ems may/june 2009 by Michael Dominguez

MAY/JUNE 2009 BUYERS GUIDE LEAN MAINTENANCE CONDITION MONITORING ISSUE 11

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

INDUSTRY NEWS

SPARES MANAGEMENT

SPOTLIGHT ON VALVES

TURN TO PAGE 3 FOR THE FULL STORY

COMPRESSORS

www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 101 on IBC

PAGE

RELIABILITY & MAINTENANCE

SHORT TERM GAIN

PAGE

Anyone with financial assets can buy the same equipment and processes. With the same, or older, manufacturing equipment and processes the last significant competitive tool is to increase manufacturing reliability and speed through product output.

Cut costs or improve reliability?

INDUSTRY NEWS Latest trends, news and technology

PAGE

SPOTLIGHT ON OIL ANALYSIS

The first step in oil analysis

PAGE

SPOTLIGHT ON VIBRATION

Remote diagnostic monitoring

means long term pain! This has of course always been true but in the past 40+ years the increase/decrease of investment in maintenance and capital has increased or decreased depending on good or bad financial times. For many years the industry built bigger and faster machines and manufacturing processes than their competitors. Sooner or later this often resulted in overcapacity and lower prices which, in turn, forced cycles of shut downs and mergers. Another reason for these cycles is the short term focus on maintenance costs instead of a longer term focus on what drives these costs. If maintenance managers placed more emphasis on long term improvements of reliability and speed of throughput, steady improvements of faster throughput and lower maintenance costs will follow. FOR THE FULL STORY PLEASE TURN TO PAGE 3

EMS, MSL Group, Cobalt House, Centre Court Sir Thomas Longley Road, Rochester, Kent ME2 4BQ +44 (0)1634 731646 www.engineeringmaintenance.info

PAGE

COMPRESSORS

New high performance range

PAGE

SPOTLIGHT ON OFFSHORE SWIRL valve technology

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer Idhammar Alan France, Mark Haarman editorial@engineeringmaintenance.info ADVERTISEMENT SALES: Michael Dominguez (Publisher) michael@engineeringmaintenance.info Paul Miles paul@engineeringmaintenance.info Paul Reynolds preynolds@engineeringmaintenance.info

WEB MANAGER: Oliver Gibbs info@engineeringmaintenance.info DATABASE MANAGER: Steve Hill TECHNICAL MANAGER: Igor Seke CREATIVE: Ric Cooper production@engineeringmaintenance.info ARTWORK PRODUCTION: Elaine Cooper production@engineeringmaintenance.info

Published six times per year by EMS Annual subscription: UK FOC Rest of World £90

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

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

For more information quote EMS Enquiry No. 170 on IBC

For more information quote EMS Enquiry No. 103 on IBC

In 1980 I conducted the first seminars titled â&#x20AC;&#x153;Reliability, the future competitiveness factorâ&#x20AC;?. Looking back I realize how true the title of these seminars was

Reliability and Maintenance in a recessionary market;

CUT COSTS OR IMPROVE RELIABILITY Anyone with financial assets can buy the same equipment and processes. With the same, or older, manufacturing equipment and processes the last significant competitiveness tool is to increase manufacturing reliability and speed up throughput of product you have sold. This has of course always been true but in the past 40+ years the increase/decrease of investment in maintenance and capital has gone up or down depending on good or bad financial times. For many years the industry built bigger and faster machines and manufacturing processes than their competitors. Sooner or later this often resulted in overcapacity and lower prices which, in turn, forced cycles of shut downs and mergers. Another reason for these cycles is the short term focus on maintenance costs instead of a longer term focus on what drives these costs. If management of maintenance emphasizes more on long term improvements of reliability and speed of throughput, steady improvements of faster throughput and lower maintenance costs will follow.

Capital and maintenance costs. I have always claimed that there is a strong correlation between maintenance costs and capital spending. In an economic downturn, one thing to do to reduce costs includes postponing or eliminating capital work. This will have the following affects; Maintenance costs for the affected assets will go up within the next one to four years because they will require more maintenance. Many necessary investments will be hidden in the maintenance budget. If some capital work has to be done, but there is no money in the capital budget, the work will be done anyway using funds from the maintenance budget. Long term versus short term If a company is driven by next quarter or annual financial results it will be difficult to justify long term investments. Privately held companies are not driven by short term results to the same extent as public companies. They have more consistent leadership and tend to have less changes of direction to meet shareholders expectations on short term profits. Instead

The data in chart 1 is based on a survey of nine plants in four countries. The trend in these plants is clear. Plants with a higher cost for maintenance have a lower budget for capital. Average for the six plants is a ratio for Maintenance cost to Capital cost of 8.6 to 1 or Capital cost is 11.6% of maintenance cost in these plants.

decisions are more based on long term results and long term survival. Good maintenance has to be managed long term, at least beyond two to three years. One reason for this is that superiority in reliability and maintenance performance is partly about technology, but much more about people. The challenge is to pull maintenance and operations functions together so they work towards the same goals. This requires that many entrenched habits must change and better practices must be put into practice and executed in a disciplined manner. Technology is the easy part of this equation. Maintenance people like gadgets and new tools. To use these tools and practices in a disciplined manner is another story. Reactive maintenance is by its character not executed in a disciplined manner and it is easy to fall in the trap to only give recognition for reactive work because it is visible. Good maintenance practices are more invisible and recognition for these less visible activities is often forgotten. Activities during a break down are very visible and many people are involved, it is also 76% likely that the situation calls for overtime, production is down and there is an urgency to start up. In this situation maintenance employees are the heroes and we depend on them. In a controlled situation, inspections could have detected the problem early which would allow time to plan and then schedule corrective actions during a scheduled shut down. The corrective action would then be done in a more invisible manner. This is in a nutshell the change many organizations need to do, and it takes two to three years to change an organization to work in a more disciplined manner. The reason why it takes time to implement better practices is not that people do not agree with what needs to be done, the reason is that they do not believe the improvement initiative will last long enough before a new initiative is initiated. Mobility of management and best practices execution. If your organization does not have very

3 EMS May/June 2009 www.engineeringmaintenance.info

Artesis MCM – Advanced Technology for Simple, Effective Condition Monitoring

Every now and then, a new solution comes along and changes your thinking. Artesis MCM is a new approach to condition monitoring, providing all the benefits without the complication and costs of traditional systems. Artesis MCM monitors the condition of equipment driven by electric motors, using the motor itself as a sophisticated transducer. It requires only connection into the motor’s electrical supply, avoiding the need to attach specialised sensors to the plant. Because Artesis MCM is permanently installed, it provides continuous fault monitoring and doesn’t require the manual data collection that represents a major cost of using walkaround systems. So Artesis MCM is especially applicable to situations where the plant is not easily accessible, either because it is remote or because the local environment is hazardous.

DEVELO

ED TECHNO

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

simple, effective

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

www.artesis.com For more information quote EMS Enquiry No. 104 on IBC

RELIABILITY AND MAINTENANCE IN A RECESSIONARY MARKET; CUT COSTS OR IMPROVE RELIABILITY? well documented and executed best practices for reliability and maintenance, your organization is at risk to frequently change direction with the arrival of a new manager in a key position. A poll at www.idcon.com shows that 60% of mills do not have any reliability improvement plans in place for the next 1 to five years. Another poll at the same website shows that mobility of plant management is high.

In the turmoil the world goes through now, mobility of management will most probably increase. This is another occurrence that will create confusion and stalled improvements in reliability and maintenance performance. Your organization must develop and implement a best practices plan and then ensure that new managers will use their experience to continue to implement best practices within your best practices framework. If you do that you stand a very good chance to become very successful in your improvement efforts.

A good parallel is safety programs. In 1990 the OSHA Total Case Incident Rate for the one industry was 8.91. 16 years later it was 1.88. (Ref. www.ppsa.org). This has been accomplished because it is a long term process with continuous training and education to increase awareness and to change behaviors. Every incident is noted and acted upon in majority of plants. These results will be achieved also in reliability and maintenance. We need to view this as a process with a beginning but no end. Not as a program with a completion date. In another survey it shows that over 60% of all safety incidents in maintenance departments occur during reactive work. Planned and scheduled maintenance is always safer to execute than reactive work. Manage by cost or reliability? I am convinced that lower maintenance costs is a result of improved reliability and it is never the other way around unless you measure these factors over a short period of time. Maintenance costs can be lowered in three ways: Cut the budget. Prevent the need for maintenance. Execute remaining maintenance more efficiently.

Cut the budget During a market downturn it is tempting and understandable that the focus turn to cost reductions. However, the fact is that a valid maintenance job can never be eliminated. To cut the budget means that work that is eliminated is not valid to do, or it can be deferred to a later date. In some of the worst cases the focus on cost will result in layoffs of employees instead of improving the efficiency of the work that needs to be done. If you are forced to lay of skilled people based on short term management philosophy, you hopefully know that this will save money on a short term but cost more later. In addition to the effects you see in the example below you will often be forced to lay off the future of your work force; if you have a unionized workforce your latest employees have to go first. Another negative consequence is the worldwide difficulty to find skilled maintenance craftspeople and this will be more difficult in the years to come. Prevent the need for maintenance These activities drive up reliability and drives down maintenance and operations costs. They include well known activities such as: Operating practices, Alignment of

equipment, Balancing of rotating equipment, Lubrication, Filtration, Root Cause Problem Elimination etc. If all these activities are done with precision, many maintenance activities would be eliminated. Execute remaining maintenance more efficiently Also these activities are well known and will also drive up reliability and reduce costs. They include Condition Monitoring and basic inspections, Work identification, Prioritization, Planning, Scheduling, Recording and ongoing improvement of the steps in this work cycle. Is better maintenance execution important? In a declining market better execution of best maintenance practices is more important than ever because it drives up reliability, speeds up product throughput and lowers costs. Best maintenance practices comprise about 285 elements that must be executed well to achieve proven world class performance. If you like to know more about best reliability and maintenance practices feel free to contact me at info@idcon.com and I will send you an example. Better execution of best maintenance practices also has a significant positive impact on energy consumption and safety. The great thing The great thing is that excellent results can be achieved with very little or no capital investments. Most organizations have the resources and tools to accomplish substantial improvements. They just need to do better with what they already have. The investment is mostly in education and training to pull your organization together to work towards the same goals in a disciplined manner. The bad thing The only bad thing is that it might take longer time to generate the results you want and need in a difficult market.

