ems november/december 2009 by Michael Dominguez

NOV/DEC 2009 BUYERS GUIDE LEAN MAINTENANCE CONDITION MONITORING

ENGINEERING MAINTENANCE SOLUTIONS

ISSUE 14

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

FIRE SYSTEMS

MACHINING

DUST CONTROL

MAINTENANCE of wind turbines TURN TO PAGE 10 FOR THE FULL STORY

CHEMICAL CLEANING

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For more information quote EMS Enquiry No. 101 on IBC

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BEST PERFORMERS

So what are the best performers doing differently than others?

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CONDITION MONITORING Easing the task of integrating AE technology

9 PAGE

DRIVE SYSTEMS

Industrial gear units for torque output from 60,000 to 200,000 Nm

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RELIABILITY ENGINEERING What’s it all about?

BEST PERFORMERS They keep simple concepts simple. Best performers do not confuse their organizations with new names on well known best concepts and practices. They also understand the difference between a tool or methodology and a complete reliability and maintenance program. For example RCM, (Reliability Centered Maintenance) is a very good methodology used to help decide the right maintenance activity and frequency, but it does not deal much with key elements such as planning and scheduling, store room interface with maintenance, technical data bases for maintenance etc. Same goes for TPM (Total Productive Maintenance) also a very good approach, but missing some very important reliability and maintenance elements. Best reliability and maintenance practices comprise about 300 elements that must be done well if you want to be as good as you can be. They are the same as they have been for 50 years or more. For example; Operating Practices, Alignment, Balancing, Lubrication, Inspections, Planning of maintenance and operations work, Scheduling of maintenance and operations work, Continuous collection of data, Root Cause Problem Elimination etc. These elements cover very well tested and proven “Right things to do” or elements. They are used to educate an organization and to develop measurable improvement plans. First you agree on that the element is the right thing to do. Next step is to decide who shall do it. 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

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OEE

Overall Equipment Effectiveness – Myths and Realities

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BUYERS GUIDE

The comprehensive listing of engineering maintenance suppliers

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer Idhammar Alan France, Mark Haarman editorial@engineeringmaintenance.info

WEB MANAGER: Oliver Gibbs info@engineeringmaintenance.info DATABASE MANAGER: Steve Hill TECHNICAL MANAGER: Igor Seke

ADVERTISEMENT SALES: Michael Dominguez (Publisher) michael@engineeringmaintenance.info Paul Miles paul@engineeringmaintenance.info Paul Clappison paulc@engineeringmaintenance.info

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

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Here a best performer is defined as an industrial plant that has achieved a high reliability and fast throughput of manufactured products and as a consequence, manufacturing costs, including maintenance costs, are low. So what are the best performers doing differently than others? The short answer is that they do what we all know we need to do; they just do it better and better over a long period of time

WHAT ARE THE BEST PERFORMERS DOING DIFFERENTLY? â&#x20AC;&#x201C; Part III They keep simple concepts simple. Best performers do not confuse their organizations with new names on well known best concepts and practices. They also understand the difference between a tool or methodology and a complete reliability and maintenance program. For example RCM, (Reliability Centered Maintenance) is a very good methodology used to help decide the right maintenance activity and frequency, but it does not deal much with key elements such as planning and scheduling, store room interface with maintenance, technical data bases for maintenance etc. Same goes for TPM (Total Productive Maintenance) also a very good approach, but missing some very important reliability and maintenance elements. Best reliability and maintenance practices comprise about 300 elements that must be done well if you want to be as good as you can be. They are the same as they have been for 50 years or more. For example; Operating Practices, Alignment, Balancing, Lubrication,

Inspections, Planning of maintenance and operations work, Scheduling of maintenance and operations work, Continuous collection of data, Root Cause Problem Elimination etc. These elements cover very well tested and proven â&#x20AC;&#x153;Right things to doâ&#x20AC;? or elements. They are used to educate an organization and to develop measurable improvement plans. First you agree on that the element is the right thing to do. Next step is to decide who shall do it. It is very important to keep your reliability and maintenance process simple and easy to communicate to your organization. Improving maintenance is 90% about getting people to work disciplined in a disciplined system and 10% about technology. The easy part is the technology part, maintenance people like technology and gadgets, sometimes too much. To get them to break old habits and work in a planned and scheduled environment is more of a challenge. Most maintenance employees have been

rewarded and recognized more for reactive actions than for preventive actions. Many do not mind reactive maintenance because it is 76% likely to generate extra income through overtime pay, and when they fix a break down they are praised. If you can make a compelling case of why you need to improve and clearly describe what the future will look like, you can successfully overcome this change. Remember that it is really not much of a change; it is common sense and describe what your organization already knows and do to some extent, you will just help them do it much better. The following Slide 1 shows a one page description of the essential reliability and maintenance process. The market governs the production plan which in turn have to be coordinated closely with maintenance scheduling of work, especially for work that affect production run schedules. When you plan and then schedule work, you create a system that let crafts people become more efficient when they do the work. When

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WHAT ARE THE BEST PERFORMERS DOING DIFFERENTLY? PART III

SLIDE 1

work is done you should record what was done, why it was done etc. This will create a second backlog of well documented problems to be solved and eliminated. If your organization is doing all these things you work in a continuously improving environment. Most organizations know all of this and do some of it. A great organization works 20% + in the SLIDE 2

continuous improvement area with Root Cause Problem Elimination, most organizations know they should do this, but they do not have time. The most common reason many organizations do not have the time is that they work in the red circle, the circle of despair. For different reasons your organization reacts to problems and repair

them as fast as they can. This often leads to that they have to return to redo the repair and this process is repeated. The more work done this way, the less time your organization will have to do what they should do and after a while you are completely reactive. To improve this situation you need to reinstitute essential processes such as maintenance prevention, the right priorities on work requests and condition monitoring. All these activities will prevent work and/or give your organization the necessary lead time needed to do good planning and then scheduling of work. To do effective planning a Technical data base is needed so parts, tools and work descriptions easily can be found in a matter of seconds. The aforementioned slide describes the essential elements of a good maintenance process. If all elements are executed well, they will deliver increased reliability and lower costs. A job done in the “Circle of despair” can be described in the left box (Slide 2). A planned and scheduled job is described in the right box; it is a description of a best practice. The difference in efficiency is substantial. Depending on how much work is done as described in the left box the improvement potential derived from moving more work to the process described in the “Best Practice” box is 30% to 60%. 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

www.engineeringmaintenance.info November/December 2009 EMS

FILTRATION

Parker Hannifin, the global leader in motion and control technologies, has launched the STF Series of tank top mounted return filters, which combine effective filtration with a cast steel filter head assembly, making the units ideal for marine and industrial applications were the use of aluminium is restricted in accordance to latest regulations

NEW RETURN LINE FILTERS with cast steel filter head

FOR MARINE APPLICATIONS The STF filters feature “In-to-Out” filtration to ensure contaminated oil cannot leak back into the system, and are capable of handling flow capacities of up to 500 l/min at 10 bar working pressure, making them suitable for severe return line applications, and reducing downtime due to filter failures. The filters provide pre-filtration by means of a magnet column, improving fluid cleanliness levels and extending element lifetime with typically over 20%. An effective flow bypass with low hysteresis reduces the bypass period and ensures only a small part of the total flow is bypassing the element, offering improved protection for the system. Additionally, multiple ports in the filter head make it easy to integrate return line filtration into power packs, reducing cost and space. The STF range can be customised to match the specific requirements of an application and facilitate integration. This helps minimise initial costs and ensure effective filtration. Optional air tight diffusers are available to avoid air ingress in the return line. The funnels can be

supplied with a customised length, ensuring an ideal oil under the oil level and reduce the risk of foaming. The filters are compatible with Parker’s patented LEIF® elements, which minimise waste and therefore reduce the environmental impact of a system. These innovative elements provide guaranteed high quality filtration in line with ISO 14001 for complete peace of mind. The robust STF Series filters are ideal for use in a wide range of applications including marine power packs, steel mills, mining equipment, and drilling machinery. Thanks to the ATEX certification, the STF filter can be applied for in potentially explosive atmospheres. Parker Hannifin plc European Product Information Centre Parker House, 55 Maylands Avenue Hemel Hempstead Herts, HP2 4SJ

T: 00800 27 27 5374 E: epic@parker.com www.parker.com Reader Reply Number: 301

EMS November/December 2009 www.engineeringmaintenance.info

NEW BELZONA AUTHORISED COATING CENTRE

On Wednesday 21st October 2009, Belzona, a design and manufacturer of industrial protective coatings and polymer repair composites, celebrated the launch of a new Authorized Coating Centre, Knowlton and Newman, at one of their three branches located in Southampton

Knowlton and Newman launched as

Belzona Authorized Coating Centre On Wednesday 21st October 2009, Belzona, a design and manufacturer of industrial protective coatings and polymer repair composites, celebrated the launch of a new Authorized Coating Centre, Knowlton and Newman, at one of their three branches located in Southampton. Achieving the Authorized Coating Centre Status now means that Knowlton and Newman are recognized by Belzona as a specialist service centre for the rebuilding, long term protection and efficiency enhancement of rotating equipment such as Pumps, Fans & Blowers, Screw Conveyors and Agitators. It is envisaged that this new partnership will further improve the level of support offered to customers and offer a full turnkey repair service on rotating equipment. Mike Knowlton, one of the five Directors for Knowlton and Newman commented about the day, ‘‘I am

extremely pleased as it has been a really successful day, I don’t think there will be one person who will go away without learning something new which will add value to both of our businesses.’ Daniel Knowlton, one of the other Directors further commented, ‘I thought that overall the day was a great success and credit is due to all involved. I really look forward to a bright future for the BelzonaKnowlton and Newman joint effort.’ Belzona introduced the Authorized Coating Centre scheme to differentiate and reward specialist service centres that invest heavily in surface preparation equipment and are dedicated to maintaining high levels of application procedures and customer service. Gordon Cairns, National Sales Manager for Belzona explained, “The BACC concept was created to distinguish between regular machinery and equipment contractors and a specialist group of service centres that go the extra distance. This gives us the platform to target key industries that require a “total service” which include Petrochemical, Power, Paper and Water/Wastewater.” Belzona is represented by a single Authorized Coating Centre for each UK region and BACC status has already been granted to four companies in Glasgow, Teesside, Manchester and now

Southampton. Belzona are now looking to recruit a final Coating Centre to be based in the Midlands which will complete the network. To receive recognized status, service centre’s must demonstrate high performance equipment and facilities, a dedicated coating room with a temperature controlled area and invest heavily in Surface Preparation equipment whilst also maintaining high levels of application procedures and after sales support. Knowlton and Newman have been providing industry since 1973 with a wide range of mechanical services to minimize downtime for customers and drive down costs, operating from three branches, Southampton, Portsmouth and Chatham. www.belzona.com Reader Reply Number: 302

www.engineeringmaintenance.info November/December 2009 EMS

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CONDITION MONITORING

It is common knowledge that a range of Condition Monitoring (CM) techniques are available such as Vibration Analysis, Oil & Wear Debris Analysis, Thermography and Acoustic Emission. Each of these techniques has its own particular areas of strength and in this regard the Acoustic Emission (AE) technique has the noted advantage of giving real time information with early sensitivity to faults and applicability to a wide range of rotational speeds including slowly rotating (source : ISO 22096)

EASING THE TASK OF INTEGRATING AE TECHNOLOGY

into third party monitoring systems

It follows that on-line monitoring systems should be capable of integrating the required mix of CM technologies for each particular spread of machine types in an installation. However the use of AE for machinery condition monitoring has historically been viewed as a separate specialist field and it has not been easy to integrate it into third party or industry standard monitoring and control systems. To address this issue Holroyd Instruments has developed a range of smart AE sensors, which have finally opened the door to the wider use of AE for continuous monitoring alongside, say, vibration, and temperature sensors. Holroyd Instruments is a world leader in the industrial application of AE techniques to machinery condition monitoring and has pioneered autonomous signal processing algorithms which further extend these advantages by removing the need for machine specific interpretations. Whilst these algorithms have been successfully used for many years in a range of portable instruments it is only recently that they have been integrated into smart AE sensors (MHC-DS1 and MHCSM1). These compact sensors provide simple but effective continuous monitoring of rotating machinery from motor speeds down to 0.25 rpm. They are ideal for incorporating into third party systems for data acquisition, monitoring and alarm

purposes, since they have high level, slowly varying outputs of field proven signal characterisations. In some applications however there is no infrastructure to accept trendable sensor outputs and this is typical when retro-fitting to existing installations. In these cases switched sensor outputs are preferable since they can be readily wired into spare input channels on PLCâ&#x20AC;&#x2122;s. Acknowledging this requirement switched alarm outputs are also built into the smart AE sensors. The alarm levels and hold-off periods, to discriminate against false triggers, are user adjustable and stored in the sensors own non-volatile memory. The interest generated by the successful development of these smart AE sensors is fuelling further demands from the technology. For example, a growing interest with some users is in the monitoring of nonrotating and intermittent machine actions. The high signal to noise ratio of AE makes direct time domain analysis of AE signals useful in a very wide range of industrial applications. To address these applications a new development is the 24/7 Ultraspan sensor which continuously outputs a logarithmically compressed dynamic envelope of the AE signal requiring only a +24 VDC electrical supply. In this way the pertinent features of wide dynamic range and high frequency AE signals are transformed into a very easily handled form.

