what information can CM techniques give me easily and quickly?”.

This is a question to put to the relevant vendors and holds out the prospect of getting a quick return from CBM for a minimum of investment in CM. To illustrate this approach a number of examples are given in Table 2 based on the use of the MHC Memo Pro manufactured by Holroyd Instruments. This is an Acoustic Emission based portable CM instrument (see photo). First a brief word about the use of this type of instrument. Each measurement takes in the region of 15 seconds, requires no set-up, previous history or knowledge of machine design details (such as bearing type, number of balls, race diameters etc..) and the same interpretation is applied across all of the machine types; if Distress® is greater than 10 there is a problem.

Maintenance personnel periodically monitored 500 points at the site where the measurements shown in Table 2 were taken. Actions were only taken if Distress® was greater than 10 and Table 2 is concerned only with those items falling into this category for one particular month.

TABLE 2 Measurement Point

Distress®

Action

Consequence

Conveyor C5 TE pulley bearing NDE Bag Conveyor C Shaft Bearing DE Silo Conveyor snub pulley bearing Flue Gas Compressor Big Bag Conveyor Gearbox Output Bag Transfer Gearbox output Jet 3 Pump NDE

11

Re-greased

Distress fell to 01

25

Distress fell to 01

39

Found 4 loose brg. bolts.

Re-tightened.

Re-greased

18 45

Re-greased Re-greased

Distress fell to 13 Distress fell to 13

40

Gearbox oil changed

Distress fell to 05

21

Bearing cartridge oil changed.

Thorough inspection reveals bearing too loose.

Replacement recommended.

Distress up to 23

12 EMS Mar/Apr 2008 www.engineeringmaintenance.info

Distress fell to 06

In fact Table 2 provides a perfect illustration of the simplest form of CBM in action; one off measurements on hundreds of machines instantly identify those few machine points where a problem has arisen and straightforward maintenance procedures are carried out to effect an immediate and measurable improvement. (Note : It is clear that some problem still exists after re-greasing of the Flue Gas Compressor and the Big Bag Conveyor Gearbox Output since Distress® only fell to 13 and this is usually indicative of a degree of surface damage beyond that which can be cushioned by improved lubrication.)

Of course with a little further investment in time the regularly taken readings could be trended in order to reveal the rate of deterioration and it is even possible to do a frequency domain diagnosis from the AE signals but interpretation of this requires a much greater level of skill. However the important point to note is that simple CM instruments exist which can very easily provide immediately useful information, which can be acted upon to provide tangible benefits.

In fact starting simple with CM has a number of additional benefits to those of CBM listed earlier : immediate payback confidence in CM and CBM is nurtured existing maintenance personnel are empowered efficiency of the maintenance function is enhanced justification of expanding CM is easier financial savings continue to be evident as CM expands At whatever level you decide to get into CM, it is important to bear in mind that the act of purchasing CM instrumentation is the easy part. Regularly using the instruments properly, interpreting their outputs correctly and having the confidence and organisation in place to act upon their findings in a timely way are the keys to a successful CBM strategy. To help achieve this goal it is most important to avoid buying CM instruments that are incompatible with the time and/or skills you will have available. www.holroyd-instruments.com Tel: 01629 822060

Reader Reply Number: 312 ABOUT THE AUTHOR Trevor Holroyd is the Managing Director of Holroyd Instruments Limited and has been continuously active in the development and use of AE for industrial monitoring since 1974.

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For more information quote EMS Enquiry No. 112 on IBC

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PLANT MAINTENANCE Speciality lubricants made by Klüber Lubrication enhance the reliability of winches on AHTS vessels while at the same time reducing operating costs

HIGHLY RECOMMENDED Whether they tow oil rigs, supply them with goods or provide emergency services: for the operators of AHTS (Anchor Handling Tug Supply) vessels the operational reliability of their winches is of vital importance. These winches must be ready to work anywhere, at any time.

In the pursuit of this goal the lubricant used for the winches' open gears plays a major role. If it fails to meet the extraordinary requirements of these applications, the winch gears will suffer premature wear, fretting or corrosion, with the ultimate risk of winch failure.

Extremely high repair costs and lost profit are normally the consequence. The speciality supplier Klüber Lubrication offers products that help to avoid such highly unwelcome effects. They are tailored to meet the requirements of the gear materials used and the demanding conditions encountered at sea, thus supporting winch reliability and contributing to operating cost reduction.

Rolls-Royce has been highly satisfied with the use of lubricants made by Klüber for their low-pressure hydraulic motors for deck machinery, and consequently recommends them to their customers: The Klüber product GRAFLOSCON B-SG 00 Ultra is to be used for running in the tooth flanks, while Klüberfluid C-F 3 Ultra is recommended for subsequent operational lubrication.

The adhesive lubricants developed for open gears by Klüber Lubrication meet the

demanding requirements of anchor handling winches and have proven successful on such vessels for many years. A further benefit is that the company offers a comprehensive range of priming, running-in, operating and repair lubricants. Klüberfluid, for example, is a series of highly viscous, transparent adhesive lubricants enabling a long component life by protecting tooth flanks reliably against wear and corrosion. The fluids' good adhesion and specific

formulation make for long relubrication intervals and hence a tangible reduction of operating costs.

Moreover, disposal of these lubricants after use is unproblematic since they are free of bitumen, heavy metals, solvents or chlorine.

Also, the quantity of Klüberfluid required for reliable lubrication is up to 50 percent lower than with operating lubricants containing graphite. All this results in considerably lower costs for the user, based on the products' high efficiency, eco-friendliness and the lower disposal costs. www.klueber.com Tel: 01422 205115 Reader Reply Number: 313

15 EMS Mar/Apr 2008 www.engineeringmaintenance.info

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PLANT MAINTENANCE

CIRCUIT TRACER

SAVES MONEY

Using a handheld circuit tracer, a Kent-based electrical services company has solved a five-year old hidden wiring problem in a residential apartment, at the same time as helping the customer save at least £1,500 in repair costs Ammes Ltd provides electrical services to commercial, industrial, retail and domestic markets in the South East of England.

Based in Kent, the company offers a wide range of services to its clients, including the installation of the latest wired and wireless digital control systems, installation of energy efficient lighting and the investigation of faults. The firm compiles test reports and risk assessment analyses for customers, using the latest testing facilities including heat seeking photographic equipment.

Ammes maintains a number of residential sites in London. One particular site in Chelsea has very high specification apartments, with prices ranging from £1 million up to £7 million. Mark Botterill, partner at Ammes Ltd comments: “In early 2008, we were called out to a job at one of the apartments in Chelsea. The customer, who was introduced to us through the apartment concierge, had been suffering from an intermittent problem with the apartment’s electrical sockets and a miniature circuit breaker, which kept tripping. Some sockets didn’t work at all and this problem had been going on for around five years. Typically, owners of the apartments use it as their second home and so do not occupy them

full time. I guess they learn to live with such inconveniences.”

Before approaching Ammes, the client had already been unsuccessful with four other companies, through either a lack of know-how or just unable to find the intermittent fault. The client had been quoted between £2,000 and £5,000, partly due to the high specification of the décor in the apartment but also due to the companies not being confident of what the issues were.

Mark continues: “Some investigations by other companies had been carried out without success and so the customer approached us for help. I sent in two electricians to investigate. Our initial tests showed very little.

Next, our electricians removed socket faces, testing as they went. This highlighted a suspected area. It was now that the electricians made use of the SureTest® circuit tracer from IDEAL INDUSTRIES. The circuit tracer showed that a short circuit was present, although only intermittently.

17 EMS Mar/Apr 2008 www.engineeringmaintenance.info

PLANT MAINTENANCE

Removing a back box on one of the sockets showed a taped up twin and earth in the cavity and un-terminated cable at the distribution board. The circuit tracer showed that these cables were not connected.