Chart A. In 2002 this plant started to reduce maintenance staffing but did not sustain or improve on maintenance planning and scheduling and preventive maintenance. They focused on cost as priority one. It shows a classical and often repeated example on what will happen when the management focus is short term cost reductions. In the third year overtime and contractor hours increased and in the fifth year total hours exceeded 2002 hours. Maintenance costs went up and reliability was down to 89.6% from 93.5%. Chart B. If the focus in 2002 had been to implement activities that drive cost such as Preventing the need for maintenance and then executing remaining maintenance more efficiently the scenario would have been as described in graph B. Reliability had remained at 93.5% or higher and manufacturing costs, including maintenance costs would have gone down. The savings in money, improved safety and less energy consumption would have been very significant.

www.idcon.com Reader Reply Number: 300

Christer Idhammar, president IDCON INC 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 1985. In 2002 he received the Euromaintenance Incentive Award for outstanding international contributions to improve Reliability and Maintenance in industries world wide. In May 2008 he received the Salvetti Foundation reward for best speaker among 154 speakers at Euromaintenance 2008 in Brussels. He can be reached at info@idcon.com

5 EMS May/June 2009 www.engineeringmaintenance.info

LATEST NEWS AND PRODUCTS

TIME TO SHAKE THE INDUSTRY

During the months of June and July 2009, Monitran is making many of its general purpose vibration sensors (including their mounting studs) available to its UK-based resellers for as little as half price; when purchased in volume orders of at least 100 units. Moreover, this is a ‘mix and match’ deal; so resellers

need not purchase 100 of any one sensor type to benefit from this exceptional offer. This limited-time offer applies to sensor models from within Monitran’s MTN/1100 range (AC output sensors ideal for vibration analysis) and its MTN/1185 range (DC output sensors ideal for condition monitoring and machine protection). Andy Anthony, Monitran’s Operations Director, comments: “As the UK’s leading OEM of vibration sensors we’re keen to give the industry a significant boost during these challenging times. By making this incredible offer, we are affording our valued resellers considerable cost savings that they can then

pass on to their customers.” The sensors in both ranges are available with connectors or with 5m of stainless steel overbraided integral cables. They are also available with an integral male stud (for direct mounting), with a 1 /4” female thread (for mounting via a threaded stud) or as QuickFit. In addition to this offer, subject to quantity [negotiated at the time of order], discounts will be available on ATEX-approved and waterproof versions of certain sensors in the MTN/1100 and MTN/1185 ranges; but only during the months of June and July 2009. Also during this period, and in

High voltage test range for POWER INDUSTRY APPLICATIONS Seaward Electronic’s range of high voltage test equipment has been specially designed for the safe and practical detection of voltages on electrical systems in the power generation and distribution, rail network, petrochemical and electrical service and maintenance industries. The range of high voltage safety testing equipment available includes neon and digital voltage indictors, safe discharge units, neon and digital phasing equipment, insulator leakage detectors and current clamps. The KDIE high voltage indicators include both neon and digital systems to confirm

the presence of voltage on earthed neutral electrical circuits up to 33KV. These are supported by a range of high voltage phasing rods that enable phase comparisons to be made at the point of paralleling two circuits without the interposition of voltage transformers or secondary wiring circuits. A neon type instrument is available for use on circuits up to 11.5KV and digital versions are available for use on systems up to 15KV and 33KV. The range of HV Indicators and HV Phasing Units is supported by a hook ammeter for accurately measuring current flow on overhead power lines and a large jaw clamp meter for the measurement of current flow through large conductors.

a break from its traditional make-to-order strategy, Monitran is manufacturing some sensor types to be available as off-the-shelf items. Anthony concludes: “Why are we doing this? All the indicators are that everyone in the industry is still holding their breath and waiting for a recovery to just happen. In our experience, it is necessary to make things happen; and having helped our customers during the recession in the 1980s, we know that recovery is only possible through doing things to stimulate the supply chain.” +44 (0)1494 816569 www.monitran.com Reader Reply Number: 304

In addition to the standard range of test equipment, specialist testers are also available for the safe discharge of stored energy in large capacitors and electrically charged equipment. A dedicated airfield ground lighting voltage detector has also been introduced for proving dead on AGL systems up to 5kV. All high voltage test and measurement equipment in the Seaward range complies with international safety standards and are manufactured in accordance with IEC 61243. As well as specialist carrying cases, a range of accessories is also available in support of the main high voltage test instruments. These comprise proving units, battery chargers, overhead line extensions and bend end adaptors for specialist switchgear locations. (0191) 586 3511 www.seaward.co.uk Reader Reply Number: 305

POWER QUALITY METERS FROM ALL THE MAJOR MANUFACTURERS ARE AVAILABLE FROM ALPHA ELECTRONICS Alpha Electronics, nationwide distributor of handheld and portable electrical and electronic test equipment, offers Power Quality Meters from all the major manufacturers, including Fluke, Chauvin Arnoux, Megger and Elcomponent. The power quality test tools and power analysers offer troubleshooting, predictive maintenance and long-term recording in industrial and utility applications. Also, for developing and testing electrical equipment, power analysers can be used for easy and reliable use in the field or in test laboratories. Alpha Electronics has the technically qualified

personnel to provide advice to its customers on the best product for their needs. Examples of products offered by Alpha Electronics are 3-phase and single phase Power Quality Analysers - the Fluke 430 Series and 43B, the Chauvin Arnoux 8334 and 8335, the Megger PA9Plus and the Elecomponent PowerPro; Power Loggers – the Fluke1735 / 1740 and 1760 Series and the Elcomponent EnergyPro; and Power Quality Clamp Meters – the Fluke 345 and the Chauvin Arnoux F27. Alpha Electronics can demonstrate the products and provide a full technical back-up and after sales service.

8 EMS May/June 2009 www.engineeringmaintenance.info

Alpha Electronics also runs a comprehensive hire service for many of its products, a ‘collect-and-return’ calibration and repair service, and training services. The company has recently integrated all its southern operations into new, enlarged premises in Maidstone, Kent, to cope with an expanding workload. It also has premises at Atherton, Greater Manchester, and in Newport, South Wales (The Instrument Centre). www.alpha-electronics.com Reader Reply Number: 306

Totally transforming...

...the performance of your drives ABB’s scheduled drives reconditioning programme helps you avoid unplanned downtime of variable speed drives, optimising maintenance costs and increasing drive reliability. As part of ABB’s product lifecycle services, the drives reconditioning programme takes place at ABB’s authorised drive service workshop located in St. Neots, Cambridgeshire. The workshop is equipped with the very latest in diagnostic, testing and maintenance equipment so you can be sure that your low voltage drives are reconditioned to the highest standards. For further information call 01480 488080 or visit www.abb.com/drives

Power and productivity for a better world TM

B:I:G>C< BDC>IDG>C< HDAJI>DCH

aM&T Sub-Metering Systems

Power Quality Analysers

Energy Data Loggers

Power Factor Correction

Flexible cost-effective metering for all utilities and every type of business. We have the hardware, software, networking and installation skills to supply the package you need, on time and on budget.

High performance instruments for the most demanding energy and power quality analysis applications designed and built to the highest quality standards. Supplied complete with the latest windows software.

Easy to use portable data loggers for electricity and general utility monitoring. Safe, non-invasive.

#OST EFFECTIVE AUTOMATIC 0&# UNITS FOR fast payback and real savings.

s !LL KITS SUPPLIED @READY TO GO

s !%' #APACITORS

s !UTOMATIC DATA COLLECTION AND alarm signalling

s !LL ELECTRICAL PARAMETERS

s &LEXIBLE NETWORKING OPTIONS

s /N BOARD POWER FOR mEX #4 S

s 7EB ENABLED HARDWARE

s 0LUG IN -EMORY

s 4ENANT "ILLING

s !VAILABLE TO HIRE

s &AST $ELIVERY

s 4OUGH WATERPROOF CASES (3 phase analysers) s 3IMPLE 7INDOWS SOFTWARE

s 4($ (ARMONICS &LICKER ETC

s !VAILABLE TO HIRE

www.elcomponent.co.uk t 01279 503173 f 01279 654441 e sales@elcomponent.co.uk Unit 5, Southmill Trading Centre, Bishopâ&#x20AC;&#x2122;s Stortford, Hertfordshire CM23 3DY

For more information quote EMS Enquiry No. 108 on IBC

We can show you the way... Proviso Systems Ltd provide condition monitoring and predictive maintenance products and services predominantly to the UK market. We utilise techniques including vibration monitoring, thermal imaging, oil analysis and integrated plant management philosophies.

Let us light the way to protecting your business... Vibration Analysis Thermography Oil Analysis Hydraulic Circuit Testing RCM

Balance & Laser Alignment Pulley Alignment Electrical Inspection & Testing Motor Current Analysis Equipment Criticality Audits

Tel: +44 (0)1777 817536

Email: sales@proviso-systems.co.uk

For more information quote EMS Enquiry No. 109 on IBC

Web: www.proviso-systems.co.uk

SPARES MANAGEMENT

Spares management is a complex issue for manufacturers, almost regardless of the sector in which they are operating. Rapid access to spares is of course vital to maintaining continuity of production and avoiding costly downtime.

Adding value at every turn However, not only are the required spares often of low value and required infrequently, but the sheer range of components to which a plant needs to have access can be daunting. And, for many, that range of products means dealing with a multitude of suppliers across different product areas – from bearings and mechanical power transmission to hydraulics, pneumatics, tools and personal protective equipment (PPE). Brammer employs over 2,500 people in more than 300 locations in 16 countries, making them a leading panEuropean distributor of bearings, belts & pulleys, chains & sprockets, linear motion, motors, seals, gearboxes, pneumatics, hydraulics, clutches & couplings, tools, maintenance and health & safety products. This unique pan-European scale allows Brammer to offer a single source supply of all the world’s leading brands. Brammer

offers competitive pricing through buying power and excellent levels of product availability through the most extensive stock holding in Europe. Despite this scale across Europe, Brammer is totally committed to operating locally – A strong local presence enables Brammer to remain responsive to local requirements and offer a tailor made service adapted to specific needs. Brammer understands that different industries have different needs and our extensive experience means Brammer can offer the right products and services in any environment. Adding value at every turn In today's increasingly competitive business environment, you need more than just an MRO distributor who can supply products when you want them at a competitive price. You need added value at every turn. Brammer is a professional and proven supplier. Brammer can provide excellent

local service to support your production operations, while applying our expertise and experience to help you to reduce costs on an ongoing basis. Brammer have identified key areas in which Brammer can add real value through a range of cost-saving MRO services.: Reduce total acquisition costs Improve production effciency Reduce working capital Insite Services 24/7/365 Energy Savings Vendor managed inventory NDC Workshop Services Gearbox Repair Pump Repair & Maintenance All of this, of course, is offered 24/7/365 through our extensive UK Sales and Service Centre network. Brammer and your industry Brammer has extensive experience of working with almost all industries right across Europe. Hundreds of manufacturers

11 EMS May/June 2009 www.engineeringmaintenance.info

SPARES MANAGEMENT

have selected Brammer for their maintenance, repair and overhaul (MRO) requirements. Our experience means Brammer understand the special needs that relate specifically to your business and production processes. Brammer know how important environmental issues such as energy conservation and waste costs are to you and your business. Brammer realise the Health & Safety demands and understand the need to maintain production lines running 24/7/365. Brammer understand what impacts these issues have on you MRO requirements and how Brammer can apply our experience to provide you with the best MRO support, meaning you always have the right part, at the right time for your specific needs.

Products With over 2,100,000 product lines available from the worldâ&#x20AC;&#x2122;s most respected and reliable manufacturers, Supply includes quality bearings, belts & pulleys, chains & sprockets, linear motion, motors, seals, gearboxes, pneumatics, hydraulics, clutches & couplings, tools & maintenance and health & safety products for your key production and operational processes. Even if the part is unrecognisable Brammer can help. By accessing even limited parametric information, our Technical Sales and Support team can source and advise you or your team on specific products or applications. The 2009 Brammer Essential Maintenance Catalogue is Brammer's biggest ever, containing more than 1,600 pages and more than 46,000 products.

12 EMS May/June 2009 www.engineeringmaintenance.info

The catalogue contains information on bearings, seals and electrical and mechanical power transmission, hydraulics, pneumatics and general maintenance products. It also offers useful advice on reducing energy consumption and carbon footprint through motor management, variable speed drives (VSDs) and compressed-air audits. It contains information about Brammer's National Distribution Centre workshop and regionally located repair centres. All products detailed in the catalogue are available through Brammer's UK network of 90 sales and service centres, each of which hold substantial stock and offer technical support and expertise. www.brammer.co.uk Reader Reply Number: 307

Maintenance software just got easier

G G G

Delivering maintenance software benefits since 1990 Proven by hundreds of customers in a wide range of industries Flexible system to meet your needs Now even simpler to buy, implement and use. Fully feature systems start at £1490

Don’t taketake our our word for for yourself. Don’t word it. Call us now, and find out for yourself. Call us now, and find out for yourself.