Another area of growing interest amongst CM specialists, which can also be addressed with the 24/7 Ultraspan sensor, is in the diagnostic analysis of rotating machinery. In this role the dynamic envelope signal is viewed in the frequency domain as a spectrum to reveal defect repetition frequencies. The high sensitivity of the AE technique combined with the benefits of envelope spectra enable the clear identification of high resolution peaks, even on very slowly rotating machinery. As exposure to the unique capabilities of AE spreads, evermore diverse applications are being unearthed which have previously proven difficult for other CM technologies. Our experience is that the challenges posed by these applications are especially suited to being solved in a costeffective way by highly integrated application specific (smart) AE sensors. ABOUT THE AUTHOR

Trevor Holroyd is the Managing Director of Holroyd Instruments Limited and has been continuously active in the development and use of AE for industrial monitoring since 1974. For more information about the contents of this article he can be contacted by email : trevor@holroyd-instruments.com

Holroyd Instruments Limited Matlock, Derbyshire, UK, DE4 2AJ

T: +44 (0)1629 822060 E: sales@holroyd-instruments.com Reader Reply Number: 303

www.engineeringmaintenance.info November/December 2009 EMS

WEAR PROTECTION FOR WIND TURBINES

The lifetime of the bearings and gears in new as well as in existing wind turbines can be extended by REWITEC’s Nanocoating system even when the first signs of decay appear

Reconditioning and durable wear protection

for gear boxes and bearings in wind turbines

Use of Wind Energy – Future Development The share of renewable energy sources in total energy consumption is to be increased to 20% in 2020. To achieve this extremely ambitious target, the share of renewable energy sources in electricity generation in the European Union has to be increased to approximately 34% by 2020. The continuing expansion of renewables in Europe and also in Germany will be characterised mainly by the use of wind energy. 20,301 wind turbines with a total capacity of 23,903 MW have been installed in Germany at the end of 2008. 40.2 TWh of wind electricity was generated during this year. At this time the installed capacity in Europe amounted to 65,946 MW and worldwide to 120,798 MW. Maintenance of Wind Turbines The most expensive components of a wind turbine, beside tower and blades, are gearbox and bearings requiring about 13% of the total costs. The average lifetime of these important components is between five to seven years in Western Europe and about two to three years in Asian countries. To replace the main gear multiplier of a 1.5 MW wind turbine after an unexpected damage costs about 250,000 Euros including crane costs. It also has to be mentioned that availability of gears and bearings is limited. The operation and maintenance of a wind

turbine and especially of the abovementioned components can be supported by various measures, such as integrating a condition monitoring system or developing appropriate maintenance strategies. The lifetime of the bearings and gears in new as well as in existing wind turbines can be extended by REWITEC’s Nanocoating system even when the first signs of decay appear. REWITEC was founded in 2003 with the goal of reducing the problem of wear and tear in tribologic systems. REWITEC Technology – Nanocoating for Tribosystems The coating technology is not based on modification of the oil film, but on modification of the surface texture of frictional metal parts and the creation of a new very smooth metal silicate coating. This metal silicate coating reduces friction and increases efficiency, especially in older engines and gearboxes. Due to optimisation of compression pressure in engines, oil and fuel consumption will be noticeably reduced (Figures 1 to 3). The synthesised metal silicate compound only has to be added to the original lubricant and is carried to the affected areas of the engine or gear box. In the rubbing area, the metal silicates react due to friction, temperature and high partial pressure and bond into the metal surfaces. They fill the smallest corrugations,

pores or micro cracks in the metal surface and build an extremely smooth and solid metal silicate layer. The treated metal silicate surfaces have a much higher resistance to abrasion and wear, have a lower friction coefficient and allow for better and faster build-up of a lubricating film. A complete lubricant analysis proved that REWITEC is not an additive but a surface enhancement treatment. The important oil characteristics such as total acid number TAN and air and water release capabilities will not be altered. Appearance and colour are changed due to the coating concentrate. Viscosity and foam test show only a slight change in the run-in phase, but within tolerances. Beside the Nanocoating concentrate that is applied through the gear and engine oils, REWITEC also produces formulated bearing and gear greases. A comparison of a standard bearing grease and the same bearing grease formulated with the Nanocoating concentrate is illustrated in Figure 4. Condition Monitoring Different methods for proving the successful outcome of the Nanocoating are useful: Oil analysis for measuring the metal particles in the oil, silicon imprints of the metal surfaces for microscopic analysis of the metal texture, electrical resistance analysis of the metal surfaces and the

Figure 1. Friction and pressure in engines and gearboxes generates high temperatures on metal surfaces that trigger the chemical bonding process of REWITEC.

Figure 2. The soft nanoparticles remove dirt from the rubbing metal surfaces and react with the metal atoms to form a smooth and protective layer on the surface.

Figure 3. The final result is a new and very smooth metal surface structure. These properties, in turn, give the machine more power, higher efficiency and longer life.

EMS November/December 2009 www.engineeringmaintenance.info

WEAR PROTECTION FOR WIND TURBINES

Figure 4. a – This ball bearing shows damage due to wear and tear. The running surface of the balls clearly shows pitting. Bearing type: Nr. 6205 (d = 25 mm, D = 52 mm) Lubricant: Special bearing grease Operating time: 50 hours Rotational speed: 500 min-1 Nominal load: 5.000 N radial (range of fatigue) b – This ball bearing does not show any wear. The running surface of the balls clearly shows a wear resistant coating. Bearing type: Nr. 6205 (d = 25 mm, D = 52 mm) Lubricant: Special bearing grease treated with REWITEC Operating time: 50 hours Rotational speed: 500 min-1 Nominal load: 5.000 N radial (range of fatigue)

condition monitoring by noise and vibration harshness analysis before and after REWITEC treatment. The project partner in condition monitoring analysis is the company μ-Sen GmbH. Since 2001, μSen has established itself as a solution provider for fault detection systems for wind energy plants (WEP). Along with vibration reports for WEP, this includes a service concept for turbine condition monitoring via the Internet. Since 2001, condition monitoring systems developed by μ-Sen have been installed in more than 700 WEP (21 different types of wind turbines from 11 manufacturers). Condition Monitoring via Body Sound Analysis for Wind Energy Plants Body sound is a very sensitive indicator for changing conditions of moving machines and system components. Body sound sensors can be easily retrofitted, because they do not influence the measured object due to the relative small size and mass. The advantage of the acceleration sensors mostly used for recording of the body sound is, beside the big dynamic area, the calculation of acceleration in speed and amplitude. Thanks to these advantages acceleration sensors are ideal for recording body sound signals. Due to the fast development in the field of wind energy area since the midnineties and the simultaneous rapid increase in the power output of wind energy plants, the measuring requirements at these plants are also growing. Beside the monitoring techniques, mainly body sound based diagnosis systems (Condition Monitoring Systems – CMS) are increasing, which allows early failure detection on the main components of the drive train. The increased use of computer based CMS for

different manufactures has already reduced the cost of such a system to around 10,000 Euros, cost that is amortised in one to two years. For a better understanding of the results of the REWITEC Nanocoating via condition monitoring, the measurement data recording and measurement data analysis is explained below. Measurement Data Recording for Body Sound Analysis Condition Monitoring Systems are used for early failure detection in wind turbines in Germany. These systems are installed in the nacelle of the WEP and the body sound sensors are at the main components (main bearing, gearbox, generator) of the drive train (compare Figure 5/schematic description of drive train). For verifying the effect of REWITEC Nanocoating, the sensor position was above the high speed shaft at the second spur gear stage of the WEP. Besides other points, the trend of the spectral component (amplitude of rotary frequency of the intermediate shaft in envelope spectrum) was also measured. The envelope algorithm is a very successful

method for early failure detection of bearings and toothing damage. The spectral components in the envelope arise due to impacts which happen during roll over of chips on the running trace of rolling bearings. These impulses stimulate structure resonances and allow a very early detection of such damage. The same applies to corresponding damage on gear teeth. CMS are mostly configured so that on days without special incidents (no violation of the limit) four time series will be recorded. Out of these 300 to 400 specific values in the time- and frequency domain, the single specific values will be calculated. In the trends of the supervised specific values we get four new measuring points every day. Practical applications and results of the REWITEC treatment in different wind turbines are illustrated in the next section. Flender Gearbox of TACKE TW 250 Wind Power Plant Date: August 2007 Data: TACKE TW 250, Flender gearbox, oil content: 75 litres Mobil oil XMP SHC 320 Target of application: restoration of worn gear surfaces, reduction of micro pitting, wear protection and extension of lifetime of the gearboxes Application method: neutralisation of the oil fine filter, using main filter > 60 µm for approximately 500 running hours, application of the REWITEC concentrate to the gear oil, reactivation of the standard oil filters approximately 500 running hours after treatment (Figure 6). TACKE TW 250 – documentation of the gearbox conditions before and after the coating (Figures 7 to 8). Conditions before Coating The gears were showing significant wear

Figure 5. Illustration (scheme/left) of wind turbine drive train with acceleration sensors; (right) Gearbox with acceleration sensor (sensitivity: 100 mV/g).

www.engineeringmaintenance.info November/December 2009 EMS

WEAR PROTECTION FOR WIND TURBINES

Figure 6. Optimising the metal surfaces of tribologic systems will increase the parts life time. If the Wind Turbines life is only prolonged with about six days the product costs are already paid. Furthermore there is a targeted exchange and maintenance of the gear box and bearings possible.

and tear and fragments from the tooth flanks had broken off. The bevelled edges and tooth tips were sharp edged. Replicas were taken from the marked tooth. The measured values of the resistances of the tooth surfaces were 0 Ohm. Conditions after 1400 Operating Hours The teeth have a smooth and shiny surface. Replicas were taken from the marked tooth again. They were showing significant smoothing of the surface compared to the replicas that were taken before. Values of about 50 Ohm were measured for the resistances of the tooth surfaces due to the formation of the REWITEC coating. The highest values of resistance were measured at the lower part of the teeth. Results restoration of worn gear surfaces, reduction of micro pitting, the wind turbine has been running without any mechanical problems until December 2007. Flender Gearbox of TACKE Wind Power Plant TW 600 Date: February 2008 Data: TACKE TW 600 with 360 litres Mobil oil Castrol Optimol X320 Target of Application restoration of worn-out gear teeth surfaces, reduction of grey stoking, protection against further wear and prolongation of life time

Conditions before Treatment Wear traces and grey stoking on gear teeth surfaces. Replicas were taken from the marked gear teeth. Measurement of the electrical resistance on gear teeth surface resulted in 0 Ohm. Conditions after Two Years The gear teeth are still much smoother and shinier. Replicas were taken again from the gear teeth. In comparison to the earlier replicas there was an obvious smoothening of the teeth surfaces. Because of the REWITEC Nanocoating the electrical resistance of the gear teeth surface has increased up to 100 Ohm. The highest values were measured on top and on bottom of the gear teeth. TACKE TW 600 – Documentation of Gear Condition before and after REWITEC Treatment through Replica Analysis (Figures 9 to 10) Microscopic analysis on the replicas of the gear surfaces: The REWITEC coating is clearly visible. The grooves are smaller and the tooth surface much smoother and grey stoking was nearly completely gone. Results restoration of worn out gear teeth surfaces, reduction of grey stoking, the wind power plant is operating since the REWITEC coating without any mechanical problems. AN Bonus 1.0 MW with Flender Gear Box Date: August 2008 Data: AN Bonus 1.0 MW with Flender gear box PEAS 4355.7, 150 litres Tribol oil 1710/320 Target of application: restoration of worn out gear teeth surfaces, reduction of grey stoking, protection against further wear and prolongation of life time, analysis of REWITEC Nanocoating with CMS of µ-Sen GmbH