The SureTest® circuit tracer is a powerful, versatile and easy-to-use device for locating circuit breakers and hidden wiring problems in industrial, commercial and residential environments. The device is safe to use on both de-energised and energised circuits up to 600V AC/DC. The unit comes with IDEAL’s patented SwivelDisplayTM , the industry’s first rotating super-bright OLED display, which ensures readings stay upright, even if the tracer’s receiver is pointing downwards.

Peter Halloway, Channel Manager at IDEAL INDUSTRIES (U.K.) LTD comments: “SureTest® can be used to locate fuses and circuit breakers, pinpoint breaks in wires and shorts to ground and can trace wiring concealed behind walls, floors, ceilings and underground. The device has a CATIII 1000V safety rating. We have designed the circuit tracers to be exceptionally easy to use, for

example, rather than having a standard series of blinking LED lights like most competing models, our display provides a numeric value between 0 and 99, plus a variable pitch audible indication for quick, simple-to-understand tracing feedback.”

At the apartment in Chelsea, the electricians were armed with a SureTest® circuit tracer, which Mark Botterill had purchased back in 2007, after attending a seminar by IDEAL INDUSTRIES on BS7671: 2008 (IEE Wiring Regulations 17th Edition). As Mark adds: “At first glance, I thought the SwivelDisplay on the SureTest® receiver was just a gimmick, but the electricians are finding it very useful and it saves time on the job.”

After a short time tracing the cable in the apartment, the problem was identified and traced to a fitted wardrobe. According to Mark, a screw that was holding the wardrobe against the wall was creating the short circuit. “Our guys were able to cut a small hole in the wall and replace this section of cable,” explains Mark.

Now that Ammes had solved the short

circuit problem, the tracer was used to solve the other problem in the apartment. “All the other apartments at the Chelsea site were wired in rings, but our client’s apartment was wired radially. Tracing both ends of the discovered cables resulted in the tracer locating the other ends in the same area but on opposite sides of a wall. After asking for the client’s permission to cut a hole in the wall, Mark’s team located the other ends of both cables and terminated these into a double socket. The protective device was changed and the client now has the ring circuit they should have had installed from the start. The client was very happy and was only charged £500.

Mark concludes: “Compared to the original quotations, the client saved at least £1,500. We also restored the radial to the intended ring circuit and walked out feeling rather pleased with ourselves. SureTest® saved us time and we are now going to start using it for periodic inspections too.” www.idealindustries.co.uk Reader Reply Number: 314

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18

For more information quote EMS Enquiry No. 126 on IBC

EMS Mar/Apr 2008 www.engineeringmaintenance.info

VISIT

www.engineeringmaintenance.info for the latest Jobs News Interviews Online Seminars Events Training Products White Papers Case Studies Forum For more information quote EMS Enquiry No. 127 on IBC

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

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

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For more information quote EMS Enquiry No. 119 on IBC

For more information quote EMS Enquiry No. 120 on IBC

PLANT MAINTENANCE

Corus Northern Engineering Services (CNES) has successfully completed refurbishment work on a MultiServ operated 300-tonne slab carrier vehicle used for transporting steel slabs around Corus’ production site at Port Talbot in South Wales. MultiServ offers a range of outsourced mill services to the metals industry, including Corus plants worldwide.

CNES improves 300-tonne slab carriers from Port Talbot As part of its continuous improvement programme and maintenance operation at Port Talbot, site operator MultiServ identified a number of ways in which they could extend the life of the existing Kress Fleet. Because of the long association between MultiServ and CNES in Rotherham – where CNES had carried out structural refurbishment work on Kress machines over the last 15 years – CNES was the obvious choice to provide the necessary expertise to carry out the refurbishment programme instigated by MultiServ.

The first machine for refurbishment work was a 300-tonne Kress slab carrier

was carried out by CNES’ workshops in Rotherham, which had been transporting slab around Port Talbot for a number of years and was due for a major overhaul as part of the scheduled maintenance plan.

MultiServ contacted CNES workshops in Rotherham to inspect the stripped-down slab carrier, in order to provide a professional opinion and to recommend a course of action for other slab carrier units.

An inspection at Rotherham by CNES structural engineers suggested that the unit – the two arms, torque tube and ‘swan-neck’ – required refurbishment and so a scope of work was generated. CNES

concluded that both rear sides and a section of torque tube would need to be replaced, along with the swan-neck at the front of the vehicle. The torque tube transmits the traction forces generated by the wheels to the carrier frame, twisting as the unit moves.

CNES generated a refurbishment procedure for the torque tube and discussions were held with the slab carrier manufacturer Kress in the US. Kress approved the procedure and material selections for the tube, as well as the back end replacement.

Due to lack of technical drawings,

21 EMS Mar/Apr 2008 www.engineeringmaintenance.info

EMS Mar-Apr pg22

29/4/08

7:07 am

Page 2

For more information quote EMS Enquiry No. 135 on IBC

PLANT MAINTENANCE

CNES had to reverse engineer the templates for the back end side plates, which had to be formed, then profiled, before fabrication. All fabrication work was carried out to a very high standard, with 100% inspection before the unit was released back to Port Talbot.

Once delivered to Port Talbot, the unit was painted, and then re-assembled ready for use.

Jackie Dixon, Senior Engineering Plant Metallurgist at Corus Engineering Steels comments: “Reverse engineering the back end side plates is not easy. Fortunately, CNES has some very experienced platers, who were able to take the dimensions of the bends in the plates in order to achieve the precise profile required for the job.”

The refurbishment of the 300-tonne slab carrier was completed over a six-month time frame by CNES and MultiServ now has the carrier fully operational on site at Port Talbot. A second carrier unit from Port Talbot is now at CNES’ Rotherham workshops undergoing refurbishment, along with a smaller unit from Corus Teesside. CNES is now involved with MultiServ on a ‘rolling rebuild’ programme for the carrier fleet. The Teesside machine required a wider torque tube as part of its upgrade, so segments were fitted that were provided by Kress. www.corusnes.com Reader Reply Number: 315

For more information quote EMS Enquiry No. 121 on IBC

EMS Mar/Apr 2008 www.engineeringmaintenance.info

23

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Maintenance Software Applications Support Education & Training Compliance & Preventive Maintenance Maintenance Consultancy For more information quote EMS Enquiry No. 123 on IBC

CONDITION MONITORING

By introducing new digital functionality to its belt alignment and tensioning instruments, FAG Industrial Services has made its SMARTY2 and TRUMMY2 devices even more accurate and easier to use

ALIGNMENT AND TENSIONING

OF BELT DRIVES MADE EASY

FAG Industrial Services (F’IS), the maintenance and condition monitoring division of the Schaeffler Group, has extended the range of functions offered by two of its proven measuring instruments – SMARTY2 and TRUMMY2 – used for aligning and tensioning belt drives and chain sprockets.

Not only do the new functions make these precision instruments even easier to use, they also help to reduce wear and tear on the drive components. A correctly aligned and tensioned belt drive or chain sprocket means less friction and vibration are generated by the drive system, which means less wear on belts, belt pulleys, bearings and seals. This means the running time and reliability of the machinery is increased, energy costs are kept to a minimum and overall plant efficiency is improved.

Ideal for checking the alignment of belt-driven fans, compressors, conveyors, pumps and ventilators, the ‘FAG Top-Laser SMARTY2’ measures and adjusts the alignment of drives and pulleys significantly faster and more accurately than using conventional methods. With its

new, optional real time digital display of readings, belt drives can now be aligned even more quickly and accurately.

The device displays the parallelism and misalignment of both pulleys and is suitable for both horizontally- and vertically-mounted machinery. Only one person is required to carry out the alignment and the device can also be used on non-magnetic sprockets or pulleys.

Used on flat, toothed and Vee belts, the SMARTY2 detects angular or parallel misalignment, or a combination of the two. Mounting can be achieved in just a few seconds. The user can clearly see the laser beam on the target marks. Once the user has adjusted the laser beam to coincide with the slots in the target marks, the machine is correctly aligned.