Tel: 0191 2963816 email: sales@cayman.co.uk Web: www.cayman.co.uk For more information quote EMS Enquiry No. 110 on IBC

Boiler Door Gaskets

Boiler Doors

Tapes & Lagging

For more information quote EMS Enquiry No. 111 on IBC

Industrial Boilerhouse Supplies Ltd.

Refractory Materials

Unit 34 Brunel Way, Segensworth East, Fareham, Hampshire, PO15 5SF, England

We offer the complete Boiler and Burner Spare Parts Service

Level Gauges

Boiler Pressure Gauges

Level Gauge Spares

Grundfos Pumps

An independent stockist and supplier of spare parts and equipment for industrial and commercial steam and hot water boilers. • All makes of Boiler spare parts and Ancillaries • Distributor & Stockist of Blue-Max, Black-Max & Topog boiler door gaskets. •

Boiler water level controls stockist - Mobrey, Gestra, Spirax - All spares & new installs. • Boiler Refractory - Mouldable, Castable cements, Fire Bricks & Quarls, Ceramic materials, blanket, board, ladder & webbing tapes. • Boiler Pressure & Temperature Gauges, Boiler level gauge mountings & spare parts. • Stockist for Nabic safety valves, steam crown & water feed check valves. Safety Valves

Flow Meters

Valves

Mobrey Level Controls

Your First Choice Supplier Tel : (01489) 570737

Fax : (01489) 570767

NEW 2009 CATALOGUE FEATURING 350 PAGES OF PRODUCTS

E-mail : info@ibhs.co.uk

For more information quote EMS Enquiry No. 112 on IBC

www.ibhs.co.uk

SPOTLIGHT ON OIL ANALYSIS

Checkfluid Inc. is an ISO 9001:2000 certified manufacturer of fluid sampling valves for safe, accurate, reliable sampling of oil lubricated and hydraulic systems. Applications include engines, generators, automatic transmis-sions, hydraulics, compressors, gearboxes, pumps and motors in both mobile and stationary equipment applications

The first step in oil analysis there is an ongoing concern about the safety, accuracy and cleanliness of various sampling procedures being used. Checkfluid offers a complete range of sampling valves including ultraconvenient KP pushbuttons for engines and compressors. Simply install permanently into existing pressure ports on the oil gallery or filter housing inlet for fast, accurate sampling with no probes required. Or for splash-lubricated industrial gearboxes, avoid bottom sludge deposits and take safe operating samples with permanently installed LT Series sampling tubes. Call or email for more information or assistance in selecting the best valve for your application. We look forward to serving you. Tel: 001-519-652-6373 Fax: 001-519-652-0392 The ability to collect consistently accurate samples is the first step in a successful oil analysis program. Unfortunately, equipment operating and sampling conditions are often less than ideal- and

Email: info@checkfluid.com www.checkfluid.com Reader Reply Number: 501

DOMINO USS is a portable system providing a fast, convenient way to measure water content in oil or the dewpoint of a gas

Ultimate SAMPLING SYSTEM Easy to use, it is also a highly effective way to insure quality samples: the moisture-in-oil ppm or dewpoint reading on the Domino USS will not stabilize until all the excess moisture has been removed from the valve, ensuring that the valve or access point was adequately flushed prior to sampling. The real time graphic display allows instant monitoring of the stabilization procedure. The result? Dobleâ&#x20AC;&#x2122;s Domino USS makes quality sampling simple and easy.

Obtain accurate results in

six minutes or less.

14 EMS May/June 2009 www.engineeringmaintenance.info

Accepts two probes

simultaneously â&#x20AC;&#x201C;

recognizes both probes and their type (moisture-in-oil or dewpoint). Operates on AC voltage or rechargeable battery for portability. For more information on the Domino USS and other Doble products please contact Lee Morgan on 01483 514120 or lmorgan@doble.com Tel: Lee Morgan 01483 514120 Email: lmorgan@doble.com www.doble.com Reader Reply Number: 502

SPOTLIGHT ON OIL ANALYSIS

The CSI 5200 Machinery Health Analyzer provides comprehensive oil analysis results including particle count and size distribution, ferrous density, oil chemistry, water-in-oil, viscosity, and microscopic wear debris analysis

Industrial onsite

OIL ANALYSIS

EngineCheckUp Engine Analysis is an award winning patented simple and economical diagnostic tool which evaluates the condition of any 4 stroke gasoline (petrol) and diesel engine

IMMEDIATE in 7 Minutes! gas & diesel engine analysis FAST At only seven minutes per sample most industrial plants can test 100 samples in two days. SAMPLE The 1-2-3-4 step procedure is guided and checked by software. ACCURATE Multiple measurements for contaminants and wear debris practically eliminates false findings and often finds problems overlooked by labs. ACCEPTED Complies with ASTM D7416 and ISO 11171. Tel: +44 870 240 1978 Email: andy.hammond@emerson.com www.assetweb.com/mhm Reader Reply Number: 503

Drop the oil from a dipstick onto the EngineCheckUp test medium, and see results within 5 minutes. You will know if your engine has a major or minor problem or if it is time for oil and filter change. Using and easy-to-read reference card you are able to analyze results and check the 5 major categories of engine condition: Grime Condition of your oil Water Coolant (Glycol/Antifreeze) Fuel (Gasoline/Petrol and Diesel) Automobile and truck fleet operators Lower Operating Costs with Condition Monitoring Condition Monitoring is fast becoming the principle way Smart Maintenance Planners in the vehicle industry reduce operating costs. Condition Monitoring minimizes equipment downtime. Reduce costs of maintenance blowouts, operational delays or downtime caused by equipment failure. EngineCheckUp can assist with accurate on-site engine analysis. Analyze with EngineCheckUp and trend results. After the

engine oil has been sampled several times, engine condition trends are identified. The result will indicate abnormal wear, presence of fuel, soot, water or dust contamination, detrimental oil viscosity changes and the existence of glycol (anti-freeze). Maintenance can be scheduled conveniently with minimal downtime. If testing reveals no problems, oil change intervals can be extended! (Our tests indicate up to 38%). Condition Monitoring takes the guesswork out of Preventative Maintenance. Also from EngineCheckUp - Multi-Fluid Analysis â&#x20AC;&#x201C; accurate and fast testing of brake, power steering, transmission, differential, compressor, hydraulic and transfer case lubricants. All claims relating to EngineCheckUp have been substantiated by the German organization, TUV (Technical Monitoring Association). Significant professional discounts. Dealer and distributor inquiries welcome. E: allen@enginecheckup.com www.enginecheckup.com Reader Reply Number: 504

15 EMS May/June 2009 www.engineeringmaintenance.info

Save time and money: Register now!

www.maintain-europe.com/tickets

International Trade Fair for Industrial Maintenance

You have to participate to profit: MAINTAIN 2009! International industry forum and driving economic force Complete, special and system solutions for your company and your day-to-day operations Service providers and manufacturers as contacts for operational and strategic tasks Management solutions, service packages, products and innovative service concepts directly from the source Direct contact with colleagues, suppliers, decision-makers, trade associations, science, research and specialty media Educational program of related events including practical examples, roundtable discussions and technical lectures

Pattern Ltd. . Richmond, Surrey TW9 2LL Tel. (020) 8940 4625 . Fax (020) 8948 1442 info@pattern.co.uk

13â&#x20AC;&#x201C;15 October 2009 M,O,C, Munich www.maintain-europe.com Hotline (+49 89) 9 49 -5 53 68

For more information quote EMS Enquiry No. 113 on IBC

For more information quote EMS Enquiry No. 114 on IBC MT09 EMS 95x297 GB 1

29.05.2009 10:54:13 Uhr

SPOTLIGHT ON OIL ANALYSIS

FA-ST Filtration Analysis Services Technology Ltd (FA-ST Ltd) was formed to service the growing need of preventative & pro-active maintenance and contamination control. Our staff have many years of 'hands on' and management experience of working within the transport, quarrying, engineering, marine, construction, machinery hydraulics, service and repair industries

How clean is your oil? Oil Analysis Services Oil analysis is an ideal preventative maintenance tool and can be used in conjunction with regular maintenance procedures or as part of a condition monitoring programme. For owners and operators of all types of plant and machinery in all industries and it can provide substantial cost savings in identifying contamination and predicting possible premature failure of components.

Our Laboratory operates to ISO 9001:2000 standards and meets all manufacturer warranty requirements. The Laboratory can provide analysis for all types of synthetic and mineral, engine, gas engine, hydraulic, transmission and gear oils, coolants, grease, cutting fluids, water based oils, glycols emulsions, diesel fuel, bunker fuel and biodiesel etc. Tel: +44 (0)1246 268900 Email: info@fa-st.co.uk www.oilfiltration.co.uk Reader Reply Number: 505

Karl Storz Endoscopy is world leader in manufacturing of Industrial Endoscopes for non-destructive visual inspection of Gas Turbines, Diesel Engines, Boilers, Heat Exchangers, and equipment related to the Oil and Gas industry

REMOTE visual inspection EQUIPMENT Industrial Endoscopyâ&#x20AC;&#x2122;s advantage is the ability to convert sheer guesswork into objective visual findings, reducing costly dismantling of equipment. We manufacture the full range of remote visual inspection equipment to cover the whole spectrum of various industrial applications. We have a long reference

list of world renowned customers, some of which are Lufthansa, Air France, Olympic Airways, Schlumberger, General Electric, Rolls Royce and Pratt & Whitney.

Tel: +44 (0)1246 455371 E: industrial@karlstorz.com www.karlstorz.com Reader Reply Number: 506

17 EMS May/June 2009 www.engineeringmaintenance.info

SPOTLIGHT ON OIL ANALYSIS

A mining company keeps on digging with RFID-Enabled Maintenance Asset Tracking

MASS Group Maintenance

Oil Sample Tracking

CASE STUDY Customer Profile: One of the worldâ&#x20AC;&#x2122;s largest mining companies must keep a large fleet of massive mining equipment up and running, reliably, in the harsh outdoor environment of an open pit coal mine. Unscheduled downtime, repeat maintenance procedures due to errors, and inaccurate test results were potentially costing them production time at their coal mine located near the Rocky Mountains. Business Situation: Profitability of their worldwide operations requires that complex mining equipment be reliably operated under harsh conditions. A robust system of preventive maintenance enables high equipment uptime on these sites. The mining companyâ&#x20AC;&#x2122;s preventive maintenance plan was difficult to implement due to several process failures as fluid samples were taken from multiple ports on the massive mining equipment and transported to a lab for analysis. Human input errors and paper travelers that were destroyed or misplaced led to a high rework rate and service errors from incorrect labeling of samples. Challenge: There are more than 100 pieces of equipment in operation. Equipment maintenance personnel collect as many as 50 fluid samples from a single piece of equipment. Each sample is associated with a particular location on the equipment and is sent to a lab for analysis. The fluids collected (engine oils, hydraulic fluids, brake fluids, etc.) are analyzed for chemical breakdowns which can mean the machine may have excessive wear and potentially requires maintenance to avoid a major production stoppage. The previous method of tracking the samples consisted of writing down the location, temperature, equipment ID, and time stamp on a paper form. This form was sometimes lost, destroyed, or illegible which resulted in misinterpretation between the mine and laboratory. Solution: Durable, encapsulated RFID tags from Datalogic EMS, the LRP-S series, are used to uniquely identify equipment (asset), port, sample, and technician. A portable printer creates a unique barcode label for each sample. An RFID-enabled portable handheld computer is used to import the RFID tag information of sample, equipment location, and technician into a unique record and feeds the tag data into FactoryServer CMMS EAM, an asset management maintenance software solution by MASS Group. FactoryServer CMMS EAM creates, stores and reports on the data. Results: The new, complete solution using FactoryServer CMMS EAM software by MASS Group, a portable RFID handheld, and unique durable RFID tags allows the company to have 100% confidence in the sampling and reporting accuracy of the mechanical fluids from each machine. Every step of the process is now immune to human error and failure under the harsh conditions of a mining operation. www.massgroup.com