Documentation of Gear Condition before and after REWITEC Treatment Conditions before the Treatment Different wear traces, partly due to metal shavings passing through the gear teeth. Imprints were taken from the gear teeth marked, and measurements of the electrical resistance on the teeth surface showed 0 Ohm. Conditions after about Seven Months after the Treatment Gear teeth surfaces are clearly much smoother and shinier. Replicas were taken again from the gear teeth, and compared to the earlier replicas. There was a clear smoothening of the teeth surfaces. Because of the REWITEC coating the electrical resistance of the gear teeth has increased up to 50 Ohm. μ-Sen – Condition Monitoring System (CMS) Results The frequency spectrum after =REWITEC treatment from the μ-Sen Condition Monitoring System (CMS) shows that the amount and level of the peaks of the rotary frequency of the high speed shaft is reduced by about 20% (Figure 11 ). The acoustic analyses show also that the conditions of the gear box and bearings are clearly improved, even though readings after the REWITEC treatment were taken in the time of the year with more wind and higher load. This new report indicates the first, much promising results of the use of REWITEC Nanocoating in wind turbine gearboxes, analysed via the condition monitoring system. The condition monitoring system further validates the positive results measured by other means. The intention of the cooperation between μ-Sen and REWITEC is to increase the lifetime of the existing wind energy plants. The intent is to prove that it is possible to effectively reduce the initial damage in wind energy gearboxes (grey stoking, micro pitting, micro cracks)

Figure 7. Conditions before the coating

Figure 8. Conditions after the coating

EMS November/December 2009 www.engineeringmaintenance.info

WEAR PROTECTION FOR WIND TURBINES

Table 1. Nano coating payback analysis for prevention of downtime.

Turbine power

1,500 kW

Output per year

4,500,000 kWh

Output per day

12,329 kWh

Commission

9.1 Ct/kWh

Commission per day 1,121 Euro

Figure 9. Before December 2006

Figure 10. After November 2008.

and also to prevent or delay larger damage and failures. The targeted combination of REWITEC and CMS can provide the following advantages to the plant manager: optimised use of REWITEC via body sound analysis, increased efficiency due to reduction of friction, minimising of load due to reduction of rotor unbalances and adjustment failures, early failure detection.

Conclusions The results from the imprints, electrical resistance measurements and the CMS analyses confirm that there is a clear improvement and smoothening of the worn out gear surfaces and load-carrying areas will be clearly enlarged. These all together will lead to a prolonged gear box and bearing lifetime. The treatment of generator bearings, pitch bearings and open pitch gears with the REWITEC coating grease will prevent wear in all grease-lubricated wind

Costs of treatment

6,400 Euro

Amortsation time

5.7 days

* Output related to reference location with a medium yearly wind speed of 5.5 m/s

turbine applications. Increasing wear can be stopped and already existing damage can be “frozen”. Optimising the metal surfaces of tribologic systems will increase the lifetime of wind turbine components. The cost of the REWITEC treatment is recovered within just six days! The increased uptime of a wind power generator will result in substantial savings for operators and greatly diminished maintenance intervals (Table 1). ABOUT THE AUTHORS

Dipl.-Ing. Stefan Bill, Managing Director REWITEC GmbH Lahnau/Germany Figure 11. µ-Sen – Condition Monitoring System (CMS).

Dipl.-Phys. Holger Fritsch Managing Director μ-Sen GmbH Rudolstadt/Germany

Mr Stefan Bill Rewitec GmbH Dr. Hans Wilhelmi Weg 1 35633, Lahnau, GERMANY T: +49 6441445990 Germany E: Bill@rewitec.com

Dermott Reilly, UK & Ireland T: +353 8790 10419 E: d.reilly@rewitec.com Reader Reply Number: 304

www.engineeringmaintenance.info November/December 2009 EMS

WIND TURBINE MAINTENANCE

Tentec’s tools designed for onsite maintenance

AND SO REDUCE DOWNTIME In these cost conscious times there is an even greater emphasis on reducing downtime and ensuring that any repairs or maintenance are carried out swiftly and costeffectively. This is particularly relevant in the wind turbine industry where activities such as bolt tensioning ensure the effectiveness and the integrity of the structures. However, after vigorous use, even bolt tensioning tools themselves begin to show wear and tear and after a specified number of pressure cycles all tools require routine servicing. With these issues in mind, Tentec’s Aero range of bolt tensioning equipment is designed to be extremely maintenance

friendly. Unlike other tools on the market, the Tentec equipment can be serviced in situ either by Tentec personnel or by the operators own engineers. The modular design of the tensioners means that replacing seals and worn or damaged parts can be accomplished on site with no need to return the tool to the manufacturer or supplier. In addition the base of the Aero tensioner is fitted with an easily replaceable wear plate that again can be very easily replaced if damage to the base of the tool occurs. “We listened to the market when designing these tools.” explains Roy Sheldon, Business Manager for the Wind Turbine business at Tentec. “A real concern

For more information quote EMS Enquiry No. 108 on IBC

EMS November/December 2009 www.engineeringmaintenance.info

was that with competitive tensioning tools, the equipment had to be sent back to the manufacturer for maintenance and repair. This resulted in costly downtime.” The in situ maintenance of the Tentec tools allow wind turbine installers and maintenance engineers to keep control of time and costs and enables them to schedule tool maintenance and repairs to suit their project timescales. Tentec Ltd T: + 44 (0)121 524 1990 E: r.sheldon@tentec.net www.tentec.net Reader Reply Number: 305

For more information quote EMS Enquiry No. 109 on IBC

POWER STATION MAINTENANCE

With the assistance of ABFAD Limited of Sunderland, E.ON has reduced the carbon footprint and running costs of its 4 gas fired power stations at Connah’s Quay, North Wales BEFORE

Tube blasting REDUCES EMISSIONS

at Gas Fired Power Stations AFTER

Carbon footprint has been reduced by 246 tonnes per week and cost savings of £640,000 per year have been made on the 4 stations as a direct result of pre-heater condensate tube blasting in the boilers, using ABFAD’s surveying, grit blasting and clean up services, with results as shown in the

images of Pre Heater Tube before and after blasting. As well as pre heater tube blasting using a fairly aggressive medium, ABFAD conducted more delicate blasting of the condenser itself inside the turbine, using a more refined blast medium. ABFAD specialises in engineering services to the

power industry, including abseiling rope access inspection, maintenance and coating services.

Chris Haritou Abfad Ltd T: 0191 516 6223 E: chris@abfad.co.uk www.www.abfad.co.uk Reader Reply Number: 306

Maintenance Advisor Software (MAS) has four modules dealing with conventional Power Plants and HRSGs when operating in base-load or cycling mode

MAS has been developed by experts to help and advise power plant engineers. MAS helps and guides maintenance engineers on what to do when things go wrong. It is already in use in a number of plants in Europe. MAS has a wealth of knowledge and database

for the experienced engineer and is an excellent tool for the training of younger engineers. For further information on MAS or ETD’s Risk Based Maintenance programmes/projects for power plants please visit www.etd1.co.uk

European Technology Development

6 Axis Centre, Cleeve Road, Leatherhead Surrey KT22 7RD, UK T: +44 1372 363111 E: ashibli@etd1.co.uk www.etd1.co.uk Reader Reply Number: 307

www.engineeringmaintenance.info November/December 2009 EMS

DRIVE SYSTEMS

NORDBLOC Industrial Gear Unit range provides integrated motor swing base sub-assembly for 60 to 200 kNm torque output

NORDBLOC INDUSTRIAL

GEAR UNIT RANGE As part of its comprehensive range of NORDBLOC industrial gear units for torque output from 60,000 to 200,000 Nm, NORD supplies complete modular sub-assemblies comprising UNICASE gearbox, motor and coupling with a broad and flexible range of options and accessories. Fully preassembled on torsionally rigid motor swing base or base frame mountings, the combined units require no complex alignment and are supplied fully tested. These ready to install modular gear unit systems are completely scalable and custom built to suit specific load, mechanical interfacing and environmental specifications for heavy-duty conveying and lifting applications throughout industry. By specifying a complete sub-assembly, customers are able to reduce their project management burden, timescales and costs using the NORD design service to manage all aspects of the application – as well as making system commissioning more straightforward and simplifying purchasing. Each modular system comprises gearbox, motor and base frame with options of elastic or fluid coupling, drum or disc brake, radial or axial fan, auxiliary drive, torque support with attachment plate and protective covers as well as sealing system options. Furthermore, a broad choice of temperature management options include fans, external oil/air or oil/water cooling, and several measuring devices and sensor options

are available for oil inspection, temperature and bearing condition monitoring. The modular system design, covering 6 basic installation configurations with identical installation dimensions for all 2 and 3-stage gear ratios, allows an almost endless combination of power transmission sub-assembly options with fast delivery assured from standard off the shelf components. The symmetrical UNICASE gearbox design permits mirror image installation for dual drive applications. NORD’s own wide range of IEC frame energy saving three-phase motors are used throughout, and NORD SK 700E frequency inverters are available to offer complete gear unit and drive solutions with high performance motor control, and connection to all current factory networking communications systems. NORDBLOC industrial gear units draw on the well proven benefits of the UNICASE housing system – a one piece design produced on specialised CNC machines which offers the highest levels of

EMS November/December 2009 www.engineeringmaintenance.info

precision, rigidity and strength. With all bearings mounted directly into the cast iron UNICASE housing, and with no dividing seams between the drive and gear unit, the design allows shaft axes to be staggered in a more compact space-saving arrangement; also allowing the use of larger roller bearings to ensure a longer operational life with quieter running and reduced maintenance burden. Available in four frame sizes form 60,000 Nm to 200,000 Nm, with helical and bevel-helical gear stage designs, the range includes a wealth of options for mechanical interfacing, performance, safety and environmental conditions.

NORD GEAR LTD. (U.K.) 11 Barton Lane Abingdon Science Park, Abingdon OX14 3NB Oxfordshire United Kingdom

T: +44 (0)1235-534404 E: astephenson@nord-uk.com www.nord.com Reader Reply Number: 308

DRIVE SYSTEMS

Single casting with integrated bearing seats minimises oil leakage possibilities Helical gear stages can deliver superb energy efficiencies of up to 96%+

HIGH-TORQUE INDUSTRIAL GEARBOXES come in high-integrity single-piece housings Nord Drivesystems has extended its family of high-integrity industrial gearbox units, adding a family of high-power models with maximum torque ratings up to 200000 Nm. The new gearboxes employ Nord's proven Unicase concept. The gearbox case is a single piece casting, with all bearing seats integrated and machined in a single process. This optimises strength and eliminates sealing surfaces that could deflect under the effect of torque or radial forces â&#x20AC;&#x201D; minimising the possibility of oil leakage. The resulting high-integrity gearboxes deliver smooth, low noise operation with a long product life. There are four choices in the new High Power Unicase family, offering maximum torques of 60000, 90000, 135000 or 200000 Nm. Available in helical-parallel shaft or helical/bevel right-angled drive configurations, a very wide range of gear

ratios can be specified using two-, three-, or multi-stage reductions. The gearboxes are ideal power transmission solutions for material handling and processing equipment in applications such as steel manufacture, aggregates, mining and grain handling. The low losses of the helical gearing technology means that Unicase gearboxes can deliver excellent energy efficiencies of up to 96%-plus. The gear units conform to Nord Drivesystems' modular design concept. This provides a plug-together approach to add-ons that makes it extremely simple to configure gearboxes for specific applications. A wide range of accessories includes brakes, backstops, a drywell solution, condition monitoring equipment, and a choice of cooling systems. Combined with the flexibility to be mounted on six sides, or via an optional flange, the new

gearboxes can be adapted easily to provide customer-specific power transmission solutions. Because of the gearboxes' inherently high efficiencies, Nord Drivesystems expects the units to appeal strongly to the refurbishment and repair market, especially when replacing older relatively inefficient worm gear units. In such applications, the energy savings will often provide a payback on the investment measured in months. As with all Nord Drivesystems gearboxes, the company's production line is set up for rapid manufacture of application-specific solutions inline with customer requirements.