The target marks come in optical or digital form. For the digital version, adjustment values are shown in real time on the display. Angular misalignment is displayed as degrees and parallel misalignment in millimetres.

In addition, because the device is so lightweight (270g) the emitter and target marks can be attached to non-magnetic drive pulleys using strong, double sided adhesive tape.

Belt tensioning tool As well as alignment, correct belt tension is a prerequisite for maximising the life of a belt drive. The ‘FAG Top-Laser TRUMMY2’ is a high precision opto-electronic handheld measuring instrument for optimising belt tension (strand force). Its improved design enables users to perform measurements using only one hand.

TRUMMY2 consists of a cableless measurement probe and a robust, handheld control unit. Measurement parameters are shown in the display either as frequency (Hz) or force (N). The device

also has a measurement probe with cable for areas that are difficult to access.

To calculate the optimum strand force (belt tensioning force) for a drive, the belt mass and length are entered into the instrument. By generating an impulse – for example by striking the stationary belt – the tensioned belt is excited to its natural vibration. The individual static natural frequency generated is measured within seconds by the TRUMMY2’s sensor using ‘clock pulse light’ and shown on the display.

The strand force is calculated and then compared with the specified nominal value.

This measurement technology (clock pulse light) is superior to conventional methods – such as measurements using sound waves – because the measurement result is not distorted by disruptive external influences.

The optimised belt tension increases the service life of the belt drive. Moreover, it prevents potential consequential damage to rolling bearings, seals and shafts caused by excessively high belt tension. In this way, costly unplanned downtime is minimised. www.schaeffler.co.uk Reader Reply Number: 316

25 EMS Mar/Apr 2008 www.engineeringmaintenance.info

CONDITION MONITORING Ultrasonic inspection and monitoring of bearings is one of the most reliable methods for detecting incipient bearing failure. The ultrasonic warning appears prior to a rise in temperature or an increase in low frequency vibration levels

ULTRASOUND BEARING INSPECTION Ultrasonic inspection of bearings is useful in recognizing: The beginning of fatigue failure Brinelling of bearing surfaces Flooding of or lack of lubricant Beginning of Fatigue Failure In ball bearings, as the metal in the raceway, roller or ball bearing begins to fatigue, a subtle deformation begins to occur. This deforming of the metal will produce irregular surfaces, which will cause an increase in the emission of ultrasonic sound waves.

A change in amplitude from the original reading is an indication of incipient bearing failure. When an ultrasonic reading exceeds any previous reading by 12dB, it can be assumed that the bearing has entered the beginning of the failure mode.

This information was originally discovered through experimentation performed by NASA on ball bearings. In tests performed while monitoring bearings at frequencies ranging from 24 through 50kHz, they found that the changes in amplitude indicate incipient bearing failure before any other indicators including heat and vibration changes. An ultrasonic system based on detection and analysis of modulations of bearing resonance frequencies can provide subtle detection capability, whereas conventional methods are incapable of detecting very slight faults. As a ball passes over a pit or fault in the race surface, it produces an impact. A structural resonance of one of the bearing components vibrates or “rings” by this repetitive impact. The sound produced is observed as an increase in amplitude in the monitored ultrasonic frequencies of the bearing.

Brinelling of Bearing Surfaces Brinelling of bearing surfaces will produce a similar increase in amplitude due to the flattening process as the balls get out of round.

These flat spots also produce a repetitive ringing that is detected as an increase in amplitude of monitored frequencies.

The ultrasonic frequencies detected by the Ultraprobe are reproduced as audible

sounds. This “heterodyned” signal can greatly assist a user in determining bearing problems. When listening, it is recommended that a user become familiar with the sounds of a good bearing. A good bearing is heard as a rushing or hissing noise. Crackling or rough sounds indicate a bearing in the failure stage. In certain cases a damaged ball can be heard as a clicking sound whereas a high intensity, uniform rough sound may indicate a damaged race or uniform ball damage.

Loud rushing sounds similar to the rushing sound of a good bearing only slightly rougher, can indicate lack of lubrication.

Short duration increases in the sound level with “rough” or “scratchy” components indicate a rolling element hitting a “flat” spot and sliding on the bearing surfaces rather than rotating. If this condition is detected, more frequent examinations should be scheduled. In some instances a loud sound similar to an electric “hum”, referred to as a change in “tonal quality” will indicate a bearing failure that can be confirmed with the use of a vibration analyzer to show the fault frequency.

Detecting Bearing Failure There are two basic procedures of testing for bearing problems: COMPARATIVE AND HISTORICAL The comparative method involves testing two or more similar bearings and “comparing” potential differences.

Historical testing requires monitoring a specific bearing over a period of time to establish its history. By analyzing bearing history, wear patterns at particular ultrasonic frequencies become obvious, which allows for early detection and correction of bearing problems.

Some general guidelines: Minimize variables. Try to be as consistent from test to test as possible.

Select one test point and identify it for future tests.

Select same type bearings under similar load conditions and same rotational speed.

Test at the same angle.

26 EMS Mar/Apr 2008 www.engineeringmaintenance.info

If the inspection instrument has frequency tuning, note and use the same frequency.

Compare differences of meter reading/dB and sound quality.

Establish a baseline by comparing similar bearings, using the lowest dB level for the baseline.

Save the baseline reading for future reference.

Compare this reading with previous (or future readings). On all future readings, adjust frequency to the original level.

If the decibel level has moved up 8-10dB over the baseline accompanied by a uniform “rushing” noise, this is an indication of lack of lubrication. A 12 to 16dB rise over the base- line accompanied by crackling or popping noises will indicate the bearing has entered the incipient failure mode.

Slow Speed Bearings Monitoring slow speed bearings is possible with ultrasound technology. Most of the ultrasound instruments will have a wide sensitivity range and some will have frequency tuning. With these features it is quite possible to listen to the acoustic quality of bearings. In extremely slow bearings (less 25 RPM), it is often necessary to disregard the meter display and listen to the sound of the bearing. In these extreme situations, the bearings are usually large (1/2" and up) and greased with high viscosity lubricant. Most often no sound will be heard as the grease will absorb most of the acoustic energy. If a sound is heard,

CONDITION MONITORING

usually a crackling sound, there is some indication of deformity occurring.

On most other slow speed bearings, it is possible to set a baseline and monitor as described above.

Lubrication It is important to consider two elements of potential failure.

One is lack of lubrication while the other is over-lubrication.

Normal bearing loads cause an elastic deformation of the elements in the contact area providing a smooth elliptical distribution. But bearing surfaces are not perfectly smooth. For this reason the actual stress distribution in the contact area will be affected by a random surface roughness. In the presence of a lubricant film on a bearing surface, there is a dampening effect on the stress distribution and the acoustic energy produced will be low.

Should lubrication be reduced to a point where the stress distribution is no longer present, the normal rough spots will make contact with the face surfaces and increase the acoustic energy. These normal microscopic deformities will begin to produce wear and the possibilities of small fissures may develop which contributes to the “Pre-Failure” condition. Therefore, aside from normal wear, the fatigue or service life of a bearing is strongly influenced by the relative film thickness provided by an appropriate lubricant.

The right amount of lubrication is very important. If a bearing is over-lubricated, the bearing can be pushed excessively by the lubricant causing additional wear of the bearing. On the other hand, if there is not enough lubricant, the bearing will rub on the solid surface…again causing friction and wear on the bearings. Either case is detrimental to the life of the bearing. In using airborne/structure-borne ultrasound, you can take the guess out of lubrication.

To avoid lack of lubrication note the following: As the lubricant film reduces, the sound level will increase. A rise of about 8dB over baseline accompanied by a uniform rushing sound will indicate lack of lubrication.

When lubricating, add just enough to return the reading to baseline or until the reading goes down.

Use Caution! Some lubricants will need time to run to uniformly cover the bearings surface.

Lubricate a little at a time.

An alternative method is to add lubricant until the sound level drops off and then add a small amount of grease to assure the bearing has enough grease to fill the cavity. It would be prudent to recheck the bearing within 24 hours to verify that enough grease has been added.