Reader Reply Number: 507

18 EMS May/June 2009 www.engineeringmaintenance.info

Turner Designs Hydrocarbon Instruments has developed a revolutionary bench-top method to measure oil-in-water that uses no solvent

Now you can perform oil-in-water analysis WITHOUT EXTRACTION SOLVENTS! The advantages are significant in that we have eliminated the health and safety hazards of transporting, handling and disposing of solvents commonly used in the field for oil-in-water analysis. Along with safety, the method eliminates operator error associated with precision liquid measurements during the analysis process. This new method is designed to be compatible with our TD-500D hand held oil-in-water analyzer. It is a robust method using a simple

surfactant instead of solvent, with unprecedented accuracy and repeatability. To learn more about our products, please visit us at www.oilinwatermonitors.com. If you have specific questions about any of our products, you can contact our Sales department at sales@oilinwatermonitors.com or call (559) 253-1414. 559 253-1414 sales@oilinwatermonitors.com www.oilinwatermonitors.com Reader Reply Number: 508

SPOTLIGHT ON OIL ANALYSIS

Scientifics Ltd, a nationally based consultancy and testing company, have a long pedigree in providing Oil Condition Monitoring services through their associations with the transport industry

MONITOR the full condition of components, NOT JUST OIL Scientifics recognises that testing can only realise its true potential when results are managed alongside maintenance and operational actions. With the introduction of Dingo TraKKa, Web Based Asset Management Software, the management of results, actions and

work orders can be controlled resulting in an effective work tool to reduce breakdowns and extend the working life of your valuable assets. For further information on how Scientifics and TraKKa can help you manage your valuable assets please contact:Scientifics Ltd, 4 Hexthorpe Road,Donacaster DN4 0AE. Tel: +44 (0)1302 380150 www.scientifics.com

E: graham.baird@scientifics.com Reader Reply Number: 509

LUBRICATION The Bank of England cut in interest rates may be important in the long term, but do nothing to alleviate the immediate pressures on production companies’ profit margins. These margins are being eroded by prices rises in electrical energy, plant maintenance and replacement part expenditures

Saving electrical energy and repair

OF WORN MECHANICAL ASSETS IN SITU SLIPSTREAM are the formulators and manufacturers of highly advanced bespoke lubricants that can make an immediate impact in improving the financial profits of a production company’s bottom line a certainty. SLIPSTREAM has been established since 1988 with a customer base covering the food, pharmaceutical and industrial sectors. Over the years, SLIPSTREAM has become the preferred supplier to many of the leading brands with its range of fully synthetic food grade lubricants. Formulated from synthetic food grade chemicals SLIPSTREAM’s product range lubricate, protect and extend the working life of all types of mechanical assets at varying stages of wear. The products

minimise the friction between asset components and as a result reduce both energy consumption and maintenance costs. Benefits of the SLIPSTREAM lubricants are: USDA H1 and NSF for incidental food contact approvals Meet the of requirements of the UK Food Standards agency Significant electrical energy savings Treats and repairs worn machinery in situ Minimum working life of fluids 7 years Gels last five times longer than conventional greases Environmentally friendly and non-toxic Independent testing carried out by the National Centre of Tribology

proved that the SLIPSTREAM lubricants significantly reduced wear by around 26 and a saving of over 10% in electrical energy when compared to equivalent competitor lubricants.

Tel: 01424 465 527 sales@slipstreamlubricants.co.uk www.hydralube.co.uk Reader Reply Number: 311

19 EMS May/June 2009 www.engineeringmaintenance.info

SPOTLIGHT ON OIL ANALYSIS

SPOTLIGHT ON VALVES

Kittiwake are continually looking for ways to cut the cost of testing for our customers. One way of doing this is to decrease the hazardous nature of our tests for use and for transportation. Over the past two years we have reclassified over 80 reagents and a recent breakthrough by our Scientists now enables us to provide many of the Kittiwake DIGI Test Kits in non-hazardous for shipping versions

Flowstream, established in 1842, was the first company to produce all British designed and manufactured control valves; a leader in its field with a world-wide installed base and recognition

EasySHIP Water in Oil

reagent is here The new EasySHIP reagent sachet has been developed solely with shipping costs in mind. For the first time you can now buy the DIGI Kittiwake Water in Oil test which is non-hazardous for transport and for use. On average this will save over 70% on shipping costs, dramatically reducing the overall cost per test*. The new non hazardous, single dose, no mess sachet requires absolutely no pre-work and no mixing before use. The simple test method then provides accurate PPM water in oil results in just 3 minutes. The addition of EasySHIP Water in Oil reagent also means that a variety of Kittiwake DIGI test kits can now also be shipped as non-hazardous products. To download the latest PDF showing the Kittiwake Oil Test Solutions Range go to http://www.kittiwake.com/docs/MAK27467-KW_Oil_Test_Solutions_Flyer.pdf EasySHIP Options; FG-K1-101-KW - EasySHIP DIGI Water in Oil Test Kit FG-K1-102-KW - EasySHIP DIGI Water in Oil & Viscosity Test Kit FG-K1-103-KW - EasySHIP DIGI Basic Test Kit FG-K1-107-KW - EasySHIP DIGI Industrial Test Kit FG-K1-109-KW - EasySHIP DIGI Industrial Oil Test Kit (with Viscotube) FG-K1-110-KW - EasySHIP DIGI Combined Test Kit FG-K2-101-KW - EasySHIP Water in Oil Reagent Pack (50 Tests)** Contact your local office now for more information on the EasySHIP range. * Saving based on a sample of orders including shipping costs ** EasySHIP Reagents can only be used on DIGI Cells with EasySHIP software and Cell Logo Reagent B Water in Oil Powder sachets are still available as are the current range of test kits. Patent Pending.

Tel: +44 (0) 1903 731470 Email: sales@kittiwake.com Reader Reply Number: 524

Fax: + 44 (0) 1903 731480 www.kittiwake.com

20 EMS May/June 2009 www.engineeringmaintenance.info

It is possible you may have seen some of comprehensive valve ranges under the following brand names: Hunt & Mitton; ITT Flowstream; and Johnson Controls MacLaren Products. Today, Flowstream International Limited manufactures valves, supplies spare parts and offers a refurbishment and repair services for our complete and extensive range of process valves, which have been tried, tested and field-proven, giving troublefree service for several decades in all types of industries. We have currently 3 ranges of products: 1. Flowstream Process Control Valves range for general and severe service applications. 2. Flowstream Inline and Hydraulic vales range for fast cyclic on-off duty (to 6000 psi duty) with impeccable service to rubber, steel and many other industries. 3. Flowstream manual stop valves range for hazardous chemical service such as Chlorine, Phosgene and other toxic and noxious media. We are here to help. For further details, please contact: Dr M.Soufian, Flowstream International Limited 104 Wrentham Street, Birmingham, B5 6QL United Kingdom

M: +44 (0) 7900 19 4414 F: +44 (0) 121 622 2099 W: ww.flowstream.co.uk Reader Reply Number: 510

T: +44 (0) 121 622 2110 E: sales@flowstream.co.uk

OEE

I was invited to speak at the recent launch of MaEx, the Manufacturing Excellence exhibition taking place in Brussels in February 2010, which is a joint event with MetaPro. Hence the venue for the launch - the futuristic Arcelor-Mittal OCAS metals research centre in Zelzate. . .

OEE –

the Art of Persuasion The session made one thing clearer to me than ever: Manufacturing Excellence is a pretty big subject which means different things to different people, and companies can take lots of different approaches (TPM, Lean, Six Sigma etc). But whichever route you take, it all comes down to the same thing - persuading the team to change in some way. There is a whole library of work written on the subject of change management, but I maintain systems like OEE play a vital part in

achieving Manufacturing Excellence; OEE helps to focus people on the necessity for change by highlighting and quantifying opportunities for improvement - providing the carrot and the stick. Measure, Prioritise, Allocate, Resolve It’s all well and good having an industry standard measurement in place to gauge how well you’re doing, but it’s what improvement teams do with it that counts. Establishing priorities and dealing with them couldn’t be easier if you’ve got the

right system in place. For example, let’s start by quantifying the ‘Top 5’ losses for a precise time period, usually a shift. It’s part of the accountability and responsibility process to review the ‘Top 5’ losses and assign each of them to the individual best able to resolve them. If the worst loss has been slow materials supply stopping the line, there is very little point in involving maintenance engineering or the quality department. Only the materials manager can improve the situation, so make him

21 EMS May/June 2009 www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 115 on IBC

OEE

accountable. Review that single loss for the last 13 weeks; agree what needs to be done in a fixed time-scale, and then monitor progress towards resolution. Too often, I see recognised failures cropping up in plants time and time again – and there is nothing more frustrating. The reason the same failure keeps occurring? Everyone gets involved in dealing with the latest ‘big problem’, forgetting to follow through and properly and permanently resolve the ‘big problem’ from last week. Honda UK has some good ideas for overcoming this issue. Meet with the key people, for as short a time as possible. That means a clear agenda, and time limits. Limit the meeting to 30 minutes and use a room with no chairs (talk about making people think on their feet!). Just prior to the meeting, the shift manager places on the floor of the ‘campaign’ room large red and green vinyl circles. The ‘hotspot’ system provides an incentive to improve and focuses the team on what can be done to ensure the next shift is better:

notes showing what has been tried and tested (what has worked and what has not). A photograph of the person accountable for resolving the loss next to the display also works. It helps to reinforce the ‘I’m responsible for fixing this’ concept. An Improvement Agenda is also a powerful persuasion tool. Each time a review session identifies what needs to be done, record the elements for each participant. Include figures for the costs and savings of resolving the loss as well as target completion and review dates. Identify the person accountable and the team members, then record progress made at each review meeting. Don’t let the problem drop off the list to be replaced by the latest problem identified - stick at it until it goes away. Even better, use traffic lights to make progress highly visible; green to show on target through amber to red as overdue. When the task has been completed use ticks of a corresponding colour so that you can easily see ‘on-time’ tasks compared to those which were completed late. An Improvement Agenda with a Traffic Light system makes progress (or lack of) highly visible and identifies any losses without an improvement plan

Based on the performance of the previous shift, if the team leader has achieved target he or she can stand on a green circle, if below target they get to stand on a red circle. It’s tough if yours is the only red circle, but it’s quite an incentive to improve. After a few seconds spent praising the teams on the green circles, the rest of the 30 minutes is spent discussing what went wrong for the team leader on the ‘hotspot’ and, most importantly, how things can be improved for a better shift tomorrow. The key issue is to learn from any mistakes, not adopt a blame culture. The best sites have their Top 5 losses on display in a campaign room, and for each of those losses they display the trend for that loss over recent weeks, together with a few

Whilst the CI teams and front line managers need to see the OEE and loss details, more senior managers can just review the improvement traffic lights to check their teams are making progress and are on target. More importantly, they can check at a glance to see if there are any recent issues without an improvement plan. Resolving the Top 5 losses requires attention to detail and persistence; don’t rush things, follow through carefully, don’t get distracted, and don’t let anyone off the hook. Bring in extra support when progress is slow. And remember the magic formula according to Peter Willmott’ study: Remember the formula For every 100 unplanned breakdowns and stoppages: 40 Can be fixed by restoring equipment to standard conditions 20 Can be fixed by daily asset care checks 25 Can be fixed by regular and relevant condition monitoring 15 Can be fixed by designing out physical weaknesses in the equipment Many people jump to the last element and believe every problem needs an equipment re-design project to resolve it. In reality, most problems are made to go away if everyone can be persuaded to just complete their designated tasks properly. www.idhammarsystems.com Reader Reply Number: 308

ABOUT THE AUTHOR Alan France is Operations Director of Idhammar Systems Limited. Contact him by e-mail: alan.france@idhammarsystems.com, or visit www.idhammarsystems.com for more on OEE software.