NORD GEAR LTD. (U.K.) T: +44 (0)1235-534404 E: astephenson@nord-uk.com www.nord.com Reader Reply Number: 309

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For more information quote EMS Enquiry No. 110 on IBC

www.engineeringmaintenance.info November/December 2009 EMS

FIRE SYSTEMS When NASA Kennedy Space Centre’s fire safety experts decided to replace the fire suppression system in its giant twin crawler transporters, it turned to the next generation firefighting system for enclosed spaces – a clean, compact, cost effective, safe and simple system called Stat-X

NASA selects STAT-X

FIRE SUPPRESSION SYSTEM Designed and manufactured by Fireaway LLC in the USA, Stat-X kills fires quickly without harming the environment and is available in the UK through its exclusive distributor, Nobel Fire Systems. NASA has ordered Stat-X generators for three areas in both its crawlers and approximately 100 fire suppression units will be installed in the control areas, machine rooms and communication rooms of the crawlers which carry the space shuttles to the Kennedy launch pads for lift off. “NASA’s crawler transporters are two of the world’s largest moving machines. They are complex environments with a great deal of equipment packed into tight spaces which makes the piping for gaseous fire suppression systems very cumbersome and expensive”

said James Lavin, CEO of Fireaway. “Stat-X fire suppression systems were invented to address these types of challenges.” On an agent weight basis, Stat-X aerosol is ten times more effective than gaseous agent alternatives. Another benefit is that all units are environmentally friendly with zero ozone depletion and zero global warming potential. It has ultra fast fire knock down and possesses long post fire security due to the potassium aerosol being suspended in the air of the enclosure for up to an hour. In the event of fire breaking out, suppression is rapidly achieved through interference between the ultra-fine aerosol particulate and the flame’s free radicals, terminating propagation of the fire.

Stat-X is available in five pre-engineered sizes for operation and storage in temperatures in the range, -40 degrees to + 54 degrees Centigrade. Ben Parker, Commercial Director of Nobel Fire Systems, the UK’s exclusive Stat-X distributor said, “Stat-X is being recognised as a world leading fire suppression product and the fact that NASA has selected it for its giant crawler transporters underlines its growing reputation. In the UK, its effectiveness is also apparent as more businesses continue to install Stat-X across a wide sector of industries and applications.” T: +44 (0)1706 625 777 F: +44 (0)1706 625 325 E: Ben.Parker@nobel-fire-systems.com Reader Reply Number: 310

MACHINING There has never been a more critical time for work’s production operations to drive costs down, achieve greater efficiencies whilst at the same time maintain manufacturing quality

MQL DRIVES machining costs down

It is estimated that on large scale production sites cooling lubricant can make up nearly 20% of the total manufacturing cost. A typical ‘wet’ machine may use 10 to 10,000 litres/hour of lubricant depending on application; whilst much is recycled, due to natural wastage as aerosol spray into the atmosphere and adherence to swarf, overall losses can amount to between 3 and 15 litres/hour.

With bielomatik Minimal Quantity Lubrication (MQL) system oil consumption can drop significantly to between 100 and 150 millilitres/hour. Apart from reducing the amount of lubricant used, any machine shop that switches to MQL benefits from much easier disposal of metal cuttings since they are virtually oil-free and machine performance is enhanced, particularly production time. Another important feature that allows near dry machining is the elimination of coolant carryover in component pockets aiding faster processing times between operations. Up-grading to the Bielomatik MQL system which delivers precise measured quantities of lubricant to the cutting tip offers tremendous beneficial financial gains. Also, in hard turning applications, achieving slower tool wear while maintaining cutting forces/power at reasonable levels, provided that the MQL parameters can be strategically tuned. With MQL manufacturing costs can be

EMS November/December 2009 www.engineeringmaintenance.info

reduced by up to 15% without detriment to the quality of the finished component. Recognition of the financial and environmental benefits of MQL systems mean that nowadays new machine builds often come complete with MQL technology; it has invariably been more difficult and more costly to add to ‘older’ machines. The latest Single Channel MQL system from Bielomatik overcomes most of the difficulties, enabling existing machining operations to be converted to MQL and thus enjoy all the inherent benefits. For companies genuinely interested in switching to MQL technology Bielomatik is able to provide a test rig allowing users to judge for themselves the environmental and cost savings to be made. T: 01480 408500 F: 01480 403808 E: jim.hughes@bielomatik.co.uk www: bielomatik.co.uk Reader Reply Number: 311

HYDRAULICS

WFE Hydraulic Services Repairs department has over 30 years experience in the manufacture and repair of bespoke and standard hydraulic cylinders

Performance under pressure Replaced body on a rotary coupling

Telescopic Jib before & after straightening

WFE have the expertise and capability to undertake any cylinder repair irrespective of length or diameter. We can straighten rods, hone cylinder bores, machine new parts if required, and all of which are

Remanufacture of original components

done in-house all within our 35,000 sq/ft factory based in Sheffield off J34 M1. WFE can arrange for any cylinder to be collected and delivered to and from our customer’s depot if required.

WFE are proud of the fact that all of our customers are long standing, and the ones who have used us for the first time always come back to us. Many hydraulically operated plant manufacturers; mobile crane operators and offshore companies rely extensively on our service to cover their vast needs. Every Hydraulic cylinder repaired by WFE is fully pressure tested, and painted or sprayed to meet the customer’s requirements. All work is carried out under the scope of ISO 9001:2008 quality management system. Gary Marsh (Service Manager) WFE Hydraulic Services Ltd Tyler Street, Sheffield S9 1GL

Tel: +44 (0)114 2430936 Fax: +44 (0)114 2425516 www.wfehydraulics.co.uk Reader Reply Number: 312

“An excellent repair, a fast turnaround, collection and delivery and very competitive prices.”

COUPLINGS

Dixon Group Europe offers a comprehensive range couplings and hose fittings for your plant maintenance and fluid handling requirements A wide selection of materials including Steel, Aluminium, Brass, 316 & 303 Stainless Steel are available, together with thread configurations including BSP & NPT and body sizes ranging from 1/8” and higher to ensure compatibility in a variety of installations. Stainless Steel hygienic fittings are available in a variety of fitting types (RJT, SMS, DIN, IDF & Triclamp) with sizes from ½”-12” that meets or exceeds 3A standards. The Dixon range of hydraulic & pneumatic quick connect/disconnect fittings

offer interchanges with other manufacturers. The ISO7241 ISO A interchange series of fittings has recently been revised for superior wear resistance and to offer astounding performance results. Dixon also offers a full hose range to complement their already long established couplings sales, this is inclusive of composite, rubber, metallic, PTFE, food & beverage, anti static and spiral PVC hose. Visit www.dixoneurope.co.uk to view the full range of products.

Contact Gill Brown, Dixon Group Europe Ltd T: +44 (0) 1772 323529 E: marketing@dixoneurope.co.uk Reader Reply Number: 313

www.engineeringmaintenance.info November/December 2009 EMS

Objectivity. Do not let the fox in the hen house. IDCON prides itself by being Totally Objective. We are not associated with any organizations including suppliers of computer systems, engineering services or out-sourcing companies.

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IDCON, INC. 7200 Falls of the Neuse Road Suite 200 Raleigh, NC 27615 Phone: +1 919 847 8764 fax: +1 919 847 8647 www.idcon.com email: info@idcon.com

For more information quote EMS Enquiry No. 111 on IBC

RAILWAY MAINTENANCE Applied Traffic has decades of field experience, test and design of High Speed Weigh in Motion. 2009 sees the launch of the VIPERWIMÂŽ classifier which has been the innovation from the collective knowledge and experience gained by our team

Applied Traffic BRIDGE PROTECTION Over the last 18 months the product has progressed from prototype stage and beta testing of pre-production units over a wide range of conditions on various road types, traffic patterns and volumes, to production and launch at the recent Traffex show. The system can interface with ANPR or CCTV cameras and can be used for weight enforcement & monitoring as well as Bridge

Specific Assessment Live Loading. We have a long history of working with bridge monitoring in the UK, including both Severn Bridges and the QE2 Bridge in Essex. We have a specialist team in place for data capture, analysis & reporting who can run the information on a weekly or monthly basis, depending on your requirements. Our services also include proactive

maintenance and regular inspection, along with routine calibrations. Applied Traffic Ltd Unit 5 Southview Park, Marsack Street Caversham, Reading RG4 5AF T: 0118 9461900 F: 0118 9461862 www.appliedtraffic.co.uk

Reader Reply Number: 314

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5FM 8FC XXX UDBSETEJSFDU DPN For more information quote EMS Enquiry No. 112 on IBC

www.engineeringmaintenance.info November/December 2009 EMS

INDUSTRIAL CAMERA

True 3D industrial camera sees three dimensions at once

Seeing three dimensions The truly innovative efector pmd 3D camera from ifm electronic is the first industrial camera that sees in three dimensions at once. Integration of their unique PMD (photonic mixer device) time-of-flight measurement sensing technology into a full vision chip, has allowed sensor market leader ifm electronic Ltd to produce a truly amazing device. The image sensor has 64 x 48 pixels. Each pixel of this chip matrix evaluates its distance to the object, resulting in 3072 distance

values. The image of the object on the matrix and the respective distance values therefore gives a 3D image. The geometrical characteristics of the object or the scene can be read from these values. This means the object and the camera can be stationary, a single camera will see the three-dimensional scene directly. With its own powerful built-in infrared light source the PMD 3D Camera provides the user with real time image data, from as far away as

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6.5m, comprising 3072 grayscale and distance values for a low-cost solution to a variety of applications in all manner of walks of life. The 30° x 40° aperture means a large area can be viewed, leading to uses so far tested varying from people counting or detection, in one case for security purposes, to vegetable picking. The applications are limited only by the imagination; they could range from packaging, storage and materials handling, through airport logistics, vehicle detection, collision avoidance and robotics, to just monitoring if a space is occupied. Designed for OEM use the O3D201 PMD 3D Camera utilises a downloadable software development kit, which provides all tools necessary for the system designer to integrate the 3D information into the control system. This gives the designer scope to create the right unit for the task. It thus complements the O3D200 unit designed for end user applications, where all evaluation is carried out internally. The device has digital and analogue outputs for the user to scale or configure, and inputs for triggering or synchronisation. For interface with the eventual users there are two pushbuttons alongside the 10-digit display, or the designer could opt to leave the interface only at the ethernet programming level. Naturally, the housing is robust, die-cast zinc with polycarbonate optics making it suitable for industrial use. The two connections on the

For more information quote EMS Enquiry No. 113 on IBC

EMS November/December 2009 www.engineeringmaintenance.info

housing, for power with inputs and outputs, as well the ethernet programming port, use industrial standard M12 connectors for a good seal, maintaining the overall IP67 environmental protection rating. The 3D vision camera thus provides illumination, depth measurement and evaluation in one industrial housing. Exceptional technology in a very small space, for a surprisingly low cost – made by ifm of course. Of course ifm electronic also supplies a range of mounting accessories to aid installation and connection of the O3D201 3D camera. ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products. Mel Lewis ifm electronic Ltd.,

Efector House, Kingsway Business Park, Oldfield Road Hampton, Middlesex TW12 2HD T: 020 8213-0000 F: 020 8213-2228 www.ifm.com/uk Reader Reply Number: 314

Thermoteknix Systems Ltd reacted to the ongoing H1N1 swine flu outbreak with the rapid launch of their new, low-cost FevIR Scan Skin Temperature Measurement system for mass screening of high pedestrian areas such as airports, train stations, factories and other public places. The system is shipping immediately ex-stock. Now Thermoteknix have announced that FevIR Scan is available on a rental basis in mainland UK for a modest monthly fee

Fev IR Scan – YOUR FIRST LINE OF DEFENCE against the H1N1 Swine Flu outbreak, now available to rent or buy The miniature, discreet and ultra portable FevIR Scan Skin Temperature Monitoring system provides peace of mind with high speed sensitive temperature measurement for high volume pedestrian transit areas. The system is based on a Thermoteknix thermal imaging camera working in conjunction with a blackbody calibration unit for high accuracy temperature measurement and with the option of a colour visible video camera display for simultaneous subject visual identification. FevIR Scan is a tried and tested screening system which is serving in numerous countries including Thailand, Mauritius, Angola and in Mexico – where units have been installed at multiple locations for national screening. FevIR Scan thermal imaging and temperature measurement system from Thermoteknix is easily installed, operated and re-located with the very minimum of setup time and operator training. On-screen alerts identify one or more individuals in a large crowd situation, aiding rapid dectection and maintaining passenger flow. The system is password protected to prevent unauthorised changes. The SARS, Bird flu and now H1N1 swine flu viruses have affected tens of thousands of people and businesses with massive disruption to all people in all walks of life and FevIR Scan ensures that a high rate of human transit is monitored effectively without slowing queues in busy areas. Thermoteknix Systems Ltd Managing Director Dr Richard Salisbury said:

‘Thermoteknix has been supplying skin temperature monitoring systems to airports and public places since the SARS epidemic in 2004 so we were ideally placed to respond immediately to the public need for for low cost skin temperature monitoring systems. Our new FevIR Scan equipment is an even faster to install accurate, high resolution system which needs an absolute minimum of operator training and is reliable and simple to use. We are delighted to say that we have been inundated with enquiries from all quarters of the globe for our FevIR Scan system and have just shipped multiple units to Mexico where the disease initially broke out.’ Thermoteknix FevIR Scan infrared thermal imaging cameras can detect temperature differences as small as 0.05°C and with their

high resolution detectors and lens options cover a wide or narrow field of view as required for transit monitoring. A calibrated temperature reference source is included in the scene for the highest temperature measurement accuracy extending the performance beyond that of industry standard thermal cameras.