Over-Lubrication When too much lubricant is put into the bearing housing the pressure builds up and can lead to an increase of heat which can create stress and deformity of the bearing or it can break or “pop” the bearing seal, allowing lubricant to spill out into unwanted areas such as a motor winding, or allow contaminants to enter the

Make complex stuff simple.

Reduce Maintenance Costs Automate Preventive Maintenance Improve Asset Reliability Reduce Breakdowns Manage Spare Parts Ensure Regulatory Compliance Paper-free PDA Work Orders

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raceway, all of which can lead to bearing failure.

To prevent this from occurring: Set a baseline dB level.

On subsequent inspections do not lubricate if the dB levels are equal to or less than 8 decibels over the established baseline level and the sound quality has not changed.

If a reading is 8-10dB over the established baseline level, add lubrication until the sound level drops and stop lubricating immediately at this point.

Conclusion Ultrasound instruments are quite versatile and are ideally suited to predictive/preventive maintenance programs. Their enhanced sensitivity makes them ideally suited to note early stages of bearing failure and especially lubrication conditions. By electronically translating ultrasound emissions down into the audible range, these instruments enable users to hear and recognize when and when not to add lubrication thus preventing over lubrication. www.alpine-components.co.uk 01424 437000 Reader Reply Number: 317 ABOUT THE AUTHOR

Affordable and easy to use maintenance software • Browser-based • Fresh innovative design • Completely configurable • Simply great value

It’s maintenance. Managed.

To discover more agile maintenance management visit www.getagility.com or call 01924 200344

Original paper by Mark A. Goodman, VP Engineering, UE Systems Inc. For more information quote EMS Enquiry No. 125 on IBC

EMS Mar/Apr 2008 www.engineeringmaintenance.info

27

THERMOGRAPHY

Enhanced image clarity, GPS location and remote wireless operation are just three new benefits of Flir’s ThermaCAM P660

LOCATING THE BENEFITS OF

THERMOGRAPHY

ThermaCAM P660 is designed to provide superior image quality, temperature measurement accuracy and thermal image detail

Flir’s new ThermaCAM P660 is designed for applications requiring superior image quality, temperature measurement accuracy and thermal image detail. The P660 features a 640 by 480 uncooled detector with sensitivity better than 45mK. The resulting images can be further enhanced using a new contrast optimiser. This algorithm lets users clearly view the scanned object and its surroundings. Useful in low contrast surroundings, this feature clarifies detail normally lost in the background.

Claimed as an industry first, the ThermaCAM P660 features integral GPS geo-location.

Customers requested this facility which is particularly relevant for monitoring a geographically spread asset base. Utility, energy and telecom users will be major beneficiaries. It is also useful for consultants who survey different sites.

GPS data is stored automatically with the radiometric images, adding mapping information to inspection reports so field repair and service teams know the exact location of a problem.

Wireless remote control is another added-value extra. This allows setup in a sensitive or awkward location. The user then moves to a safe area and controls the camera while

it monitors or captures an event.

A new picture-in-picture function lets users overlay, pan and scale an infrared image on a visual image. As all measurement data is retained, the combined image can be fully analysed. Thermal fusion is included, allowing image overlay, in real-time, at the push of a button.

Flir has also added a 3.2 megapixel onboard visual camera, 5.6in colour LCD, tilting viewfinder and three-hour battery.

Housed in a rugged, lightweight magnesium casing, the camera is claimed to weigh less than designs with a fraction of the resolution or features. The standard model measures temperatures from -40 to 500°C with optional range up to 2,000°C. UK sales and marketing manager, Paul Sacker, said: “The first generation of our 640 by 480 IR cameras focused on the merits of higher resolution for the professional thermography. The ThermaCAM P660 takes the concept several stages further by rolling-out a host of additional features that complement this performance.” www.flirthermography.co.uk Reader Reply Number: 318

Features include a 5.6in colour LCD

28 EMS Mar/Apr 2008 www.engineeringmaintenance.info

MAINTEC REVIEW 2008

easyFairs has reported a 10 per cent increase in visitor numbers to easyFairs MAINTEC 2008 following this year’s event at the NEC – and announced landmark plans to take the expo forward in 2009

easyFairs announces exciting MAINTEC show future The event – which attracted 150 exhibitors and 1,873 people from March 11-13 – has acted as a hotbed for innovation in the fields of condition monitoring and hazard prediction technology for more than three decades.

And easyFairs plan to extend MAINTEC’s reach and appeal in 2009, whilst remaining faithful to traditions that have been the show’s cornerstone since 1975. Next year’s event – scheduled for March 18-19 – is set to feature a wider range of plant and factory equipment, introduce industrial premises and facilities maintenance, and address environmental issues of specific interest to MAINTEC visitors. easyFairs is especially keen to expand the show’s ‘green’ credentials by showcasing relevant eco-technologies, energy efficient products, energy monitoring instruments, and factory health and safety developments.

Peter Heath, Managing Director of easyFairs UK Ltd, said: “Our research indicates that today’s maintenance professionals often wear more than one hat. As organisations slim down their headcounts, these professionals carry heavier burdens and need to find a broader range of reliable, innovative suppliers of technology and outsource services. We need to move with the times to ensure the show concept remains compelling for MAINTEC’s visitor audience.

This move will create an even better event for senior and operational decision makers.

“The focus for easyFairs MAINTEC 2009 will still be principally on condition monitoring and predictive maintenance technologies – and we feel embracing other related businesses will enable exhibitors to reach a much broader cross-section of relevant professionals.” easyFairs commitment, investment

and understanding of the maintenance market is evident in its portfolio of events across Europe, many of which take place in the Continent’s industry heartlands.

They include next month’s (9-10 April) easyFairs EUROMAINTENANCE expo in Brussels – a highly prestigious event which runs alongside a key conference of the same name – easyFairs INSTANDHALTUNG OST (26-28 June) in Chemnitz, Germany, and other maintenance shows in Lyon, Zurich and Dortmund. “easyFairs has many years’ experience in delivering effective, fascinating trade shows,” added Mr Heath. “easyFairs MAINTEC 2008 has been a great success; a 10 per cent year-on-year rise in visitor numbers is very creditable given the testing economic climate. I’m extremely excited about the future of easyFairs MAINTEC and am confident the show will continue to go from strength to strength.”

29 EMS Mar/Apr 2008 www.engineeringmaintenance.info

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Applications: Benefits: - Stairs - Industrial Flooring - Walkways - Platforms - Assembly Lines - Wash Bays - Work Stations

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For more information quote EMS Enquiry No. 128 on IBC

EMS Mar-Apr pg29-31

29/4/08

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MAINTEC REVIEW 2008

SOLID partnership For the first time, easyFairs MAINTEC was co-hosted alongside easyFairs SOLIDS, the UK’s only show dedicated to the solids processing, handling and storage sector.

One visitor, Doug Ovenden from NDO Consultants, said: “The co-hosting made perfect sense because there’s a lot of synergy between exhibitors…and the new section dedicated to environmental aspects is a great asset as products helping factories adhere to ‘green’ legislation are going to become increasingly important.”

Another, Mark Weaver from electrical engineers Quartzelec – formerly Cegelec Ltd – was impressed with the programme of educational seminars. He added: “There was a real wealth of knowledge and experience at the seminars –

normally you’d expect to pay to access such expert advice so these free debates are a show highlight for me.”

Exhibitors were equally impressed with the shows. PCB Piezotronics Ltd was a secondtime exhibitor at easyFairs MAINTEC. MD Graham Turgoose,

For more information quote EMS Enquiry No. 129 on IBC

said: “We came to showcase our sensors and instrumentation for industrial process monitoring.

There were lots of visitors from big name companies on our target list present here. easyFairs MAINTEC is the best show at which we have exhibited in the United Kingdom.”