23 EMS May/June 2009 www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 116 on IBC

For more information quote EMS Enquiry No. 117 on IBC

" QSPWFO NBOBHFNFOU UPPM UP IFMQ LFFQ USBDL BMMPDBUF BOE JNQSPWF FG¾DJFODZ

7JTVBM 1MBOOJOH GPS &OHJOFFSJOH BOE .BJOUFOBODF 8IBU XF DBO IFMQ ZPV EP 1MBO ZPVS XPSL NPSF FG¾DJFOUMZ *NQSPWF ZPVS EFQBSUNFOUµT QFSGPSNBODF 1SJPSJUJTF VSHFOU UBTLT *NQSPWF $PNNVOJDBUJPO #F $PTU &GGFDUJWF ²*OGPSNBUJPO BU B HMBODF³

)PX XF DBO EP JU 5BJMPSFE UP ZPVS SFRVJSFNFOUT 1MBOOFE 1SFWFOUBUJWF .BJOUFOBODF 3FBDUJWF #SFBLEPXO #PBSET )FBMUI 4BGFUZ 4ZTUFN $POUJOVPVT *NQSPWFNFOU ,"/#"/ 1SPEVDUJPO 1MBOOJOH $POUSPM

#PBSE BT JMMVTUSBUFE JODMVEJOH .BJOUFOBODF 5 $BSET

MACH INE LINE No.

EST. TIME

MACHINE

DATE

LINE No.

PRIORITY

DESC RIPTIO NAME N OF

DATE DESCRIPTIO

N OF FAULT

HIGH / LOW NAME

FAULT

: IBLE CAUSE AND POSS

AND PO

SSIBLE

PRIOR

ITY

SHIFT HI GH / LO W

CAUSE:

EST. TIM E SHIFT

POMZ 0SEFST BSF 1 1 7"5

INV No QTY.

INV No

QTY.

UIRED REQ ARES SPARESSP NREQU DESCRIPTIO DESC

COST

IRED

RIPTIO

N COST

5FM

8FC XXX UDBSETEJSFDU DPN

For more information quote EMS Enquiry No. 118 on IBC

SPOTLIGHT ON VIBRATION

Brüel & Kjær Vibro, the world leading independent supplier of safety, condition and performance monitoring products and services, announces the release of the VIBROCONTROL 1500 (VC-1500)

REMOTE diagnostic monitoring This powerful 2/4 channel vibration monitor combines reliable safety monitoring with advanced condition monitoring functionality at a fraction of the cost of traditional rack-based systems. The VC-1500 accepts inputs from two accelerometers and two temperature sensors (an integrated sensor is available) and provides vibration, temperature and bearing condition measurements from each channel. In addition, the unit offers trending capability, frequency analysis, post mortem analysis and remote monitoring capability! All of this is packed in a small DIN-

rail box measuring 90 x 75 x 115 mm. The intuitive functionality of the system requires no expertise to install, commission or use this product.

Brüel & Kjær Vibro

Dietmar Gleissner, Sales Manager

Leydheckerstraße 10, 64293 Darmstadt, Germany Tel: +49 (0) 6151 428 1172

Mobile: +49 (0) 151 1428 1162

Fax: +49 (0) 6151 428 1101 E: dietmar.gleissner@bkvibro.de www.bkvibro.com

Reader Reply Number: 511

Perpetuum Ltd designs and manufactures vibration energy harvesters for powering a variety of wireless and remote electronics

VIBRATION

energy harvesting

MONITORING Vibration harvesters convert unused mechanical energy into useable electrical energy. That energy is stored until it’s needed by the sensor and wireless communication radio. Condition monitoring and predictive maintenance programs require hardware that

is deployed in the field and in harsh environments. A power source that offers a “power for life” performance and maintenance free service is the ideal solution for powering wireless sensor nodes. The family of products Perpetuum offers includes harvesters tuned

to 22 Hz, 100 Hz, and 120 Hz for optimal power generation. Perpetuum also offers a rugged field assessment kit, wSNAK and wSNAK Lite that are full wireless sensor nodes powered by the vibration harvesters. These kits (above) demonstrate the quick and easy deployment of field

hardware powered by an environmentally friendly “fit and forget” power source. Tel: +44 (0)23 8076 5888 Email: info@perpetuum.com www.perpetuum.com Reader Reply Number: 512

25 EMS May/June 2009 www.engineeringmaintenance.info

SPOTLIGHT ON VIBRATION

This flexible instrument can be used for machine condition monitoring, process control and emergency shut-off

UNIVERSAL vibration monitor It provides various outputs like AC, DC, 4-20 mA and a relay contact for interfacing it with data acquisition systems, PLCs, panel meters, alarm devices and other equipment. The DIN rail module accepts the input signal from an IEPE compatible piezoelectric accelerometer. It features adjustable gain, high pass and low pass filter modules, RMS and peak detection. At the front side there is a bar graph display for the vibration level. The unit is powered from a 12 to 28 V DC source. The manufacturer also offers a wide range of piezoelectric accelerometers. Metra Mess- und Frequenztechnik, Meissner Str. 58D-01445, Radebeul, (Germany)

Tel: +49-351-849 2104

Fax: +49-351-849 2169

Email: info@mmf.de

www.mmf.de

Reader Reply Number: 513

Online Intelligence

Online condition monitoring

spminstrument.co.uk I intellinova.se

Intellinova速 is distinguished by its great flexibility and ease of use, enabling fast implementation of customer-defined solutions. Accuracy and reliability are also trademarks of this high performance system.

For more information quote EMS Enquiry No. 130 on IBC

EMS May/June 2009 www.engineeringmaintenance.info

lli

CRANE MODERNISATION & MAINTENANCE SERVICES

LET KONECRANES TAKE CARE OF ALL YOUR CRANE AND LIFTING EQUIPMENT NEEDS We can ensure your cranes and hoists are capable of the task, our crane and hoist maintenance services offer the most advanced recording and reporting systems in the business. Our inspection and maintenance technicians are trained in accordance with the latest legislation and codes of practice.

WE DONâ&#x20AC;&#x2122;T JUST LIFT THINGS, BUT ENTIRE BUSINESSES.

e-mail: sales.uk@konecranes.com

www.konecranes.co.uk

For further information please contact, Free Phone 0800 035 2843

For more information quote EMS Enquiry No. 119 on IBC

SPOTLIGHT ON ATEX MAGAZINE NEXT ISSUE: SEPT/OCT Baseefa is a world-renowned name in the hazardous area world. Principally known for the certification of electrical, non-electrical and mechanical equipment, intended for installation and use in potentially explosive atmospheres, Baseefa also offers a more extensive range of services

Helping to make the world safer CERTIFICATION: Certification is still our core business. Baseefa is a world leader within the IECEx scheme as well as being one of the most respected Notified Bodies within Europe. Baseefa engineers are actively involved in the standards making process meaning we are uniquely placed to provide our customers with up to date information on standards developments which might affect their products. DSEAR: Baseefa offers a full range of DSEAR services including: Hazardous area health checks DSEAR/ATEX user risk assessments Hazardous area classification DSEAR implementation, planning and project management Plant and operational hazard analysis Management system auditing and plant inspection services SERVICE REPAIR: Baseefa was the first certification body within the IECEx scheme to be accepted in the Service Repair Facility Scheme. This centres mainly on workshops offering repair facilities to IEC60079-19 but does allow for other related activities.

ATEX 137/ DSEAR requires competent Ex staff! Have YOU got all the answers? Offsho

Specia

re Euro

l Packa

ATEX Certific Competence ation a nd Train ing

from

ÂŁ200!!

Stand 1492

Contact +44 (0)1244 670 937 for more details or Email: training@siracertification.com

www.baseefa.com

Reader Reply Number: 514

A wide range of electric heaters for the Oil & Gas, Petrochemical, Refinery and offshore industries. Products include Screwed and flanged Immersion heaters, Air Duct heaters, electric heat exchangers, and Process control systems

Are you competent in Ex?

Sira, the UKâ&#x20AC;&#x2122;s leading ATEX & DSEAR expert is offering knowledge competence training and assessment at Offshore Europe 2009

Repairers gaining IECEx certification through Baseefa will benefit from international recognition and acceptance of their service and repair facility. TRAINING: Being a world renowned organisation in the field of explosion protection our training courses are designed to compliment the other services we provide to our customers. Our philosophy is clear, we like to keep it simple and all our training have this express aim. With this in mind we are confident we can deliver and tailor our courses to suit all levels of personnel. TESTING SERVICES: Baseefa offers a wide range of testing services, performed at our purpose built laboratory premises, including: Electrical Product Tests Dimensional Tests Non-Electrical Product Tests Ingress Protection Tests Environmental Exposure Thermal Testing

For more information quote EMS Enquiry No. 120 on IBC

EMS May/June 2009 www.engineeringmaintenance.info

FATI

Industrial electric heaters, systems and controls for hazardous areas All heaters are available certified Flameproof Eex-d,ATEX cat 11G, Gas groups 11A,11B, & 11C, Temperature class T1-T6 +T special up to +650 deg C and ambient temperatures down to -60 deg C. A wide choice of materials are available Including Stainless Steels. Inconel, Incoloy, and titanium. Electric circulation heaters and process heating systems for heating a wide range of industrial liquids and gases . Mechanical design codes include ASME VII, BS 5500, Stoomwezen, AD Merkblatter, ISPESL (PED), TEMA, or any other recognised code. Control Systems designed to suit each process application, ensuring full compatibility, interfaces and safety, especially where heaters are located in a hazardous area. FATI International Ltd Email: fatiint@btconnect.com Reader Reply Number: 515

Tel/Fax: +44 01243 606007 www.fati.com

SPOTLIGHT ON ATEX MAGAZINE NEXT ISSUE: SEPT/OCT Tyco Thermal Controls has introduced a new ATEX certified oscillator which adds hazardous area capabilities to its latest 5 Series CapaciSense high temperature, tip clearance measurement systems for gas turbine engines