Thermoteknix Systems Ltd T: 01223 204000 www.thermoteknix.com Reader Reply Number: 315

www.engineeringmaintenance.info November/December 2009 EMS

ATEX

Michell Instruments has added to its range of Easidew dew-point transmitters with the Easidew PRO I.S., a rugged, intrinsically safe transmitter suitable for use in the natural gas, petrochemical and process industries where a rugged transmitter is required

Rugged I.S dew point transmitter with ATEX certification from Michell Instruments A natural progression from the Easidew TX I.S., the Easidew PRO I.S. is certified by ATEX for use in hazardous area zone 0, as well as for use with galvanic isolators. Like the other transmitters in the Easidew Range, the Easidew PRO I.S. is part of the Sensor Calibration Exchange Programme – enabling customers to maintain traceability through periodic recalibration while keeping the process in operation. Signing up to the programme means that customers can order a new sensor, install it and then send back the old one to Michell for recalibration at a fraction of the cost of completely replacing the sensor – with the added benefit of no down-time. The key to the success of the exchange programme is the innovative Easidew

sensor technology. All the calibration data is stored within the transmitter’s flash memory and so calibration exchange, or service, can be affected in seconds, even by untrained personnel. The Easidew PRO I.S. is simply disconnected, removed from its sampling block and replaced by a new fully calibrated unit. The Sensor Calibration Exchange Program for Easidew PRO I.S. makes it the perfect choice for measurement of dew point or moisture content in all hazardous area applications where a calibration traceability of the used equipment is crucial. Specific applications include CNG (compressed natural gas) dryers, hydrogen coolant in power generators, industrial gas manufacture and supply and many more.

Nick Malby, Global Product Manager

Michell Instruments 48 Lancaster Way, Ely, Cambridgeshire CB6 3NW T: 01353 658 000 F: 01353 658 199 E: info@michell.co.uk

Reader Reply Number: 316

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. 114 on IBC

EMS November/December 2009 www.engineeringmaintenance.info

Web: www.proviso-systems.co.uk

VIBRATION MONITORING

Unbalanced rotating bodies cause vibration and mechanical stress which is transmitted to the machine’s entire structure

N300 Portable balancing and vibration monitoring Field balancing reduces the amount of vibration and improves the machines overall condition. In addition, field balancing reduces stress on the bearings, temperature, energy consumption, noise, maintenance frequency and operating costs. With the N300, CEMB meets the needs of engineering companies and maintenance personnel who need a compact and ergonomic balancer. The N300 can be used to measure the overall vibration value (ISO10816-3), take synchronous measurements (1xRPM) and for field balancing of rotating bodies on one or two planes. Thanks to the backlit graphic display and intuitive “step-by-step” software, even occasional users will find the N300 easy to use.

The quick coupling connectors connect two independent and simultaneous measuring channels and a photocell. The data can be transferred to a PC via the mini USB port. The N300 is equipped with N-Pro, Professional Environment software for NInstruments. This software can transfer all of the data recorded by the instrument and automatically file it by simply pressing a button. It can be displayed, processed, analysed and employed to generate reports

in PDF format or on paper at any time. For all your condition monitoring and balancing requirements visit www.cembhofmann.co.uk Mark Davies CEMB Hofmann UK Ltd 1 Longwood Road, Trafford Park, Manchester M17 1PZ T: 0161 8723123 www.cembhofmann.co.uk

Reader Reply Number: 317

For more information quote EMS Enquiry No. 115 on IBC

www.engineeringmaintenance.info November/December 2009 EMS

CONDUIT

Flexicon claims to have launched the most liquid tight conduit system in the UK by further enhancing its range of compression fittings. It has an IP rating of IP69k

Flexicon launch most liquid tight conduit system in the UK

The compression fittings are suitable for the company’s LTP galvanised steel plastic coated liquid tight range and also for its LPC smooth spiral reinforced pvc system. An IP69k rating allows equipment to be steam cleaned

by a high pressure, high temperature jet wash. It is suitable for equipment that needs regular intensive cleaning such as in food processing. The IP69k rating extends the BS EN 60529 rating system to a new standard DIN 40050.

The fittings include a multipart compression fitting with a nylon seal, which you can use for knockout or threaded entries as it rotates until tightened. Also available are compression fittings that swivel about the main body even after tightening, a 90°, 45° and a multipart compression coupler that includes seals for joining two conduits. These fittings can be used with conduit sizes ranging from 10mm to 63mm and are available with metric, PG and NPT thread variants. The LTP conduit range has a smooth, wipe clean outer cover, is resistant to oils and greases and UV light for external applications. For applications requiring a wide temperature range, you can use the LTPHC

variant for temperatures between -45°C to 135°C. The LPC spiral reinforced pvc range is a non-metallic alternative and can accept some torsional movement. Colour coded versions provide oil resistance (green), high flexibility (orange) or protection against wider temperature ranges of between -5°C to 90°C (blue). It is a lighter weight than metallic versions and is faster to install, particularly when cutting to length. The LPC range can also be used with nonmetallic or stainless steel fittings making it ideal for the food processing industry.

Flexicon Ltd T: 01675 466900 E: colin.legg@flexicon.uk.com www.flexicon.uk.com Reader Reply Number: 318

DUST EXTRACTION Nederman have launched a new free test service to provide accurate measurement of airborne contamination

FREE AIR QUALITY TEST SERVICE from Nederman The new test can measure many types of airborne contamination including weld fume, vehicle exhaust, oil mist and dust of varied particle sizes (1 to 10microns). The process is comprehensive, involving capture and collation of multiple data samples through work cycles and across operating zones. Overall results are then compared to the relevant long term (8-hour time weight average – “TWA”) or short term (15 minute) Workplace Exposure Limits (WELs) to identify if further action is needed. “We regularly encounter customer uncertainty regarding the contamination limits specified by HSE,” said Mark Hodgens, Nederman’s Managing Director. “In many cases, it’s not straightforward, so this free measurement and consultation service offers real benefits. Our analysis not only enables us to offer qualified opinion, it’s also the perfect foundation for designing effective

extraction if required. We’re concentrating on weld fume as a first phase.” The devil is in the detail as whilst HSE Guidance Note EH54 specifies an 8 hour TWA WEL of 5mg/m3 for particulate welding fume, it’s a ceiling level that’s dramatically reduced by the presence of more harmful elements in the consumable and it can also be impacted by the welding method. Nederman considers all these factors to establish appropriate test parameters. If limits are exceeded, there’s the option of commissioning more detailed analysis of component concentrations or implementing improved local exhaust ventilation (LEV). Either way, action will be required to avoid the legal risks associated with employee exposure to hazardous levels of dust and fume. Nederman are rolling this initiative out across Europe, having launched it at the

EMS November/December 2009 www.engineeringmaintenance.info

Schweissen & Schneiden exhibition for welding and cutting technology in Essen, Germany (September 14th – 19th). Nederman also exhibited a new filter for harmful elements in weld fume that’s compatible with existing FilterBox systems to provide safe removal and efficient cleaning of hazardous particles from high chrome content stainless steel and other difficult material. A new on torch extraction concept for automated robotic welding equipment was also shown for the first time. These latest innovations are driven by Nederman’s continuing aim to improve workspaces by enabling better health, quality and productivity.

T: 08452 743436 E: info@nederman.co.uk www.nederman.co.uk Reader Reply Number: 319

DUST CONTROL Rolls-Royce has extended capability at its Distributed Generation Systems business in Winsford, Cheshire, by investing in a fine particle decontamination facility to clean-up military power generators. Diesel powered generator sets, often returning from harsh overseas environments, have to be disassembled and thoroughly cleaned before being stripped down and overhauled

DCS bust the dust for Rolls-Royce

Recognising the need for an efficient method of removing the dust and fine airborne particulate during the cleaning process, Rolls-Royce called in extraction specialists, Dust Control Systems (DCS), to

discuss their requirements.DCS proposed and installed twelve environmental control booths (ECBs) and a centralised vacuum cleaning system to deal with dust lying on the floor.

ECBs feature a unique design that pulls dust filled air away from operatives at a rate of 0.7m/s, providing 99.97% filtration efficiency. With clean air moving at the same rate, this ‘cross flow’ method of air circulation eliminates the ‘stopping and starting’ caused by dust accumulation and poor visibility. Chris Goodwin, Works Director at the business, said: “It was vitally important that we had an extraction system that would ensure a healthy and safe environment for the team working in the area and also protect other workers outside the area from the nuisance of dust and noise.” Dust Control Systems Limited T: 0800 040 7116 F: 01924 482530 www.DCSlimited.co.uk Reader Reply Number: 320

Dust and fume extraction hoses from Masterflex

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 For more information quote EMS Enquiry No. 116 on IBC

CONNECTIONS

TUBE PROTECTION

For more information quote EMS Enquiry No. 117 on IBC

www.engineeringmaintenance.info November/December 2009 EMS

AWARDS

Barkston Plastics Ltd, one of the UK's most comprehensive and innovative plastics companies, has launched an ‘Innovations in Plastic’ awards scheme to help identify and celebrate the talent pool of designers, engineers, scientists, artists and technology students in UK universities

Barkston launches ‘Innovations in Plastic’ Awards Launched 1 November 2009, the competition is open to any UK university who wishes to enter and products put forward to win the award must be made entirely or in part of plastic. The competition will be judged by a panel including representation from Barkston and the wider manufacturing industry. Items entered into the awards scheme can be stand alone products or parts of products; and can be functional or simply aesthetic. Products can be new inventions or improved versions of existing products. Initial applications for the awards

scheme should be made online by 1 February 2010 with final deadline for completed entries by 1 May 2010. Judging will take place during June 2010. The winner of the ‘Innovations in Plastic’ award will be offered the chance to benefit from their product being put into manufacture; and marketed through Barkston’s website. The scheme will also assist Barkston in fulfilling its pledge to develop 40 new consumer products during 2009-10 – the company’s 40th year of trading. Tim Kiernan, Managing Director of Barkston, said: “The idea behind the

awards scheme is not only to recognise that we have a wealth of talent coming from our universities but also to celebrate the versatility of plastic. Many products that have been traditionally manufactured out of alternative materials are rapidly moving into production in plastic and this is great news for our industry and the future of British manufacturing.” For award entry information please log on to: www.barkstonltd.co.uk www.barkstonltd.co.uk Reader Reply Number: 321

CONDITION MONITORING Richard Chambers GmbH has been operating in the quality-conscious German-speaking world for over 27 years. The company is unique in that it does not concentrate on one technology, but with five offers as its real product "Saving with more Performance". This programme was recognised with an award at a leading maintenance show in 2009

As the European importer of the "Ultrasonic SPY", a device which locates defects in all industrial systems, and of which two have been working on the ISS since 2001, the company counts as customers nearly every big and many

medium-sized firms. With software added, the SPY offers much more information than vibration analysis, at a fraction of the cost and much simpler. Friction reduction in industry and transport can save significant energy costs. "SX-6000" is certified to reduce wear by up to 88%, compared with oil alone. Simply added to the oil system, it produces a longlasting coating on the friction surfaces. This product is the only one in the world using high-density PTFE (CoF 0.02), not to be confused with Teflon (CoF 0.04). With the death sentence for inefficient, hot-running lights in the EU, the "IntelliLight" series offers savings of up to 80% in warehouses, 60% in production areas. Each light unit has its own "intelligence", which has been proven to offer significant savings compared to even the most efficient units working in groups.. Installation is possible