Orthos Engineering, a UKbased supplier and technical consultant for European and American process equipment, used easyFairs SOLIDS to promote three of its principal product lines: Firefly, a leading dust explosion protection system for process industries, Allgaier vibratory screens and Lindor drum blenders.

Director Keith Scott was enthusiastic about the return on investment. “We have already booked four stands for 2010 on the basis of the business we’ve done over the past two days. This show has replaced the old Solidex in our opinion. We really do need a dedicated bulk solids event in the United Kingdom and this is it – PPMA just doesn’t deliver the goods, I’m sorry to say.” www.easyfairs.com Reader Reply Number: 319

For more information quote EMS Enquiry No. 130 on IBC

EMS Mar/Apr 2008 www.engineeringmaintenance.info

31

CMMS

PIRANA EATING THE COSTS OF BROWSER-BASED CMMS Shire Systems – the UK’s leading CMMS Company has revealed, a groundbreaking new browser-based computerised maintenance management system (CMMS). The new system was released at the recent MAINTEC 2008 exhibition. It has clearly caused quite a stir and is set to be one of the most unique and important software releases of 2008.

Pirana sets fresh benchmarks for performance and ease of use at a new industry-low price-point. The cost of ownership has been pared down and its stunning simplicity ensures instant access to a powerhouse of essential features the combination guarantees rapid success in any size of company.

Compact, nimble and powerful, Pirana was born out of the wish-lists of maintenance practitioners. Only the features they rate as vital are included, making Pirana supremely light and affordable.

Pirana is easy and intuitive; nothing gets in the way of users accessing its phenomenal ability to store, organise, search and report essential maintenance data.

Pirana dove-tails exactly with critical real-world maintenance priorities: taking control, keeping good order and guaranteeing compliance.

Chris Lee, Shire applications specialist, explained, “The vast majority of engineers just want a simple and easy-to-use CMMS; they want the lightest, race-ready sports car, not a Chelsea Tractor with all the extras. Pirana fits that bill exactly. It is a lean, mean tool with superb feel and handling. There’s not an ounce of fat, just pure hard CMMS muscle.”

Alex Thompson, Pirana Project Manager, added, “Maintenance professionals have designed Pirana themselves. Shire added its quarter century of FrontLine maintenance software development expertise to deliver the sleek and singularly affordable CMMS vehicle they craved.”

Shire forecasts a high take-up for the new CMMS as first-time users are attracted by the Pirana’s access-fromanywhere capability and the new entry price-point - coupled with the security of

32 EMS Mar/Apr 2008 www.engineeringmaintenance.info

knowing that Pirana is from the UK’s leading CMMS supplier. www.shiresystems.co.uk Reader Reply Number: 320 KEY FACTS Sets a new price-performance standard Stunningly easy to use Ensures success for micro, mini, medium and mega companies

EMS Mar-Apr pg33

29/4/08

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Page 1

COMPRESSED AIR AND COMPRESSORS

A RELIABLE PARTNERSHIP Airchannel and Speedy Compressors have agreed a partnership arrangement which will combine Airchannel’s expertise of designing and managing compressed air systems with Speedy’s experience of running a modern fleet of mobile compressors. The aim is to give their customer base a truly reliable service.

Airchannel has recently launched a Reliability Promise and Alastair Shanks (Managing Director - Airchannel) is obviously excited about what the partnership will bring; “The new partnership with Speedy will enable us to increase still further the reliability of our service. Speedy can pretty much guarantee to get back up compressor(s) on site and running anywhere in the UK within 12 hours which means that our customers’ systems will be more secure than ever.”

For most compressed air users the air supply is critical, many people call it the

fourth utility, if the air supply stops then so does production, whether that is a printing press or a factory line. Due to this criticality many sites have a standby compressor so as to be ready for breakdowns, however there is always a risk that things can go wrong, a power cut, a double failure etc.

This is where the Speedy/Airchannel partnership will bring benefits, if one of Airchannel’s customers has such a failure then Airchannel can call on Speedy’s extensive stock of compressors to provide a very quick solution to the issue. Airchannel will offer this service to all of its customers, either as an ad hoc hire or as part of an all inclusive contract where Airchannel takes full responsibility.

Speedy has worked with Airchannel for a few years now but this partnership is about real collaboration between the two businesses. Darren Maynard (Sales Director Speedy Compressors) comments, “This

partnership will work well as it benefits not only both businesses but also the customers.

Both companies work in the compressed air industry and are leaders in our own product areas, our product offerings are complementary rather than conflicting so give the opportunity to add value to each others customers. Much of our business comes from hires when a customer’s own compressor breaks down – it will be great to have a reliable partner who can repair our customer’s existing system while they have our compressors on hire.” www.airchannel.co.uk Reader Reply Number: 321

For more information quote EMS Enquiry No. 131 on IBC

EMS Mar/Apr 2008 www.engineeringmaintenance.info

33

COMPRESSED AIR AND COMPRESSORS

Businesses faced with increasing costs can reduce the impact of energy prices by readdressing their compressed air supply

DELIVERING

ENERGY EFFICIENCY The first step to achieving an efficient compressed air system is to build a complete picture of actual compressed air usage. Traditionally this was a complicated process encompassing an investigation of compressor configuration, individual compressor control modes, the number of compressors needed to meet the business’ demand, overall system control, pressure drops through air treatment equipment and sizing of pipe systems. However, with data logging, it becomes simple.

Key to the exercise is the CompAir SmartACE intelligent data logger. It is connected to the existing compressor system in a non-intrusive process that does not interfere with normal running and monitors the system over a sevenday cycle. When the loggers are removed, the data gathered is analysed using bespoke software that demonstrates patterns of real site demand.

This data is then used to show the energy savings that could be achieved with alternative machines or system configuration. If a number of different options are modelled, the comparisons produced will assist a more informed purchasing decision, eliminating the ‘guesstimate’ factor when it comes to specifying a compressed air system.

Whereas once an engineer might have looked at the capacity required and then added 20 to 30 per cent for ‘luck’ or system expansion, a system designed using the results of a data logging exercise will be sized more accurately to the actual level of demand and can be sized for planned expansions.

Opting for a compressor system using a combination of fixed drive and speed regulated compressors sequenced by an

intelligent control system can deliver considerable energy savings. The control system analyses demand and sequences the compressors to implement the most efficient configuration. By combining fixed and regulated speed compressors in a modular system, companies can ensure the compressed air supply exactly meets demand, however variable it may be.

In most production scenarios, demand varies according to production levels or shift patterns, which place different requirements on the system. With a traditional compressed air system this can mean compressors being on stand by for long periods, consuming up to 30% of full load power, without supplying air.

Production realignment can also see processes being added or removed, which will impact on air supply.

One CompAir customer that recognised the benefits of a more efficient combination of fixed and variable speed compressors is Jaguar Cars. Data logging was carried out on Jaguar’s existing compressors at the Veneer Manufacturing Centre in Browns Lane, Coventry, to assess their energy usage. The collated data highlighted the existing system was simply not cost effective enough in energy terms because, with large variations in demand, it was incurring major wastage by continuously generating the output to meet peak requirements.

CompAir recommended a combination of a L75SR variable speed drive screw compressor complemented with two L75 fixed speed machines. At Jaguar, the two fixed speed L75R machines provide the base power to the production line with the variable speed L75SR compressor, which is capable of fluctuating the speed of the drive motor to match power

34 EMS Mar/Apr 2008 www.engineeringmaintenance.info

consumption with air demand, catering for the swings in demand.

Most companies with compressors over 10 years old will identify potential energy savings by undertaking a thorough evaluation of their system. Countering the ‘if it’s not broke, don’t fix it’ argument, it is easy to confuse system reliability with system efficiency. Without the full supporting evidence, it can be difficult to argue the case for capital expenditure where the compressor is performing without any maintenance or downtime problems.

But energy savings can outstrip the cost of new equipment within five years.

Many users find that a modular system with intelligent controls can actually reduce the number of compressors required on site. It offers a good combination of flexibility and energy saving, together with increased reliability since the air supply is never dependent upon a single compressor.