NEW ATEX certified oscillator and longer cables for capacisense tip clearance MEASUREMENT SYSTEMS Whilst the earlier 4 Series systems also featured a full ATEX approved engine-mounted electronics package, the new oscillator in the 5 Series enables energy limited outputs to the sensing probe and connection and disconnection functions to be performed within the hazardous area. When used in combination with Tyco Thermal Controls latest cable, probes up to 10 metres in length can be supported so the oscillator can be installed outside of the turbine compartment for easier access and thermal management, whilst the rack electronics can still be 100 metres away from the oscillators. This latest development further demonstrates that capacitive sensors have progressed well beyond experimental and scientific projects and are providing industrial solutions with major benefits for users in the aerospace and power generation industries. Capable of monitoring gas turbine engines in operation, CapaciSense capacitive sensors deliver real time data on compressor and turbine blade-tip clearance measurements, rotor shaft and disc displacement. With its 400 kHz bandwidth, the 5 Series also allows tip timing measurements to be performed for blade vibration monitoring. CapaciSense high temperature clearance measurement systems accurately monitor a wide range of clearances within modern gas turbine engines. These systems have a patented capacitive sensor design that can be used with AM or FM electronics and are capable of withstanding tip temperatures up to 2550DegF (1400C). Using advanced electronic processing, CapaciSense will output real-time, high accuracy, blade-clearance and blade deflection information and can be configured to assist with engine condition monitoring, blade vibration and rotodynamic measurements. With over 10 years experience in developing capacitive sensing tip clearance and timing systems for this application, Tyco Thermal Controls is at the forefront of this technology. Its CapaciSense systems, with their exceptional probe life, have been in operational service on production engines for the last six years. In addition to the design, manufacture and supply of measurement systems, the Company provides full technical support, including sensor advice and a calibration service. Paul Seccombe, Technical Manager at Tyco Thermal Controls commented, "We set ourselves challenging performance targets for the new 5 Series and are excited to have exceeded our goals for all criteria. I believe that users will be impressed with the new system performance and appreciate how user-friendly we have made it." Tyco Thermal Controls, 3 Rutherford Road

Stephenson Industrial Estate, Washington NE37 3HX F: +44 (0)191 419 8357 www.capacisense.com

A FILTER IS A FILTER? CLEARPOINT® MAKES THE DIFFERENCE COMPRESSED AIR FILTER WITH ENERGY SAVING THANKS TO UP TO 50 % LOWER DIFFERENTIAL PRESSURE CLEARPOINT® • is thoughtfully constructed. Enlarged cross sections, soft radii, the absence of con-rods in the air stream and an optimally dimensioned filtration area all make a contribution to its outstanding efficiency. • is convincing because of its reliability due to needle felt element material. • offers verified efficiency – the separation performance is proved by an independent

CLEARPOINT® Compressed Air Filters are available for volume flows of 35 – 40,000 m3/h, a particle separation of up to 0.01 μm and a residual oil content of up to 0.001 mg/m3. Please contact us for more information.

BEKO TECHNOLOGIES LTD. 2 West Court Buntsford Park Road Bromsgrove Worcestershire B60 3 DX

Phone +44 1527 57 57 78 Fax +44 1527 57 57 79 info@beko-uk.com www.bekotechnologies.com

T: +44 (0)191 419 8310 E: PSeccombe@tycothermal.com Reader Reply Number: 516

For more information quote EMS Enquiry No. 122 on IBC

EMS May/June 2009 www.engineeringmaintenance.info

COMPRESSORS

The new Atlas Copco GA+ 90-160 kW range offers users a premium performance package with industry-leading free air delivery and outstanding energy efficiency. These are the first oil-injected compressors worldwide to integrate a water separator into the compressed air cooling system, thereby reducing internal pressure drops by 50% and contributing 2% to overall energy efficiency. What’s more, these are Atlas Copco’s first air compressors to offer VSD-controlled cooling fans

NEW high performance

GA+ 90-160 kW range The GA+ VSD version alone has broken eight performance records within the compressed air industry in terms of overall energy requirements, energy consumption of individual elements and the lifetime of replacement parts. The Specific Energy Requirement (SER) of the GA+ range is the best-in-class – 350 Joule/litre according to ISO 1217 edition 3 annex C (1996), thereby using up to 11% less electrical power than the previous GA models. Added to this, the new GA 160 VSD model offers the widest free air delivery (FAD) turndown range – from 100% to 17%. That is at least 18% greater than that of any comparable models. Operating at pressures from 3.5 to 14 bar(e), these machine are capable of the most energy-efficient performance even in ambient temperatures of up to 55 degrees centigrade – and at a maximum noise level

of 71 dBA, in comparison to the previous benchmark of 75 dBA. They also offer a doubled lifetime for both the oil filter and the air inlet filter. A major contribution to superior energy efficient performance is made by the stateof-the art compression elements, based on Atlas Copco’s patented asymmetric rotor profiles, designed for a 5-6% drop in energy requirements and a drastic reduction of volumetric losses. Thermodynamic losses are also minimised through optimisation of oil-injection, flow and temperature, so that the compression process is kept as cool as possible. Other features designed to reduce energy consumption include high efficiency motors and no-loss drains, plus the installation of radial fans with VSD regulation, capable of reducing energy requirements by up to 59%. All

30 EMS May/June 2009 www.engineeringmaintenance.info

components have been optimally integrated to reduce floor space and simplify connections. Air quality is assured by two key elements: a highly efficient oil removal system to give minimum residual oil content in the outlet air, and state-of-the-art refrigerant dryers. The dryers are available in both integrated and stand-alone versions, which, together with an air filter, ensure a continuous supply of clean dry air to extend the life of downstream equipment, enhance system reliability and avoid costly downtime and production delays. With the integration of its patented Saver Cycle Control, Atlas Copco has achieved further energy savings for its refrigerant dryers of up to 30% in normal load conditions. www.atlascopco.co.uk Reader Reply Number: 309

SPOTLIGHT ON FLOORING

Apollo Rapid Set is a two component repair mortar based on a methyl methacrylate liquid resin which acts as a binder and a mix of specially graded quartz aggregate and powder additives

APOLLO RAPID SET â&#x20AC;&#x201C;

first aid for concrete floors ADVANTAGES DURABLE - Very resistant to impact and wear HYGIENIC - Seamless, non-porous and easy to clean FAST - Ready for traffic after 1 hour which is ideal for minimum shut down periods RESISTANT - To most chemicals USAGE: Apollo Rapid Set has been designed has a fast and durable repair mortar to be used to repair damages,

holes, and imperfections in concrete substrates in thicknesses between 4mm and 25mm in one layer thick. Thicker applications can be made by adding additional amounts of aggregate. SURFACE PREPARATION: The substrate must be dry, firm, solid and free from dust. fat, oil, etc. All loose particles must be removed. before application porous substrates should be treated with a primer which should be applied until a continuous primer resin film is obtained.

MIXING: The powder component must be mixed with the liquid component to create a homogenous mixture that can be applied with the help of a trowel or wooden float at a minimum thickness of 4mm. Please telephone EMS parts to place an order: Tel 0845 270 2427.

Tel: 0845 270 2427 Reader Reply Number: 517

P & T Services are one of the UKâ&#x20AC;&#x2122;s premier suppliers of industrial cleaning equipment with many machines specifically designed for the engineering industry including industrial vacuums, floor scrubber dryers, vacuum sweepers, oil recovery & ATEX certified equipment

MACHINES

specifically designed for the

ENGINEERING INDUSTRY Full range of new & refurbished machines available to purchase, lease or hire with full nationwide service back up. If you have any kind of floor cleaning, dust extraction, high-level cleaning, materials handling, oil recovery, liquid

recovery or oil recycling problem contact us and we will do all we can to solve it! With over 20 years experience in the industry we have provided thousands of solutions for our customers saving them time, money and often improving

their production. The chances are we have encountered your exact cleaning problem before or at least a very similar one, please contact us if you would like further information, assistance or to arrange a free site survey or quotation.

Contact: Sharon Hosie P & T Services

9 Millcroft Road, Shawfield Ind. Est Rutherglen, Glasgow G73 1EN Tel: 0141 647 4200 Email: info@machines2clean.com www.machines2clean.com Reader Reply Number: 518

31 EMS May/June 2009 www.engineeringmaintenance.info

SPOTLIGHT ON INDUSTRIAL DOORS Door Engineering and Manufacturing is the premier manufacturer of four-fold, top hung and bottom rolling, vertical lift and various other door systems for industrial, commercial, fire rated, aviation and specialty door applications. Complete door systems from Door Engineering meet the most challenging and unique specifications

DOOR ENGINEERING DOORS

ideal for a range of applications Door Engineering’s industrial and commercial door systems are designed for maximum strength and reliability and are available in a variety of sizes and materials to meet specific requirements. Door Engineering's fire rated doors are also available in a variety of configurations and are UL and FM approved for up to four hours. Door’s complete line of aviation door systems include hangar and tip-up canopy doors that provide a weather tight seal. Aperture sliding door systems are also available. From standardized systems to custom designs, Door Engineering

and Manufacturing puts more than 40 years of door system experience to work on each project. Door Engineering’s product development specialists collaborate with their client’s engineers to ensure complete customer satisfaction and long-term value. Door Engineering and Manufacturing 400 Cherry St. Kasota, MN 56050

Tel: (507) 931-6910

Fax: : (507) 931-9318

www.doorengineering.com

Reader Reply Number: 519

HVAC MAINTENANCE EQUIPMENT Coil Cleaners

Cooling Tower Foamer & Vacuum

Electric & Air Powered Tube Cleaners

Tube Cleaning Drill

Industrial Boilerhouse Supplies Ltd. are please to announce that we are now the new UK and Ireland distributor and stockist for Goodway Technologies Corporation of Stamford USA. Industrial Boilerhouse Supplies Ltd. operate from Fareham in Hampshire and are a major independent stockist and supplier of Boilerhouse Equipment and spare parts offering a nationwide delivery service.

Boiler Tube Cleaners

Condenser Tube Cleaners

Pnuematic Tube/Hose Cleaning Guns

Inspection and Test Equipment

The extensive range of products offered by Industrial Boilerhouse Supplies Ltd now includes the world famous Goodway Tube Cleaning products and maintenance equipment, renowned for their high quality and proven results in cleaning tubes.

FREE CATALOGUE

OVER 100 PAGES OF PRODUCTS

Industrial Boilerhouse Supplies Ltd. Duct Cleaners

Air Powered Vacuums

HEPA Vacuums

Continuous Duty Vacuum

Unit 34 Brunel Way, Segensworth East, Fareham Hampshire, PO15 5SF, England

Tel : (01489) 570737 - 6 Lines Fax : (01489) 570767 E-mail info@ibhs.co.uk

www.goodwaytubecleaning.com

For more information quote EMS Enquiry No. 123 on IBC

EMS May/June 2009 www.engineeringmaintenance.info

www.ibhs.co.uk

For more information quote EMS Enquiry No. 124 on IBC

SPOTLIGHT ON TUBING

Piper Metal Forming Co., a leading oxygen and carbon dioxide cylinder manufacturer is among the first companies to realize the dramatic cost-saving benefits of the new Airmo TestMaster® 350 Hydrostatic Cylinder Test Tool

NEW Airmo TestMaster® 350 Test Tool

decreases thread damage and reduces cost of goods

for Piper Metal Forming Company Piper was able to solve serious thread damage and product return problems as a result of the innovative collet design and selfseating piston actuation technology integrated into the Airmo TestMaster® 350 Test Tool. Piper Metal Forming uses a cold forging process to manufacture aluminum oxygen and carbon dioxide cylinders for the medical industry. Per DOT compliance, every cylinder that Piper ships must be tested before it leaves their manufacturing facility in New Albany, MS. Prior to installing 24 Airmo TestMaster® 350 Test Tools, Piper used a manual connector in their hydrostatic test process that could damage cylinder threads when it was coupled and uncoupled. But, the damage went undetected because cylinders still passed the hydrostatic test and product was shipped without Piper knowing the threads were damaged. Of course, as soon as