EMS November/December 2009 www.engineeringmaintenance.info

up to 26 metres and office and loading ramp lighting is also available. Regulating current to constant-speed electric motors which work cyclically or under their rated performance, the "Powerboss" can save energy too. And with soft-start, soft or braked stopping and several other programmable features such as idle-time limit and dry pump stop, the investment can be well below that of a new high-efficiency motor when the other functions have to be bought seperately. Oil leaks can be eliminated with "LecWec", now being exported to 26 countries for use in vehicles and industrial machines. Down-time, often more costly than the repair itself, is eliminated - simply add 3% to the oil and carry on. www.chambers-company.com Reader Reply Number: 322

CHEMICAL CLEANING

Halliburton Chemical

CLEANING SERVICES Almost 50 years of chemical cleaning experience enables Halliburton Pipeline and Process Services to provide best-inclass, proven technology for

preoperational, operational and decommissioning cleaning operations. Halliburtonâ&#x20AC;&#x2122;s single-fill methods dramatically reduce waste volume and

cleaning time when compared to traditional multi-fill cleaning methods. Single-fill methods are available for cleaning a broad range of equipment including boilers, process tanks, transfer piping, pipelines, refinery process equipment, heat transfer systems, utility systems and pulp and paper process equipment. Proven technologies include the citric acid-based MagSolvTM cleaning process that provides degreasing, scale removal, neutralization and passivation with only one solvent fill. Technical support centers in Houston, TX, Duncan, OK, and Pune, India combined with field laboratories in most operational locations, enable Halliburton to design the most cost-effective approach to virtually any process system cleaning challenge. For more information about Halliburtonâ&#x20AC;&#x2122;s chemical cleaning capabilities, phone (44) 1224 350118 in Aberdeen or email pps@Halliburton.com

T: +44 (0)1224 350118 E: pps@Halliburton.com www.halliburton.com Reader Reply Number: 323

Adler and Allan Group Adler and Allan is the market leader in the provision of rapid response services to the public and private sector. Operating from an unrivalled network of bases, we respond quickly and effectively to customer requirements from oil and chemical spillages, critical fuel deliveries and tank servicing to managing major turn-key installation and dismantling projects, disaster recovery and industrial cleansing.

For a free, no obligation quotation please contact Adler and Allan: T: 0800 592 827 E: sales@adlerandallan.co.uk

More detail on our services, locations and contacts view: www.adlerandallan.co.uk Reader Reply Number: 324

Spill Response Services Resources and skills to tackle the most challenging of situations from domestic tank leaks to major industrial disasters Fuel Services For challenging fuel deliveries and providing a 24 hour call out service for retained customers Fuel Installation Services Expertise to service, design and install all fuel equipment Tank Services Experience of cleaning all types of storage tanks from small industrial to major refinery holding tanks Industrial Water Jetting and Cleansing Separator Services Pollution Prevention Oil & Hazardous Waste Management Services

www.engineeringmaintenance.info November/December 2009 EMS

WORKWEAR

Are you providing your workforce with the correct level of hand protection? Looking for specific, industrial work gloves? Well look no further as you have come to the right place

HAND PROTECTION SPECIALISTS

We provide a wide range of industrial gloves including chemical resistant gloves, specialist handling gloves, general purpose gloves and much more to assist people in various industries, such as the below. Sharp-edge Steel and Glass handling Building and Construction Areas Mechanical Assembly Lines Heavy Industrial Works

Wiring Industry Car Industry Food Processing Spontex is committed to providing and finding cost effective solutions to all your hand protection requirements. As much as a task can be carried out and to a satisfactory level with bare hands, it could be performed far more efficiently,

safely and easily due to the enhanced manual dexterity that the right glove can provide.

Rugged & Tough Ltd consists of Rugged & Tough Sourcing and Rugged & Tough Work Wear Stores. Rugged & Tough operates upon a platform to provide you, our clients with â&#x20AC;&#x153;Best in Class: - Professional and Industrial Grade Work Clothing and Kitâ&#x20AC;?. We offer the flexibility of being able to source large and small volumes. Our client base covers all the major industries and professions from the Multi-National Heavy Industries to SMEs.

Our Sourcing Division works with you to meet your specific requirements, finding you the right products and the right prices, from fire/ mosquito repellent clothing for use in Africa to arctic clothing for Russia and everything in between. Our main showroom in Bedfordshire offers around 4,500 products and operates an on-site embroidery and personalisation workshop. We are authorised dealers and distributors for Carhartt Workwear,

Walls Industries, Jobman Workwear, Blaklader Workwear and U-Power to name just a few. For more information about how we can help you, please contact Chris Turowska.

EMS November/December 2009 www.engineeringmaintenance.info

Spontex Workwear T: 0151 486 6540 E: sales@spontex-workwear.co.uk www.spontex-workwear.co.uk Reader Reply Number: 325

T: 07743 816632 E: chris@ruggedandtough.com www.ruggedtough.com Reader Reply Number: 326

WORKWEAR

Interactive Wear AG playing a significant role in a new ZIM/AIF funded project

DOCKING TECHNOLOGY APPLIED TO integration of computing equipment in work garments for industrial use Entry point into industrial projects in the area of wearable computing Project funded by Central Innovation Programme (ZIM) for SMEs of German Federation of Industrial Research Associations (AiF) Interactive Wear project partners: teXXmo, Plastec and Starringer A wearable electronics pioneer, Interactive Wear, plays a significant role in a new ZIM/AIF funded project dedicated to integration of wearable computing components into garments for industrial use. Together with their partners teXXmo, Plastec and Starringer, Interactive Wear embarks on developing a docking concept for portable computer equipment use in industrial work wear. The objective of this project is to integrate rugged computing components into a flexible wearable architecture based on the "Plug 'n Wear" project by wearable computing expert teXXmo. Ultimately, the developed products will be transferred into mass production.

Interactive Wear has extensive experience in developing electronic products and integrated solutions for apparel and accessories. However, the industrial garment market requirements are very complex and demanding. Computing equipment integrated into the industrial work wear for either technical services or fire fighting personnel must be easily detachable and interchangeable. In addition to straight forward mounting and connectivity, the user must be able to operate the equipment while wearing gloves. Moreover, the garments must be washable with the fasteners and interconnecting wires in place. This project aims at developing an architecture comprising three core modules, cabling, and the connectors for peripheral equipment and input devices, like textile sensors. The three core modules consist of a Central Processing Unit (CPU), a universal power supply with a semi-flexible rechargeable battery

module that can be easily adapted to different operating conditions and operating time requirements, as well as a display unit that can be integrated into the garment's fabric. Optionally, a head mounted display can also be used. Each participating partner brings to the project its unique expertise, and maintains focus on the particular project development segments accordingly. Interactive Wear's contribution is in the areas of modular power supply, the universal interface development, and hardware/textile integration. TeXXmo's responsibility concentrates on the CPU and display technology with interfaces, while Plastec defines material properties and takes charge of the interface encapsulation and mechanical connectors. Finally, Starringer provides the ergonomic apparel design. "By taking part in this ambitious project, we reaffirm our position as a wearable electronics technology leader", said Andreas Rรถpert, founder and CEO of Interactive Wear. "The main objective of this development is to find the optimum combination of textile components, actual garments, modular hardware units and their performance. In contrast, the similar products currently existing on the market are either highly specialized niche items, or systems built with components that were not necessarily specifically designed for this kind of applications." The project duration is set to be 18 months, and its completion is scheduled for September 2010. The launch of the new development, for example as a rugged PC alternative, is anticipated to begin in late 2010.

Andreas Rรถpert Interactive Wear AG T: +49 (0) 8151-55506-0 F: +49 (0) 8151-55506-60 E: andreas.roepert@interactive-wear.com www.interactive-wear.com Reader Reply Number: 327

www.engineeringmaintenance.info November/December 2009 EMS

INDUSTRIAL PAINT

World class repair & maintenance products for all types of industry

FLOOR COATINGS GUARANTEED

for 10-20 years Robex, now celebrating our 29th year and to complement our superb range of building maintenance and repair products, have developed a range of ‘fluid applied’ floor coatings that are so hard wearing they are guaranteed for in excess of 10 years! The top of the range ‘five star’ system can be guaranteed for 20 years and is available in a wide range of colours and safety non-slip finishes. All of the coatings are suitable for ‘DIY’ application or an approved Robex

contractor can apply if necessary; we are proud to include a number of prestigious hotels and leisure complexes amongst our extensive client list. All of our coating systems are based on the Robex 20/10 Macro Molecular Resin Technology, have no smell and will bond to almost any surface. T: 01462 422 260 www.robex.co.uk Reader Reply Number: 328

For more information quote EMS Enquiry No. 118 on IBC

EMS November/December 2009 www.engineeringmaintenance.info

RELIABILITY ENGINEERING

The contribution of maintenance to an organisation is unfortunately too often not fully understood until something goes wrong e.g. a failure of a significant plant item or asset. This will inevitably result in a consequential loss through the inability to produce or provide a service or the occurrence of an environmental health, safety or quality incident

RELIABILITY

ENGINEERING â&#x20AC;&#x201C; Whatâ&#x20AC;&#x2122;s it all about? I believe Reliability Engineering is the backbone of a Professional Maintenance organisation providing structured methods and tools to maintain assets in a consistent and cost effective manner. It can not also yield financial benefits through reduced costs and increased asset utilisation but can provide an invaluable audit trail of decisions made to satisfy regulators and both internal and external bodies. So why do so many organisations still not have the capability and processes in place to meet this objective? This may be because they do not truly understand the requirements, potential benefits and the levels of maturity that can be achieved in providing an effective Reliability Function. It may well be they are so reactive that they can not identify available resource to focus on what the business really requires. Professional Asset Management involves not only doing things right but doing the right things.This poses a number of questions for the modern maintenance manager wishing to optimize his assets: What value is added by the maintenance plans? How can the utilisation of assets be maximized?

www.engineeringmaintenance.info November/December 2009 EMS

RELIABILITY ENGINEERING

What is the optimum level of maintenance? How do I comply with regulations? What is the impact on production? What spare parts are required to support business? To answer these questions and simplify the requirements for anyone considering on embarking on a Reliability improvement programme I believe this can be best explained by breaking the requirements down into some logical steps: Step1: Business Alignment The starting point must be to ensure that the objectives of the Maintenance function are closely aligned with those of the Business. The decision to focus on Reliability Engineering must be appropriate and based on the dominant drivers for the business and its current market situation. The level of ambition of the organisation to create a Reliability Engineering capability must consider current and future capability, technology levels and both financial and organisational constraints. Many external factors are clearly out of the control of a business but there is significant opportunity to take control of the maintenance function and ensure that it is doing the right things in the most effective manner

Step 2- Calculate the Value Potential The use of benchmarking and auditing is a useful mechanism which will allow an organisation to assess gaps in performance versus best in class and if executed correctly should identify the priority areas for improvement and quantify the potential benefits based on realistic target setting. Clearly, maximising the use of scarce resource requires an assessment of the value potential of the asset base and by this I mean determining which assets deliver the most to the business and ranking them based on their value contribution and impact. Step 3: Know your People Each organisation will have developed its own culture based on geographical, historical and financial factors. To ignite the desire to change it is imperative the change history of the organisation is understood before embarking on an improvement programme. This will allow realistic and achievable targets to be set that match the capability and desire of the organisation. If goals are over ambitious then motivation will be impacted and if too conservative benefits may not be realised. In developing the Reliability function their must be close alignment between the people, processes and tools deployed.