Organisations looking to lower their running costs by improving the energy efficiency of their plant must examine all aspects of their operation. A company’s compressed air system can be a significant user of power – the government’s Carbon Trust estimates that as much as 10% of industry’s entire electrical energy consumption is used to generate compressed air. Although a system may be running reliably, it doesn’t necessarily mean that compressed air is being generated as efficiently as possible.

Through data-logging, it is possible to determine the most energy efficient compressor set up to make an informed decision about upgrading equipment and make significant energy savings. www.compair.com Reader Reply Number: 322

COMPRESSED AIR AND COMPRESSORS

Oil control watches out The new dimension of process reliability for compressed-air users: the Oil Control residual-oil monitoring system alerts air users to any increase in the concentration of contaminants in the compressed-air flow during operation, online and with high precision.

Compressed air contaminated by oil is the horror of every compressed-air user.

Depending on the application, there is a risk for production plant, the environment, or even for health. In the majority of cases, some residual oil content cannot totally be avoided, but needs to be monitored to ensure recommended levels aren’t exceeded. The compressed air classes defined in ISO 8753-1 offers a standard for the assessment of the compressed-air quality. However, it is important for the user to be informed about the concentration at all times.

Sampling and laboratory evaluation are

complex and expensive and, in addition, represent nothing but a snapshot of a past moment in time.

With Oil Control, these problems are a thing of the past. The Beko Instruments monitoring system allows permanent oilcontent monitoring of flowing compressed air. Measurement is carried out by means of an ion-exchange method, using a probe inserted into the flow on a special calibration section of pipe. The sensitivity of the sensor guarantees immediate detection of increasing oil content, resulting, for example, from defective filters. The air user is notified via a potential free signal from Oil Control which can be linked to an existing alarm system if required. This helps to successfully avoid consequential damage to machines, products or health. Compressed air as a production medium therefore gains in reliability, and the user avoids unnecessary expenses, as the purchasing costs of an Oil Control monitoring system is significantly lower than the cost of a production stop.

Beko Instruments offers three versions of the Oil Control: the Oil Control OCC for compressor monitoring up to 100 mg/m3, Oil Control OCF for the monitoring subsequent to compressed-air processing from 20 mg/Nm3 to 0.01 mg/Nm3, and Oil Control OCA for the monitoring of activated -carbon filters and catalytic converters from 1.0 mg/Nm3 to 0.001 mg/Nm3. The scope of delivery includes a probe, a measuring cell and evaluation electronics as well as a calibrated pipe section. In addition data logger and software can be purchased separately.

The Oil Control monitoring system corresponds to ISO 8573. It operates reliably in a temperature range between 0 and +60°C, independent of varying flow conditions and unaffected by humidity. The allowable operating overpressure lies at 10 bar (as standard), 16 and 45 bar are also optionally possible. www.bekotechnologies.com Reader Reply Number: 323

Atlas Copco sets new industry standard for energy efficiency Energy efficiency in the new GA range is achieved through, among other things, state-of-the-art compression elements based on Atlas Copco’s patented asymmetric rotor profiles, which drastically reduce volumetric losses.

Through the optimisation of oil injection, flow and temperature, the compression process is kept at the coolest possible temperature, thereby minimising thermodynamic losses.

Other design features to further reduce energy

consumption include the use of radial fans with VSD regulation, high-efficiency motors and no-loss drains.

Extra energy-saving options such as an integrated energy recovery system and/or VSD for the main motor can provide even greater benefits.

In tandem with its new GA compressors and once again as the result of continuous efforts to improve its core products,

Atlas Copco has also developed a new range of integrated and stand-alone refrigerant dryers with energy saving features such as “Saver Cycle Control” and highly-efficient heat exchangers with minimal pressure drops.

The robust and compact design of the new GA ensures continuous operation under the most demanding conditions, such as ambient temperatures of up to 55°C/131°F and in dusty environments. These features dramatically increase component and unit lifetime.

Air quality is provided by

two key elements: A highlyefficient oil removal system to give minimum residual oil content in the outlet air and state-of-the-art refrigerant dryers which are available in both integrated and stand-alone versions. Finally, great attention has been paid to integration. www.atlascopco.com Reader Reply Number: 324

35 EMS Mar/Apr 2008 www.engineeringmaintenance.info

BOILERS AND BURNERS

BOILER OPERATOR

TRAINING Mention steam, and most members of the public would conjure up images of Fred Dibnah, steam rollers and traction engines.

These images are far removed from the truth, however, when considering the hitech boiler and boiler control equipment installed in such as a modern food processing facility. Conversely the attitude towards the training of the man operating this equipment is often not as forward thinking, and would be more suited to the middle of last century. There are legitimate reasons for this, after the demise of the old City and Guilds boiler qualification there has been no formal differentiation between a competent and incompetent operator. Also, Thermal Engineering is generally not covered in the University degrees of Plant Engineers and Managers and so we are left with knowledge just being inherited from one operator to another. These â&#x20AC;&#x153;passed downâ&#x20AC;? procedures vary from perfect to downright dangerous, but are usually somewhere in between.

This general apathy towards boiler operator training is extremely disturbing when considering that each 1000kgs of water in a boiler at 10 bar has the explosive equivalent of over 20kgs of plastic explosive! Put another way if a small 5 tonne boiler went bang it could launch a family hatchback 800 metres into

the air! Transfer that thought to the damage to life and property that could ensue from your boiler house, and it gets more serious. The annual insurance inspection of the boilers proves that the boiler is fit for purpose at that moment in time, however it could be rendered dangerous by improper use in a few weeks. Self monitoring equipment on the boiler, in accordance with HSE guidance note PM5 for unmanned boiler houses, does not absolve the user from this training requirement. There still needs to be a qualified operator on site at all times, but maybe not in the boiler house.

In order to fill this gap, the Combustion Engineering Association launched a new training course leading to the accreditation Certified Industrial Boiler Operator (Cert IBO). This scheme, developed in association with the HSE, the Insurance industry, boiler manufacturers and backed by the Carbon Trust, is now entering its third year. After a slow take up rate, not helped by the scarcity of trainers possessing in depth boiler knowledge, industries such as pharmaceuticals, who prioritise safety and training, have embraced the scheme with enthusiasm. It has been the practice for Blue Chip companies to ensure that at least one operator and relief operator per shift is

fully qualified, plus the Plant Managers.

Shorter courses are also arranged for other personnel who may come into contact with the boilers in their general duties.

In addition to safety, correct operation of boilers ensures that the plant is running at peak efficiency, keeping fuel costs and emissions in check. This benefit alone will render payback on the investment in training very quickly. The satisfaction of the operator himself, in obtaining this qualification should also not be underestimated.

The course itself is not a lightweight affair with an almost guaranteed result, it includes an intense 4 day practical and theoretical training followed by challenging written exams and a practical assessment. Success is not guaranteed, and the candidates should have prior experience with boilers. The independent assessors are provided by Gastec who mark the written exams and carry out the practical assessments. A log book must be kept by candidates afterwards which ensures that procedures learnt are applied back on site.

The syllabus covers: Basic heat and heat transfer concepts Draught and combustion Feed water Control and Instrumentation Safety and Legal requirements Energy efficiency Environment Boilers and auxiliaries Step by step operation Fuel concepts Training courses are normally held in a small selection of training centres across the UK, but one provider, Byworth Boilers will carry out training on a customers site, if over 5 people are on the course. www.byworth.co.uk Reader Reply Number: 325

36 EMS Mar/Apr 2008 www.engineeringmaintenance.info

BALCAN'S NEW UNIQUE DESIGN OF WASTE LAMP RECYCLER ACCEPTS ALL TYPES AND SIZES OF LAMPS AT A VERY COMPETITIVE PRICE BALCAN, the award-winning electric lamp recycling specialist, has produced a new multi-purpose recycling plant capable of processing all kinds and sizes of both whole and pre-crushed lamps.