For more information quote EMS Enquiry No. 125 on IBC

EMS May/June 2009 www.engineeringmaintenance.info

the Piper customer realized the cylinder threads were corrupted, Piper would replace the cylinder which added to their raw materials costs and shipping costs. Kyle Green, Sr. Manufacturing Engineer at Piper and the Airmo design team formed a strategic working partnership to custom design the TestMaster® 350 to meet Piper's specific hydrostatic testing applications. Green said, "We needed to eliminate thread damage on our oxygen cylinders and we did it. We've not had any products returned since January, 2008. We've significantly reduced our scrap and at the current rate we see a payback on the 24 TestMaster® 350's in less than two years. With the reduced scrap and no returns our production rates should increase as well." Charles Smida, Airmo President said, "It took some trial and error, but in the end we engineered the perfect solution for Piper. Currently, Piper Metal Forming is in the process of adding 24 more Airmo TestMaster® 350 Test Tools to their carbon dioxide bottle line." Harry Morán, Airmo COO stated, "The TestMaster® 350 increases production rates, reduces scrap, and improves bottom line performance." In addition, to a full line of hydrostatic test tools, Airmo also manufactures ExpanTek® tube expansion and tube to tube sheet swaging equipment, and SelectForm® end forming equipment. To learn more about the Airmo TestMaster® 350 Hydrostatic Bottle and Cylinder Test Tool, contact: Harry Morán Tel: 763-786-0000

Airmo, Inc. Email: harrym@airmo.com

www.airmo.com

Reader Reply Number: 520

SPOTLIGHT ON OFFSHORE

Twister SWIRL Valve™ – a new gas processing product which improves the separation of two-phase flow across a pressure reduction valve, such as a choke valve, Joule Thomson (JT) valve or control valve. This in turn significantly improves the separation efficiency of downstream separators

Twister BV introduces SWIRL valve technology

The Twister SWIRL Valve avoids turbulent mixing of fluids Valves are used in the oil and gas industry to control pressure, temperature and flow. In many cases fluids will expand in the valve, once sufficient pressure drop is created over the valve. This throttling process normally results in a flashed liquid or a condensed gas, which needs to be separated afterwards. It is expected that this SWIRL Valve technology will be effective in flow debottlenecking of existing separator trains, whilst also minimising liquid carryover and/or gas carry under, reducing chemical losses and enabling significantly higher liquid recovery. The improved separation efficiency of the Twister SWIRL Valve can be used to either increase the flow capacity of existing JT-LTS plants, or to reduce the pressure drop required for JT cooling, or to lower the hydrocarbon dew point, and also to reduce glycol carry-over. SWIRL Valves can be applied for all Joule Thomson expansion gas flows.

Field test results A Twister SWIRL Valve was installed and operated in a JT-LTS plant in September 2008 replacing an existing JT valve. The LTS or cold separator utilises a state-of-the-art separator internal (type: SMSM). The installation was completed within one day, with minimal disruption. The export gas quality was monitored for two months utilising an online hydrocarbon dew point analyser and a mobile GACOM unit, which measured the liquid drop-out at -3°C and 27 bar. These measurements demonstrated that by using the SWIRL Valve as a JT choke: The HC dew-point was reduced by 7°C at design capacity. The flow rate was increased by 20% of max. flow capacity. The cold separator temperature was increased by 5°C, indicating that the pressure drop over the JT valve could be reduced by 20%. The SWIRL Valve noise level was 70dB(A) at design capacity. The SWIRL Valve had a linear control

characteristic similar to other traditional cage valves. The Netherlands-based Twister BV Company was launched by Shell Technology Ventures in April 2000, and holds significant experience in natural gas processing technology development, plant delivery and operational support. Their main product line is the Twister Supersonic Separator which produces gas at supersonic velocities, extracting water & hydrocarbon liquids. Compared to conventional technologies, the Twister process requires no chemicals and hence reduces exposure to hazardous gas emissions. It has no moving parts, permits near instant start up and allows considerable cost reduction, particularly for offshore installations. Additional details are available on the company website www.TwisterBV.com

Tel: +31 (0)6 1104 7631 Fax: +31 (0)70 300 2200 Email: Hugh.Epsom@TwisterBV.com www.www.TwisterBV.com Reader Reply Number: 521

35 EMS May/June 2009 www.engineeringmaintenance.info

SPOTLIGHT ON OFFSHORE

Many companies are facing a down turn in demand. Some cease trading, others cut back on production or take plant out of production until demand requires the plant to be re-commissioned. Mothballing protects plant during shut down enabling a speedy return to production when required

CORROSION CONTROL Corroless Corrosion Inhibitors are used on offshore drilling platforms, power plant, ships and chemical plant, protecting pipe work, bulk systems, heat exchangers, electrical enclosures, motors, control panels, SCR Rooms, navigational and telecommunications equipment, engines, standby equipment, compressors, hydraulic systems, wire ropes, shafts, bearings, valves, , grease points, threaded connections, deck/drill floor/derrick equipment, cranes, and void spaces. We also have a product used in hydrostatic pressure testing, water treatment and cooling systems.

Corroless Corrosion Control is involved world wide in Mothballing through two offices. Corroless Offshore (www.corrolessoffshore.com) in Aberdeen covering Europe, Africa and the Americas and Corroless Asia Pacific (www.corroless.com.sg) in Singapore covering the Pacific Rim and the Far East. For advice contact the appropriate office or head office via www.corroless.com www.corroless.com Reader Reply Number: 522

SPOTLIGHT ON MEASUREMENT KITS Cirrus Research plc, the UK company which specialises in the design and development of noise measurement equipment for health and safety applications, is offering a wide range of versatile and cost effective Safety Officers Measurement Kits

Cirrus offers versatile and value for money

Safety Officers Measurement Kits Sophisticated and adaptable, yet easy to operate, Cirrus’ Safety Officers Measurement Kits are designed to be used by in-house health and safety officers to measure and record occupational (inside) and environmental (outside) noise. They are intended to help organisations meet their legal obligations with regard to noise safety, without the need to employ external consultants. Each kit contains a sound level meter and three Cirrus ‘doseBadge’ personal noise dosemeters - small devices worn by individual members of staff to measure the noise they are exposed to during a typical working day. What distinguishes the five separate kits in the range is the specification of the sound level meter selected. As James Tingay, Cirrus Research explains, “Which sound level monitor (and therefore which kit) customers need will depend on two things: what they want to record, be it noise in the workplace or noise levels at the perimeter fence, and how much data they need to store. We will help them to choose the right kit for their business and demonstrate how it can help them to meet the requirements of the 2005 Control of Noise at Work regulations.” He went on to say, “Cirrus Safety Officers Measurement Kits are flexible enough for almost any occupational or environmental noise

36 EMS May/June 2009 www.engineeringmaintenance.info

monitoring programme and by using them, organisations can save themselves the cost and effort of employing external consultants.” As with all Cirrus equipment, the Safety Officers Measurement Kit is issued with Cirrus’ industry leading ‘2-12’ year warranty. This provides an initial 24-month warranty which can be extended up to 12 years if the equipment is serviced and recalibrated by Cirrus every 12 months. Free backup and support, including the license free Deaf Defier3 software and updates, is provided with every Cirrus noise measurement product. Cirrus Research plc has over 30 years experience in the design and manufacture of noise measurement instruments. During that time, the company has developed a reputation for producing robust, practical equipment which can perform in real situations. All Cirrus equipment is made in the UK and the company is responsible for all after sales service and calibration work. Spare parts and support are therefore always available. In 1991 Cirrus Research plc was awarded the Queen’s Award for Export Achievement, and exports noise measurement equipment to over 50 countries worldwide. +44 (0)1723 891655 www.cirrusresearch.co.uk

sales@cirrusresearch.co.uk Reader Reply Number: 522

Speedy is just one of the companies to throw its weight behind educating people and providing products to help them. In its guide, ‘Let’s clear the air on dust control’, it explains why dust is such a big issue, how it can kill and injure, the methods of controlling it and ways to avoid generating it in the first place

Manufacturers CRACK PPE It makes it clear that PPE must be the last line of defence. Similar campaigns are being run by other hire companies. Responsible manufacturers are also bringing through products designed to crack this problem. For example, Bosch recently launched the GBH 2-23 REA Professional hammer drill with dust extraction, which has been designed to provide highly efficient dust extraction when drilling within interiors. Bosch claims it is the lowest weight, most compact product of its kind on the market. The machine has an integrated dust extraction unit with builtin fill level indicator. It also has an exchangeable filter for high service life. The tool has a transparent dust collector allowing a better view of the hole being drilled. A suction tube is provided for

cleaning drilled holes and the tool has an integrated depth stop. A few months ago, Makita launched its 447M dust extraction unit, which is able to remove dust from the work area efficiently so that there is no pollution greater than 0.1milligrams per cubic metre of air. The 447M has a maximum airflow volume of 127 cubic feet per minute and has a mandatory airflow sensor fitted which provides an audible warning to the operator if the airflow velocity reduces below the required minimum 20 metres per second standard, if the filter is not performing adequately. The 447M has the required extra fine PET-fleece filter with a maximum permeability of 0.1%. For a couple of years now, the entrepreneurs at Trident Blasters

SIMPLIFY PIPE JOINING

1” to 24” Pipe Systems

G G G G G G

have been promoting a sophisticated system that uses only half a litre of water per minute - sufficient only to coat the individual abrasive particles with moisture. This mixture, plus the air, is delivered to the work along the one hose. When the mixture meets the work, the water is so heavily aerated that the vast majority immediately disperses as a mist, while the grit and the removed waste material being damp and therefore heavy - simply drops to the ground to be swept, shovelled or vacuumed up. At all times the operator can see to work in confined spaces and work in areas without inconveniencing or endangering the other trades. Reader Reply Number: 310

Dust and fume extraction hoses from Masterflex

‘‘With STRAUB, pipe joining and repairs are carried out quickly and economically with total reliability’’

Simple & Rapid Installations - in Minutes Joins plain-end Pipe - No Prep Required Reusable in Pipework Dis/Assembly Stress-Free Joining with Misalignment Problem Solver in Restricted Spaces Lloyds Approved for Machinery Spaces

MV Fluids Handling Marven House • 1 Field Road • Reading RG1 6AP ENGLAND Tel: 0118-9503707 Fax: 0118-9504066 Intern’l Dialling: 44-118+No. Email: info@mvfh.co.uk • Website: www.straub .co.uk For more information quote EMS Enquiry No. 126 on IBC

Temperature range -260°C to +1100°C Size range 38 mm to 900 mm Very flexible, small bend radius Long service life, low operating costs Suitable installation and connecting systems Masterflex Technical Hoses Ltd GB-Oldham OL1 4ER Tel: 0161 626 8066 www.masterflex-uk.com PU / FABRIC HOSES

CONNECTIONS

TUBE PROTECTION

For more information quote EMS Enquiry No. 127 on IBC

EMS May/June 2009 www.engineeringmaintenance.info

SPOTLIGHT ON SENSORS

For over 20 years Katy Instruments has provided plant operators and engineers with the most accurate, reliable, and cost-effective AC current sensors available on the market

Now is no time for downtime Manufactured with the highest quality components, KI current sensors make measuring amperage simple and fast, without the inconvenience of recalibration. Metal encasing and high grade components accommodate high cable voltage (up to 5000V) and extended temperature ranges of -25°C to 85°C KI current sensors offer unparalleled response times (150 ms max), accuracy (0.2%), and repeatability (0.1% Full Scale) Eight different models that will accommodate cables up to two inches in diameter with standard ranges from 5-1000 Amps

w w w. m s l re c r u i t m e n t . c o m Reference Job Description

Salary eference Job Description

Salary

9508 POWER AND ENERGY DESIGN ENGINEER ROLES We are very pleased to offer the superb chance to become part of one of the worlds most successful engineering firms as a design engineer in their Sunder land office to be involved on their current benchmark projects. £ 40 TO £ 50 K (PER YEAR) + PACKAGE 9368 POWER GENERATION ENGINEERS We are seeking applications from degree qualified engineers to join our growing Power Generation teams based in Glasgow and are keen to hear from candidates with previous relevant experience gained within the UK power or energy industries £ 30 TO £ 50 K (PER YEAR)

w w w. m s l re c r u i t m e n t . c o m

38 EMS May/June 2009 www.engineeringmaintenance.info

The quality and reliability of KI sensors will enable you to confidently identify the warning signs of potential equipment failures when it matters, before it happens. Trust your plant with the company who invented the AC current sensor. Brian Geissen – National Accounts Manager 16514 Park Row Boulevard, Houston, Texas 77084 USA