EMS November/December 2009 www.engineeringmaintenance.info

To be sustainable the aim must be to build competency at the right levels of the organisation. Step 4: Know your Assets One of the initial tasks of reliability engineering is to adequately specify the reliability requirements and system boundaries. To do this will require ready access to accurate drawings, asset performance data and technical manuals. Recording the right data in the right way in the Enterprise Asset Management System is a prerequisite to perform adequate analysis. EN/ISO 14224 provides guidelines for collection and exchange of reliability and maintenance (RM) data for equipment. You need to start with the right definitions, formats of: equipment data, e.g. equipment attributes; failure data, e.g. failure cause, failure consequence; maintenance data, e.g. maintenance action, resources, consequences, down time It is necessary to ensure that a comprehensive asset base is established so that all assets can be assessed based on their value to the organisation. This assessment may be quantitative or qualitative depending on the availability

RELIABILITY ENGINEERING

of asset data and is typically conducted by a mixed team of Engineers, Operators, Technician, and Production staff. It is important to remember that the initial criticality ranking based on value is merely a tool to determine the best strategy for the equipment and in itself will yield no financial benefit. Clearly, an asset with little impact or value to the organisation will not command the resource for a detailed reliability study. As the criticality assessment progresses, natural grouping of assets will be determined which should allow the appropriate strategy to be selected. Thus a decision can be made to undertake a detailed study for high ranked assets, perhaps some PM optimisation for mid ranged and a simpler PM approach or run to failure for lower ranked assets. Step 5: Select the right Tools There are many well documented methods and tools available to assist organisations in enhancing the reliability of their assets yet so many organisations still have a very unstructured approach to determining the life plans for their assets resulting in either over or under maintaining and high levels of breakdowns and corrective maintenance tasks. The key challenge is to find the right balance between preventive and corrective maintenance tasks. Even the more developed organisations that have adopted processes such as Reliability Centred Maintenance ( RCM) and Failure Modes Effect & Criticality Analysis ( FMECA) can often fall short. This is because in their desire to improve and mitigate all identified failure modes they often forget to assess the financial implications of the decisions made and make an informed decision balancing the risks to the business versus the costs. This can have a cumulative impact on the Maintenance budget across the life of the assets assessed. The underpinning feature of the most common reliability tools is that they allow an organisation to determine the appropriate strategy by considering in a proactive way the potential functions, failure modes, cause and effects and then determine the necessary defence strategy. The process for selection of the appropriate strategy may vary either through flow charts, decision trees, risk matrices but provided there is a sound understanding of the underlying principles then the right tasks should be improved from a reliability best practice principle. However, to provide a sharp business focus

the best tools should consider not just the mitigation against the identified failure mode but the ongoing maintenance cost and resource burden to conducting the tasks. Thus, consideration should be given as to whether the risk of failure is acceptable or not and if not what is the most cost effective strategy to be implemented. Step 6: Resource Planning As the Reliability function develops and studies are created there will be a need to consider the impact of the selected strategy on resources. Typically, this will impact in a number of areas. Firstly, Inventory management, changing or introducing new tasks will challenge whether the right type and quantity of spares is held. This issue is normally best resolved by assessing risks of stock out, versus cost of holding and any decisions made must be aligned with the maintenance assessment. Critical spares are often expensive parts that are rarely used and as such justification for holding on stock is not always obvious. Secondly, there may well be a significant impact on the manufacturing plan and thus asset availability and it will be necessary to take a pragmatic approach bundling tasks together to allow execution with minimum impact, or identifying non intrusive tasks. Step 7: Implementation To build capability and confidence a pilot approach is the most cost effective way to validate the methodology, processes and tools to be used. It is imperative that adequate preparation and prioritisation is done upfront to ensure the pilot is targeted correctly. This will provide an opportunity to gain buy in from relevant staff, demonstrate the improvement potential and allow any necessary adjustments to be made based on real experience. It will also allow confidence and competence to build in a relatively controlled environment. A pilot study will allow relevant learningâ&#x20AC;&#x2122;s to be captured and translated into future activities. If external support is involved in supporting this process, the deliverable should be to leave an organisation with competence at the desired levels, provide a good understanding of the underlying principles of reliability engineering and a process that is easy to understand and deploy in a timely fashion. For the benefits to be realised it is imperative that the hard work gathered through studies is captured in an efficient

manner that can be readily transferred to the maintenance system. If this process is not efficient then there is danger that the final stage will not be completed and benefits not realised. More commonly integrated software is now available to take output from studies and transfer in an efficient manner to the EAM, utilising bulk uploads of data. Finally, the processes must be clearly defined to support the Reliability activities and transferred to the organisation by carefully defining roles and responsibilities. Step 8 : Monitor and Review progress To maximise the benefit from a reliability programme there is a need to provide an efficient means of accessing and analysing data. Too often the work undertaken as part of a reliability improvement programme is viewed as a one off activity but in truth needs to be managed much more dynamically based on equipment achieved levels of performance. The quality of data gathered will be based on the experience and knowledge of the staff involved and the integrity of the data utilised. As both of these continue to develop, then it is vital that the initial work is revisited based on new information and in doing so will continue to validate the reliability study and continue to drive increased levels of performance. Unfortunately, this improvement cycle is often not fulfilled due to poor motivation, lack of integration of systems, and inadequate reporting and functionality of systems used. The best performing organisations will have clearly designed targets based on benchmark data and realistic levels of improvement, processes firmly embedded in the organisation at all levels and efficient data capturing and reporting. Ideally, the performance indicators selected to drive improvement should not just focus on cost reduction and asset utilisation. They should highlight the effectiveness of the maintenance tasks deployed in reducing failure rates and the subsequent impact on the works order management process. In reality many organisations struggle to extract data in a way that makes it transparent to them what the real trends and issues are. Step 9: Design for Reliability As an organisation becomes more mature in its level of reliability competency, their will be more focus on the total life cycle of assets. This will drive more involvement in investment and acquisition decisions based

www.engineeringmaintenance.info November/December 2009 EMS

RELIABILITY ENGINEERING

on sound knowledge and data. Equipment will be specified more frequently using reliability and maintainability criteria that meet the desired performance levels of the business. There will be closer working and transferring of information with suppliers and OEMâ&#x20AC;&#x2122;s to drive up standards of components and systems. More complex techniques, simulation modelling and scenario planning may be a requirement for more complex systems. Reliability studies will in time become less reactive and more proactive and delivered earlier in the life cycle where there is opportunity to redesign at minimum impact and cost. Levels of standardisation will improve and the Reliability Function will be truly embedded in the organisation as a value added activity.

ABOUT THE AUTHOR

Mick Saltzer is a Managing Consultant for Mainnovation, a leading consultancy firm with offices in the UK, US, Sweden, Belgium and Netherlands. Mick has over 20 years experience in Asset Management and is leading business development in the UK. MORE INFORMATION

Do you want to know more about the way in which Reliability Engineering gives you insight information in the added value of maintenance,please contact: Mainnovation at www.mainnovation.com Mainnovation is a leading consultancy organisation, specialists in maintenance improvement projects, from audit right through to implementation. With the Value Driven MaintenanceÂŽ methodology, Mainnovation innovates organisations in the maintenance market.

www.mainnovation.com Reader Reply Number: 329

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excavation, which is expensive and time-consuming. Advantages URETEKâ&#x20AC;&#x2122;s unique technologies are particularly effective and there are a number of advantages that are not offered by alternative methods. Universally accepted Our methods are universally accepted by architects, national and international authorities and are even recommend by insurers. Phenomenal lifting capacity Our methods have a lifting capacity of 40,000 kg per square metre. We can restore your concrete to full working strength no matter how heavy a load it supports.

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INDUSTRIAL DOORS

Rowland Doors â&#x20AC;&#x201C; 23 Years of Excellence Rowland Doors was founded in 1986 with the concept of adding a level of service and professionalism that was not yet offered In the industrial door and loading bay industry. 23 years later this approach has seen them secure blue chip clients such as Land Rover, BMW, Argos, Birmingham International Airport, DHL and Tesco who rely on Rowland Doors for all their loading bay installations and maintenance.

Specialists in the industry The success of the company comes from their thoughtful and insightful approach to all jobs undertaken. Before any task the RDS team undertake an in-depth site survey to advise the best course to take and products that best suit their clients requirements. Their services cover site surveys, product supply, installation, maintenance and a true 24/7 emergency callout.

Every conceivable loading bay and Industrial Door product can be offered from dock levelers, roller shutter doors, traffic light systems to a replacement nut or bolt! Rowland doors are a true total Industrial Door and Loading Bay Solution. T: 0121 328 8403 www.rdsindustrialdoors.co.uk Reader Reply Number: 332

Excellence in industrial equipment repairs and maintenance

UES Technology UK Limited Our mission Simply to offer you the best spares, service and repair facility for industrial doors and loading bay equipment at the keenest prices, without ever compromising on quality or safety. Company Profile Drawing on over 25 years of experience in the loading bay industry, we offer a Midlands-based spares, repair and service facility that can provide a first-time fix for most equipment breakdowns, at competitive prices. An engineering base comprising

skilled, experienced personnel along with a strong management team and sound financial backing permits first rate service to be offered across a wide range of products. Primarily, we maintain loading bay equipment and industrial doors, but our expertise has a far wider scope. So just about any type of equipment for which you need spares or repairs is likely to be within our capability. Our central location and proximity to the motorway network enables us to service a wide range of sites within easy traveling times.

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For Service and Repairs: T: 01789 800218 F: 01789 764276 For General Enquiries:

T: 01386 555804 UES Technology UK Limited Severn Court, Tything Road East, Alcester, Warwickshire, B49 6ET Customer Support:

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E: enquiries@uestechnology.co.uk Reader Reply Number: 333

ACTUATORS

AUMA launches Generation .2 The new Generation .2 multi-turn actuator range SA 07.2 – 16.2 and new actuator controls AC 01.2 have been launched by AUMA: the products will be ready for order and delivery from first quarter 2010. Designed to cater for existing market needs, and next generation requirements, capabilities include the integration of field devices into Asset Management Systems. AUMA has introduced a number of enhanced features and expanded the functionality of its range, while retaining proven design principles. Commenting on incorporating modularity as a fundamental principle of the new products, and additional advancements, Peter Malus, the AUMA Product Manager for the actuators, said: “The new Generation .2 devices, both actuators and controls, are fully compatible with our previous products: this ensures low-risk investment and guarantees that we will always be at the forefront of technological development. “Mechanical enhancements improve positioning accuracy, the output speed range of modulating actuators and the extension of the expected actuator lifetime. These advancements are backed by improved corrosion protection.

“One focus of development was to improve device handling. As a result, the handwheel is now activated with one hand by simply pressing a button; valve connection is more flexible and a newly designed electrical connection facilitates the linking of cables with large cross sections. Operation is made easier by a new, enlarged and illuminated graphic display. The display texts are shown in plain text, available in a wide range of languages. Graphic display features are provided e.g. torque curves. Operation, setting, diagnostics and the memorisation of all actuator data is facilitated wirelessly via the AUMA PC ToolSuite.” Joachim Rist, the Product Manager of the new AC controls, reports that the innovative developments are the result of an intensive exchange between valve manufacturers, consultants, plant operators and control/communication system manufacturers. It was recognised that standards should be followed as closely as possible for all developments outside of the products’ new intelligent functions. For example, the status signals of the AC 01.2 are classified in compliance with NAMUR

Website: www.insightautomation.co.uk Email: sales@insightautomation.co.uk Tel: 01767 315 402 Fax: 01767 601619

recommendation NE 107. Consequently, the plant operator receives clearly interpretable signals from the actuators and all other field devices and new diagnostic features of the actuators are supported. Temperature/vibration sensors and applied torque recording are used to continuously monitor all parameters which contribute positively to the actuator’s life. If an actuator is operated outside the specified operation conditions, for example with an impermissible high number of starts, the plant operator receives advance information enabling appropriate action to avoid malfunction. In line with AUMA’s previous products, the new controls are available with different fieldbus interfaces, including the Profibus DP interface with V2 services. Auma Actuators Ltd T: +44 (0) 1275 871141 E: mail@auma.co.uk www.auma.com Reader Reply Number: 334

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For more information quote EMS Enquiry No. 119 on IBC

www.engineeringmaintenance.info November/December 2009 EMS

CMMS

Driving France's motorways The Challenge Sanef is one of Europe’s leading construction and maintenance companies, specialised with highways and related infrastructure. In France Sanef manages and maintains some 1700 Km of roads with 60km of roads under construction. To ensure the highest levels of service Sanef Telecommunications and Tolls Division operates a Central Telecommunications Station to manage, monitor and maintain all of the highways electronic and telecommunication equipment e.g. roadside messages signs, emergency telephones and CCTV. Objectives In 2001 the Telecommunications & Tolls divisions initiated a project to standardise their maintenance activities, to improve service levels and to reduce costs. “We wanted to implement a software system to help us achieve our maintenance objectives: to optimise the performance of the technicians and maximise our profitability. The first stage was to manage all the planned maintenance activities electronically and to ask our engineers to directly feedback work information. At the same time we wanted to implement an electronic Job Request system to track the requests for reactive activities and our responses.” Patrick Cremmer, Head of Networks Management, Telecommunications Division.