The Multi Purpose Compact Lamp Recycler (MPC4000) was developed from the company’s own original design which was recognised when the company won the Queen’s Award for Enterprise in 2006 for its ability to be used in conjunction with crushers. When mounted in lamp collection vehicles they allow up to five times more lamps to be carried when pre-crushed and loaded in vehicles than when lamps remain whole. This has obvious environmental and cost-reduction benefits.

Capable of accepting both whole and pre-crushed lamps fed from 45-gallon drums, which can hold an average of 600 x 4ft fluorescent tubes or their equivalent at an approximate rate of 8 drums per hour, the MPC4000 separates remarkably clean glass cullet from the debris. At the same time, the mercury bearing phosphor powder is drawn through filters including one containing activated carbon to remove the mercury vapour from the air so it can be exhausted safely to the outside atmosphere.

The MPC4000 produces clean aluminium end caps from fluorescent tubes or a mixture of plastic and metal components when mixtures of lamps are loaded.

FOR FURTHER INFORMATION CONTACT: Balcan Engineering Ltd, Banovallum Court, Boston Road Industrial Estate, Horncastle, Lincolnshire Tel:+44 (0)1507 528500. Fax:+44 (0)1507 528528 www.balcan.co.uk Reader Reply Number: 500

DEUTZ LAUNCH NEW GENSETS RANGE Leading diesel and gas engine manufacturer DEUTZ has introduced a new range of Air-cooled Diesel Gensets (ADG).

The powerful yet compact generating sets are available in three, four and six cylinder versions and are ideal for the provision of a backup emergency power supply, or for use in applications where no permanent power supply is available.

Powered by the well-proven DEUTZ 91 Series (912 and 914) diesel engines, with outputs from 28 to 152kVA (at cos phi 0.8), they cover mains power frequencies of 50 and 60Hz. With their innovative, compact, modular design they take up far less space and are much lighter than other similar gensets, which together with minimum maintenance and low operating costs make them exceptional value for money.

FOR FURTHER INFORMATION CONTACT: Tel: 01543 438901 www.deutzuk.com

Reader Reply Number: 501

SOLDER PASTES FOR REFLOW PROCESS The EFD advanced solder pastes help improve your soldering applications. The paste is conveniently packaged in syringes, cartridges, jars and flex packs.

It’s unique features include:

HYDRO ALUMINIUM EXTRUSION LOOK TO THE SKIES WITH ALTO TOWERS Hydro Aluminium Extrusion is assisting Alto Towers in creating a range of specialist aircraft maintenance equipment following several requests for Alto to adapt their standard scaffold products to suit the aviation industry. The result is a range of Tail Docks, Under and Overwiring Aviation access units, Undercarriage access and Passenger and Cargo door access facilities made entirely from extruded tube and box sections, and therefore engineered to be light and moved around easily. Each application also comes with effective lockdowns, staircases, buffers to avoid aircraft damage and aluminium plank decking for increased access. The equipment has already been requested by, and supplied to, several maintenance sites for some of Europe’s main flight operators around the country.

FOR FURTHER INFORMATION CONTACT: Dave Cuthbert at Hydro.

Tel: +44 (0)2920 854711 Reader Reply Number: 502

•

Precise clean and reliable soldering

•

Manual and automated dispensing systems

• •

No work, no reject Compatible with all reflow process

FOR FURTHER INFORMATION CONTACT: Tel: 01582 666 334 uk@efd-inc.com

Reader Reply Number: 503

37 EMS Mar/Apr 2008 www.engineeringmaintenance.info

RAPID-FIT COMPRESSED AIR PIPEWORK SYSTEM KEEPS THE PRESSES ROLLING When the Trinity Mirror newspaper group built its new £66m print centre in Birmingham, the critical design brief was for an operation that could meet a demand for rapid and continuing expansion. And because the print process is totally reliant on compressed air – from driving ink into the presses to taking finished newspapers off the lines – the company needed a system that could match its plans for growth every step of the way.

LEGRIS’ rapid-fit Transair aluminium pipe work system, purposely designed for compressed air, was chosen not just for its ease of installation and modification, but also for its long-term benefit in providing major energy savings.

The 40-acre Trinity Mirror site at Fort Dunlop in Birmingham produces up to six million newspapers every week, including the Birmingham Post and Mail, Coventry Evening Telegraph, Sunday Mercury and Sports Argus. With the advantage of being able to print newspapers in full colour throughout, it has already expanded to produce each morning’s Daily Mirror for the whole of the western part of the UK. In addition to the need to drive ink into the presses, Trinity Mirror relies also on a good, clean supply of compressed air for most of its post-press activities – inserting magazines into newspapers, stacking, strapping and palletising.

Six compressors of both fixed speed and variable speed types together with drying and filtration are all linked to provide an output potential of 59.08m3/min (2086cfm).

From a central manifold connecting the compressed air plant on the upper floors, Transair pipe work has been specified exclusively to take compressed air down into the plant. Because of the different volumes of air required for different applications, all of Transair’s six sizes – from 16.5mm to 100mm diameter – have been used to offer the greatest energy efficiency for each individual operation.

The new site at Fort Dunlop replaces two Trinity Mirror plants in Birmingham and Coventry and the original compressed air specification – as for the previous locations – was for traditional pipe work in galvanised steel.

FOR FURTHER INFORMATION CONTACT: Legris. Tel: 01452 623500 Reader Reply Number: 504

COMBINED DRY ICE PRODUCTION AND BLASTING CO2 pellet production

• •

and dry ice blasting at up to 10 locations com¬bined in ONE machine

A principle sketch of the combined pelletizer/dry ice blasting machine, the ” IceTech COMBI 75” which facilitates the connection of several dry ice blasting locations – all in ONE machine

The COMBI 75 combines dry ice pellet production and dry ice blasting – and facilitates the cleaning of items at several different locations – all in ONE machine. With the COMBI 75 the dry ice required will always be available in the exact quantity at the exact location, since the pelletizer unit can be set to automatically produce the quantity of dry ice pellets predefined on the blasting unit (5-75 kg/h – 11-165 lbs/h). In other words, the pelletizer unit automatically adapts its output to the dry ice consumption of the blasting unit.

Blasting guns at location The COMBI 75 is available with a distribution system faci¬litating the connection of several blasting guns placed at different locations around the production facility. The time previously used on obtaining dry ice and a blasting machine each time an item was to be cleaned is avoided. With the COMBI 75, the blasting gun installed nearby needs only to be picked up – and to be put back again right after the cleaning process.

The COMBI 75 continuously produces dry ice pellets directly into the pellet tank of the blasting unit. From there the dry ice pellets are transported through a distribution system to one or more blasting guns placed at various locations in the production.

FOR FURTHER INFORMATION CONTACT: www.icetech.de Reader Reply Number: 505

38 EMS Mar/Apr 2008 www.engineeringmaintenance.info

To view more superb vacancies please visit

www.engineeringmaintenance.info FACILITIES ENGINEER AEROSPACE & DEFENCE Location: : NEAR BRISTOL - South West Rate: £Neg (Permanent) An excellent opportunity has arisen for a Facilities Engineer to join this world-class supplier of innovative, high performance actuation systems and equipment for the aerospace and defence industry.

As Facilities Engineer, you will plan and effect the design, procurement, construction, modifications and installation of mechanical equipment and related structures and utilities for diverse development testing of company products. All efforts will be coordinated with pertinent Engineering, shop personnel, outside vendors and outside contractors to insure effective workability, safety precautions and adherence to company and government specifications. You will prepare cost estimates and be accountable for monies spent within budget limitations. You will also prepare milestone charts, schedule development and execute work on complex development laboratories. In addition to these tasks, you will trouble shoot and coordinate timely repairs of test facilities as needed.