T: 1-866-434-7736 E: brian@kiscurrentsensors.com www.kiscurrentsensors.com Reader Reply Number: 523

j o b s @ m s l re c r u i t m e n t . c o m Reference Job Description

Salary

8777 PRINCIPAL OR SENIOR SAFETY CONSULTANT You’ll hold an honours and/or masters degree (or equivalent) in a relevant subject e.g. science or engineering. You’ll also have considerable safety case production and/or management experience either with a consultancy or a licensee, effective communication skills, good report writing skills and the ability to work effectively both individually and in a team. At the Principal level we’re looking for specific team leadership experience. £NEG (PER YEAR) + WE OFFER A COMPETITIVE FLEXIBLE BENEFITS PACKAGE

j o b s @ m s l re c r u i t m e n t . c o m

TO ADVERTISE YOUR LISTING IN OUR BUYERâ&#x20AC;&#x2122;S GUIDE PLEASE PHONE 0207 9933355 Company Website Email Contact Telephone Number ACCESS EQUIPMENT Planet Platforms

www.planetplatforms.co.uk

info@planetplatforms.co.uk

0800 0854161

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

Byworth Boilers

www.byworth.co.uk

sales@byworth.co.uk

01535 665225

Certuss Steam Generators

www.certuss.co.uk

sales@certuss.co.uk

0121 3275362

Wellman Robey

www.wellman-thermal.com

info@wellman-thermal.com

0121 543 0000

Kings Boiler Hire

www.kingsboilerhire.com

enquiries@kingsboilerhire.com

01992 451629

Wellman Robey

www.wellman-thermal.com

info@wellman-thermal.com

0121 543 0000

www.nord-lock.co.uk

enquiries@nord-lock.co.uk

44 (0)1980 847129

Cayman Venture

www.cayman.co.uk

info@cayman.co.uk

0191 2963816

Idhammar Systems Ltd

www.idhammarsystems.com

info@idhammarsystems.com

0117 9309300

PMI Software

www.pmisoftware.co.uk

Louis.Tuttle@pmisoftware.com

353 (0)1404 0000

Productivity Europe

www.productivityeurope.org

m.jones@productivityeurope.org

01234 215867

Shire Systems

www.shiresystems.co.uk

info@shiresystems.co.uk

44(0) 23 80224111

Softsols Group Ltd

www.getagility.com

info@softsolsgroup.com

44(0)1924 200344

SolutionsPT

www.assetpt.co.uk

martyn.williams@assetpt.co.uk

44 (0)161 495 4600

Spidex Software Limited

www.spidex.co.uk

info@spidex.co.uk

0121 779 0888

SRO Solutions

www.srosolutions.net

info@srosolutions.net

44 (0)845 408 4250

ASSET MANAGEMENT Rockwell Automation BOILERS

BOILER HIRE

BOLT SECURING SYSTEMS Nordlock Ltd CMMS

COMPRESSED AIR Airchannel Ltd

www.airchannel.co.uk

info@airchannel.co.uk

0800 526581

Atlas Copco Compressors

www.atlascopco.co.uk

gba.info@uk.atltascopco.com

0800 181085

Gardner Denver

www.gardnerdenver.com

info.uk@gardnerdenver.com

01452 338116

www.speedyhire.co.uk/compressors

enquiries@speedycompressors.co.uk

0845 307 0777

Alpine Components

www.alpine-components.co.uk

mike@alpine-components .co.uk

01424 437000

Artesis

www.artesis.com

info@artesis.com

0845 634 3854

Elcomponent Ltd

www.elcomponent.co.uk

sales@elcomponent.co.uk

01279 503173

Holroyd Instruments

www.holroyd-instruments.com

sales@holroyd-instruments.com

01629 822060

Monitran

www.monitran.co.uk

info@monitran.co.uk

01494 816569

Proviso Systems

www.proviso-systems.co.uk

sales@proviso-systems.co.uk

01777 817536

COMPRESSED HIRE Speedy Compressors CONDITION MONITORING

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info 39 EMS May/June 2009 www.engineeringmaintenance.info

ANNUAL BUYERS GUIDE continued TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355 Company

Website

Email Contact

Telephone Number

Pruftechnik Ltd

www.pruftechnik.com

cburns@pruftechnik.co.uk

44 (0)1543 448350

Schaeffler

www.schaeffler.co.uk

info.uk@schaeffler.com

0121 351 3833

SPM Instrument UK ltd

www.spminstrument.co.uk

info@spminstrument.co.uk

01706 835331

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

www.metrum.co.uk

enquiries@metrum.co.uk

0118 973 3000

www.icm-uk.com

info@icm-uk.com

01779 474748

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

www.dixoneurope.co.uk

enquiries@dixoneurope.co.uk

44 (0)1772 323529

www.totalprocesscooling.co.uk

sales@totalprocesscooling.co.uk

44(0)121 711 4014

www.bidgroup.co.uk

sales@bidgroup.co.uk

0870 607 5050

www.ambirad.com

marketing@ambirad.co.uk

44 (0)1384 489700

CG Flooring Systems Ltd

www.cg-flooring.com

info@cg-flooring.com

01484 600085

Dura Composites

www.duracomposites.com

info@duracomposites.com

44 (0)1255 423601

www.biz.fm

hire@biz.fm

44 (0)1344 459314

www.ats-electro-lube.co.uk

info@ats-electro-lube.co.uk

0191 491 4212

www.tcardsdirect.com

sales@tcardsdirect.com

01732 871417

CONDITION MONITORING CONTINUED

CONDITION MONITORING EQUIPMENT/SERVICES Rockwell Automation DATA ACQUISITION Metrum HEALTH & SAFETY Integrity&Compliance Management HEALTH & SAFETY PRODUCTS Rockwell Automation HOSE AND COUPLINGS Dixon Europe INDUSTRIAL COOLING TPC(Total Process CoolingLtd) INDUSTRIAL DOOR SERVICES BID Group INDUSTRIAL HEATING Ambirad INDUSTRIAL FLOORING

INSTRUMENT HIRE Bisra LUBRICATION ATS Electro-lube (UK) ltd PLANNED MAINTENANCE T Cards Direct THERMOGRAPHY Express Instrument Hire

www.expresshire.net

sales@expresshire.net

01772 815600

Flir

www.flir.com

sales@flir.com

01732 221245

Fluke

www.fluke.co.uk

industrial@uk.fluke.nl

020 7942 0700

Hawk-IR

www.hawk-ir.com

sales@hawk-ir.com

01642 497000

Testo Ltd

www.testo.co.uk/testo880

–

01420 544 433

www.infraredinstitute.co.uk

info@infraredinstitute.co.uk

44 (0)151 424 4060

www.nfpc.co.uk

enquiries@nfpc.co.uk

01909 504700

www.hansfordsensors.com

sales@hansfordsensors.com

0845 6801957

THERMOGRAPHY TRAINING The Institute of Infrared Thermography

TRAINING National Fluid Power Centre VIBRATION ANALYSIS Hansford Sensors

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info 40 EMS May/June 2009 www.engineeringmaintenance.info

+44 ( 0)208 7113153 Please fill in your details if you (a) wish

(Delete as appropriate)

to continue to receive a free copy of EMS

Surname

First Name

(Mr, Mrs, Miss, Ms)

Job Title Company

or, (b) wish to be included in the magazine’s circulation list for the first

Post Code Fax

Tel

time. (Please use capitals and please

E-mail

sign and date as indicated). Fax Back on:

+44 (0)208 7113153

Signed

Date

Please send me FREE information on: PLANT MANAGEMENT Artificial Intelligence/Expert Sys

❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏

Asset Management ATEX Equipment/Services Bearings Calibration Coding Systems Computerised Maintenance Management Condition Monitoring Consult Condition Monitoring Consultancy – unspecified Contract Maintenance Corrosion Prevention Couplings Data Analysers/Loggers Degreasers Descaling Drives Electric Motors Electrical Maintenance Equipment Rental Filters Flexible Hose Flexible Ducting Flow Meters Food Safety Lubricants Gaskets

❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏

❏ ❏

General Engineering Services Handling Equipment Hose & Cable Reels

❏ ❏ ❏

Internet Services to Maintenance Labelling and/or Barcoding

❏ ❏ ❏ ❏ ❏ ❏

Leak Detection Equipment Lubrication/Oil Analysis Maintenance Consultancy Maintenance Materials Measurement Instrumentation NDT Equipment or Services Pipe Freezing Pumps, Valves and Process Equipment

Seals Sensors or Probes Specialist Maintenance Services/Products Surface Treatment and Coating Temperature Measurement Thermographic Services/Equipment Tools & Workshop Equipment TPM Consultancy Vibration

F R E E

Recruitment Training Aids and Services

BUILDING MAINTENANCE Access Equipment

Laser Alignment

Remote Monitoring

Welding and Joining

TRAINING Institutes and Professional Bodies

Hydraulics/Pneumatics

RCM Consultancy

Visual Planning

❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏

Building Maintenance Consultancy Chemicals/Paints/Finishes Cleaning Components Cleaning Machines/Equipment Computer Aided Facilities Management (CAFM) Cranes/Hoists Doors/Curtains Flooring Lifts/Escalators Lighting Property Maintenance and Management Roofing Security and Fire Prevention Storage Systems Tank Linings & Bundings

ENVIRONMENTAL Dust/Fume Extraction

❏ ❏

Environmental Health/Testing/Equipment

❏ ❏ ❏

Noise Control Pollution Control Equipment Water Treatment

HEALTH & SAFETY Communication

❏ ❏ ❏ ❏ ❏ ❏

Health & Safety Products Legislation & Compliance Machine Guards Safety Showers & Eye Baths Workwear

ENERGY MANAGEMENT Boilers

❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏

Burners Climate Change Levy Combined Heat & Power Compressed Air Equipment and Ancillaries Energy Energy Control Systems Energy Metering/Monitoring Systems Generators Heating, Ventilating and Air Conditioning Industrial Controls Power Quality Steam Traps

EMS May/June 2009

ENQUIRY? P R O D U C T

I N F O R M A T I O N

S E R V I C E

COMPLETE AND FAX THIS PAGE BACK TO +44 (0)208 7113153 enquiry no.

enquiry no.

Structural Adhesives

Cyanoacrylates (instant adhesives)

UV Curing Adhesives for bonding acrylic, glass and metals

Electrically Conductive Adhesives

Thermally Conductive Adhesives

Conformal Coatings

Threadlocker

Ultra High Temperature Ceramic Adhesives

Glob Tops

High Performance Adhesive Technology www.eurobond-adhesives.co.uk sales@ eurobond-adhesives.co.uk T 01795 427888 F 01795 479685 Bonham Drive, Eurolink Industrial Estate, Sittingbourne, Kent ME10 3RY UK Distributors of Reinhardt-Technik Metering Mixing Dispensing Systems

For more information quote EMS Enquiry No. 102 on IBC

ems may/june 2009

Articles inside

ems may/june 2009