Qualified to degree level in an engineering discipline, you will have a broad knowledge of mechanical engineering, principles in structures, hydraulics, heat transfer, thermodynamics and analysis. You will also have a strong background in design with Unigraphics and AutoCAD software and a familiarity with basic machine shop practices and general testing procedures. Excellent communication and scheduling skills are essential, as is a working knowledge of office computer programs (i.e., MSWord, Excel, Internet searches, etc.). You must be able to exercise good judgment and discretion to analyze problems and develop solutions to meet functional requirements, test objectives, safety, cost and schedule constraints.

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

SYSTEMS TEST ENGINEER Location: HAMPSHIRE - South East Rate: £Neg (Permanent) An opportunity has arisen for a Systems Test Engineer to join the UK offices of a small but world-renowned company specialising in the design and manufacture of Radar Threat and Electronic Countermeasures Simulation Equipment for EW training and test & evaluation applications. Successful candidates will work as part of a small team responsible for our range of radar simulation and test equipment.

The position encompasses a broad range of disciplines including software (MS Windows based), digital electronics and RF/microwave hardware. It requires close liaison with project and design engineers to ensure that systems are tested to satisfy both customer and project requirements.

The role is both analytical - requirements review, test plan & procedure definition (covering software and hardware testing), system performance review, as well as ‘hands-on' - major assembly testing, system integration and customer acceptance testing. During the system integration phase of a project you would be expected to take the lead in system testing, liaising with both design engineers and test personnel.

Specific responsibilities will be: • Requirements analysis for test requirements definition • Producing test plans & procedures • Controlling and undertaking system tests in collaboration with Design Engineers and Test Technicians • Ensuring that system requirements have been met • Derive tests from complex specifications • Devise and prioritise tests using risk based analysis to make best use of the time available • Participation in team/project meetings • Active role in creation, maintenance and support of test environment • Raising and following through of problem reports and change requests, as appropriate through the defect tracking system • Assist in supporting the customer, including site visits if required You will have experience in systems test development, with familiarity with Microwave systems and digital electronics (VME bus based), as well as software design and verification methods. Experience of Radar and/or EW systems would be advantageous. Some overseas travel may be required (typically 1-2 weeks duration at a time) to support customer requirements.

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

SALES ENGINEERS Airchannel provide a leading design, installation, supply and comprehensive after sales service in compressed air. With over 40 years experience in the industry and with nationwide coverage we are much more than simply the largest compressed air distributor in the UK. Due to continued growth we're looking for additional Sales Engineers to join our team. We focus heavily on customer satisfaction, offering a high quality yet cost effective national and local service. Working closely with the internal sales team you will develop the client and prospect database and manage sales through the appropriate channels. You will work closely with our suppliers to understand our product range therefore increasing sales in specific areas.

A background in sales/or engineering would be advantageous although the ambition to succeed and excellent communication skills are equally as important.

In the first instance, please e-mail your CV to: tracey.gant@airchannel.co.uk or a hard copy to: Tracey Gant at Airchannel Limited, Burrell Road, Ipswich, Suffolk, IP2 8AE.

www.airchannel.co.uk

39 EMS Mar/Apr 2008 www.engineeringmaintenance.info

ANNUAL BUYER’S GUIDE

TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355 Website

Email Contact

Telephone Number

ASSET MANAGEMENT Rockwell Automation

Company

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

BOILERS Byworth Boilers Certuss Steam Generators Wellman Robey

www.byworth.co.uk www.certuss.co.uk www.wellman-thermal.com

sales@byworth.co.uk sales@certuss.co.uk info@wellman-thermal.com

01535 665225 0121 3275362 0121 543 0000

BOILER HIRE Wellman Robey

www.wellman-thermal.com

info@wellman-thermal.com

0121 543 0000

BOLT SECURING SYSTEMS Nordlock Ltd

www.nord-lock.co.uk

enquiries@nord-lock.co.uk

+44 (0)1980 847129

CMMS Cayman Venture Productivity Europe Idhammar Systems Ltd Shire Systems Softsols Group Ltd

www.cayman.co.uk www.productivityeurope.org www.idhammarsystems.com www.shiresystems.co.uk www.getagility.com

info@cayman.co.uk m.jones@productivityeurope.org info@idhammarsystems.com info@shiresystems.co.uk info@softsolsgroup.com

0191 2963816 01234 215867 0117 9309300 44(0) 23 80224111 44(0)1924 200344

www.airchannel.co.uk www.atlascopco.co.uk www.gardnerdenver.com

info@airchannel.co.uk gba.info@uk.atltascopco.com info.uk@gardnerdenver.com

0800 526581 0800 181085 01452 338116

www.alpine-components.co.uk www.artesis.com www.elcomponent.co.uk www.holroyd-instruments.com www.proviso-systems.co.uk www.monitran.co.uk www.schaeffler.co.uk www.spminstrument.co.uk

mike@alpine-components .co.uk info@artesis.com sales@elcomponent.co.uk sales@holroyd-instruments.com sales@proviso-systems.co.uk info@monitran.co.uk info.uk@schaeffler.com info@spminstrument.co.uk

01424 437000 0845 634 3854 01279 503173 01629 822060 01777 817536 01494 816569 0121 351 3833 01706 835331

CONDITION MONITORING EQUIPMENT/SERVICES Rockwell Automation www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

DATA ACQUISITION Metrum

www.metrum.co.uk

enquiries@metrum.co.uk

0118 973 3000

HEALTH & SAFETY Integrity&Compliance Management

www.icm-uk.com

info@icm-uk.com

01779 474748

HEALTH & SAFETY PRODUCTS Rockwell Automation

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

INDUSTRIAL COOLING TPC(Total Process CoolingLtd)

www.totalprocesscooling.co.uk

sales@totalprocesscooling.co.uk

44(0)121 711 4014

LUBRICATION ATS Electro-lube (UK) ltd

www.ats-electro-lube.co.uk

info@ats-electro-lube.co.uk

0191 491 4212

PLANNED MAINTENANCE T Cards Direct

www.tcardsdirect.com

sales@tcardsdirect.com

01732 871417

THERMOGRAPHY Express Instrument Hire Flir Fluke Hawk-IR

www.expresshire.net www.flir.com www.fluke.co.uk www.hawk-ir.com

sales@expresshire.net sales@flir.com industrial@uk.fluke.nl sales@hawk-ir.com

01772 815600 01732 221245 020 7942 0700 01642 497000

TRAINING National Fluid Power Centre

www.nfpc.co.uk

enquiries@nfpc.co.uk

01909 504700

VIBRATION ANALYSIS Hansford Sensors

www.hansfordsensors.com

sales@hansfordsensors.com

0845 6801957

COMPRESSED AIR Airchannel Ltd Atlas Copco Compressors Gardner Denver CONDITION MONITORING Alpine Components Artesis Elcomponent Ltd Holroyd Instruments Proviso Systems Monitran Schaeffler SPM Instrument UK ltd

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info

40 EMS Mar/Apr 2008 www.engineeringmaintenance.info

WIN A CAR SATELLITE NAVIGATION SYSTEM Please complete the following form to be entered into a prize draw for an in car satellite navigation system:

To what degree have you embraced CMMS? ■ Not at all ■ Partially

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■ Vibration

Do you intend to purchase predictive maintenance systems in the next 12 months?

■ NO

■ YES

How much training do your craftsmen receive annually?

■ 1-5 days ■ 6-10 days ■ 11-20 days

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Maintenance and Repair...

Itâ&#x20AC;&#x2122;s what we do

In case you had any doubt, this is what Deritend is all about...

Repair or Supply New

Services

Motors

Site Services

Pumps

Asset Management

Gearboxes

Motor Management

Drives

Installation

Induction

Thermography

Valves

Vibration Analysis

For further information contact: HQ The Deritend Group Ltd, Cyprus Street Off Upper Villiers Street, Wolverhampton, West Midlands WV2 4PB 3 E-mail: marketing@deritend.co.uk

Tel: 01902 426354 WWW.DERITEND.CO.UK For more information quote EMS Enquiry No. 132 on IBC