The solution “Coswin was already successfully implemented within the Sanef group so Siveco Group consultants had already demonstrated that they could understand strategic objectives, and then quickly adapt and implement a personalised Coswin system. That’s the reason why we selected their solution again; to save time for the rest of the project By following a proven methodology proposed by Siveco, the implementation and training programs were completed in just 4 months, including analysing and automating all the working procedures, collating and inputting data and customising the Coswin screens to suit the needs of different users.” Today Coswin manages almost 50 000 pieces of equipment including optical fibre, pylons, emergency telephones, dynamic and toll equipment, and Sanef are creating more than 800 Work orders and 450 Job Requests monthly. The implementation involved the training of more than 400 web based Job Requestors and 150 Coswin users. The benefits of Coswin The KPIs for the maintenance team are now monitored using Coswin; these include the “maintenance cost per type of equipment”, and the “downtime per optical fibre network”. Much of this

EMS November/December 2009 www.engineeringmaintenance.info

information is used at a board level to provide the facts needed to decide on the right corporate strategy. Sanef intend to use more functions of Coswin to provide further business improvements - for example Sanef have recently implemented Coswin’s repair management module. This will allow engineers to track the movements and costs associated with assets under repair, ultimately resulting in faster repair times, less replacement stock and lower costs. “Coswin has improved the efficiency of our engineering team, and provided all the facts we need when we make a decision on whether it is better to repair or to replace a piece of equipment. Coswin has become the backbone for our business, and helps to share best practices within Sanef”. Coswin 7i : the first web application at Sanef Sanef has already upgraded to Coswin 7i. “This is the first Web application going live”, Mr Robert, CIO. The native web architecture (JAVA/HTML) will reduce the operational cost of the system, whilst making the power of Coswin available to more personnel. Coswin 7i will also provide further significant security and usability improvements for the business. www.siveco.com Reader Reply Number: 335

MAINTEC 2010 2-4 MARCH 2010 NEC BIRMINGHAM

Organisers of easyFairs MAINTEC 2010 at the NEC in March have announced that over 10 new products are making their UK or global debuts at the show and that many more will follow

GLOBAL PRODUCT LAUNCHES ®

at easyFairs MAINTEC 2010 The products being launched at the UK’s leading maintenance and asset management show on 2-4 March 2010 are designed to improve plant performance, reduce costs and deliver energy savings. PCB Piezotronics is releasing several new products including Echo™ Wireless Vibration Sensors. These can “interrogate” a machine several times per day and transmit the data to an existing vibration or plant monitoring system without valuable manpower being tied up in the process. PCB is also unveiling a range of USB Programmable Vibration Sensors. The new range of Smart Vibration Sensors from PCB® allow the end user to adjust multiple measurement parameters in situ to optimise the sensor to get the most out of an application. There are two launches from C-Cubed. The developer of PocketVibrA, the low cost, easy to use vibration analysis system for maintenance engineers will launch version 10 at MAINTEC 2010. PocketVibrA is a unique tool that combines machine condition analysis, balancing, thermography and process parameter trending in a handheld, rugged (IP67) unit. C-Cubed will also be using the show for its global launch of a vibration analyser specifically designed for the monitoring of machine lubrication. Whitelegg, the sole UK distributors and sales support for Baker, is launching Baker’s new on-line Motor Analysis System, NetEP. This will be the UK debut for the fully automated, network-based system for electric motor monitoring. The system works on a continuous basis and can test 40+ parameters on up to 32 motors continuously, giving live evaluation of critical equipment from any location in the world.

On display for the first time will be the latest Fluke Ti32 Thermal Imager and the TiR32 Thermal Imager, the first industrial grade, high-performance imagers on the market to incorporate a powerful 320x240 sensor to provide high-definition, strikingly crisp, detailed images for under £7,200. Their superior image quality helps to identify even the smallest temperature differences that could indicate problems. Idhammar Systems is exhibiting two new products designed to improve continuous asset monitoring, provide real time intelligence and business alerts. By clearly and continuously indicating availability and performance against key metrics, Idhammar Andon and Idhammar Business Alerts modules enable manufacturing and maintenance managers to take greater control of daily plant management. The Andon software delivers real-time intelligence on the overall equipment effectiveness of a plant, allowing decision makers to proactively track, monitor and respond to plant failures and process issues. MCP Consulting & Training is launching a new, 2-day training course entitled ‘Maintenance Explained’. MCP will teach how the fundamentals of good maintenance management in a manufacturing or service environment can lead to cost savings and efficiency improvement. easyFairs® UK Managing Director Matt Benyon, said: “This is just a taster of what were expecting at the Show. The fact that we have been given advanced warning of so many launches this early on illustrates two things – firstly the vibrancy in the sector and secondly the importance of easyFairsMAINTEC as a global launch pad for products and services aimed at factory and plant managers.

“While the show has an impressive 35 year history, our accent is firmly on the new. With capital spend being kept to a minimum; managers are trying to squeeze that last bit of value out of their current plant. To do this they need new products, new services, and new thinking. These early announcements highlight that easyFairs® MAINTEC will be serving up plenty of all three.” To underscore the central role MAINTEC is playing in the sector’s calendar The British Compressed Air Society (BCAS) has confirmed that it is hosting its 80th anniversary Spring Conference at MAINTEC. This will be the first time it has co-located its March conference at any show. There will be a ‘leak detection challenge’ staged on its stand demonstrating a mix of detection solutions. BCAS experts will provide an on the spot estimate of what leakages are likely to be currently costing visitors. There will also be Compressed Air Advice Clinics for visitors with any compressed air queries. The Show will also play host to an Innovations Pavilion, the MAINTEC Summit Conference - Chaired by Steve Morris, Deputy President of the Institute of Asset Management - plus a packed programme of over 30 expert-delivered learnShops. Companies interested in exhibiting at the Show or appearing in the Innovations Pavilion should contact Rabinder Aulakh on T:0208 622 4463 or email Rabinder.aulakh@easyfairs.com Register to attend for free by going to www.easyfairs.com/maintecuk. To book a place at the MAINTEC Summit Conference, and to take advantage of ‘early bird’ delegate prices, call Lucy Daley on 0208 622 4468 or email lucy.daley@easyfairs.com www.easyfairs.com/maintecuk Reader Reply Number: 336

www.engineeringmaintenance.info November/December 2009 EMS

INTRINSICALLY SAFE SENSORS Monitran’s Group I intrinsically safe sensors are awarded ANZEx for use in mining applications in Australia and New Zealand

Certified for use

DOWN UNDER All of Monitran’s Group I intrinsically safe accelerometers and velocity transducers have been approved by certification body Simtars to ANZEx for use in mining applications throughout Australia and New Zealand. This certification is in addition to the (EU) ATEX and (International) IECEx approvals Monitran’s Group I sensors already possess. Andy Anthony, Monitran’s Operations Director, comments: “Many countries, whilst acknowledging international standards like IECEx, still impose their own standards for certain applications. We sought ANZEx in response to requests from end-users based in Australia

and New Zealand, and companies based elsewhere wishing to supply machinery into these countries.” Eight products have been certified to ANZEx. Of these, four are from the MTN/1100 family of general purpose accelerometers with isolated AC outputs, which are ideal for vibration analysis. Included within the family, and certified to ANZEx, are the MTN/M1100I and MTN/M1100IC which are topentry devices with integral cables and connectors respectively. Both have a temperature range of -55 to 140°C and are sealed to IP67. Also included are the side-entry equivalent devices,

the MTN/M1100IS and MTN/M1100ISC. Two ANZEx-certified sensors come from Monitran’s MTN/1185 family of general purpose accelerometers with DC outputs, which are ideal for machine protection. These are the MTN/M1185IC and its waterproof variant, the MTN/M1185IWC, which are both top-entry devices with integral cables and which have an operating temperature range of -25 to 90°C. The remaining two sensors come from Monitran’s MTN/1187 family. Again, the sensors have DC outputs but this time proportional to RMS acceleration. The ANZEx-certified

devices are the MTN/M1187IC and its waterproof variant the MTN/M1187IWC. Anthony concludes: “Our ANZEx-approved sensors can be used for vibration analysis with intrinsically safe data loggers or integrated directly in machine control circuitry (such as PLCs) to afford machine protection – and therefore mine safety.” Monitran Ltd Monitor House, Hazelmere Road Penn, Bucks HP10 8AD T: +44 (0) 1494 816569 F: +44 (0) 1494 812256 E: info@monitran.com www.monitran.com

Reader Reply Number: 337

SEALED CIRCULAR CONNECTORS SRI Hermetics, Inc uses advanced engineering and material science to create the world’s leading hermetic electrical connectors

Our exclusive ceramic dielectric material provides unequaled performance and reliability. SRI Hermetics can offer hermetic circular connectors in variety of materials including, but not limited to, stainless steel,

aluminum, and titanium. SRI Hermetics also utilizes copper alloy pins for maximum current carrying capabilities. SRI Hermetics can create a fully custom connector and mate or manufacture

connectors that will interface with standard mates commercially available. Our hermetic 38999 circular connectors are fully compliant with the interface requirements of MIL-DTL-38999.

EMS November/December 2009 www.engineeringmaintenance.info

Fred Williams, Sales Manager T: 321.254.4067 E: williamsf@srihermetics.com Reader Reply Number: 338

OEE

I have had a number of interesting conversations recently with both lean consultants and manufactures over the way OEE should be measured and applied. Although it’s a simple calculation it’s often misunderstood and sometimes the differences have quite an impact on the integrity of the measure

OVERALL EQUIPMENT

EFFECTIVENESS

– Myths and Realities I can understand how views could differ over how each element should be applied; for example what is the difference between a breakdown and a minor stop? However, sometimes the

calculation itself is questioned. So here are some guidelines based on content from experts and organisations which include the Japanese Institute of Plant Maintenance (JIPM), Robert C Hansen,

The critical factor to remember is that availability losses are measured as time, whilst performance and quality are both measured in units. The equipment may have been slowed down for two hours, between 10:00 and 12:00, but the performance loss that results is measured in units. The next step introduces the six major losses of OEE. As a general rule,

breakdowns, set-up, and adjustment fall within the availability measure, with minor stops and slow running being part of the performance loss. Defects, rework, and start-up losses are part of the quality measure. Rework can be seen as a performance loss (the products take longer to make than usual), but if they are not right first time (RFT) then they really ought to be considered a quality loss.

Dennis McCarthy, Dr Nick Rich, Peter Willmott and of course Seiichi Nakajima who is credited with using the OEE metric at Nippon Denso in the late 1960’s. Let’s start with the basic calculation:

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OEE

Extensive discussion usually takes place around how to establish the target speed on which the performance rate is based. Should it be as defined by the equipment manufacturer, or should it be weighted? The basic rule is that the performance element is always product and plant specific. It’s a moving target, so make it more demanding as the plant performance improves. If all else fails it can always be set at the best

performance the plant has ever achieved, but that target may not be as demanding as it should be. The important point is to make sure the target is not too soft as it will only encourage the belief that the plant is performing better than it actually is. If the performance rate ever exceeds 100% then obviously the target is too low and you are missing the point of OEE measurement.

Here’s an example Planned run time

20 hours

Breakdown

1 hour

Changeover

1 hour

Actual run time (20 hrs – 2 hrs)

18 hours

Target rate per hour

200 units

Target products (in 18 hours)

3,600 units

Actual products made

3,000 units

Right First Time Products

2,900 units

This calculation reveals that all we have to do is investigate and fix the one hour breakdown, try and improve the changeover, see why we had slow running which ‘lost’ 600 products, and resolve the quality issue which rejected 100 units.

How can a measure that appears so simple have so many myths?

Myth 01 –

I plan my changeover for 15:00 so it should be a planned event. Whilst the changeover is planned to occur at a set time, it’s still an opportunity for improvement; for many companies the biggest opportunity. Let’s say the average lost time due to changeovers is 1 hour per day. Now imagine a competitor starts up next door with equipment that will automatically changeover at the push of a button. The competitor can produce for an extra 7 hours each week. Changeovers should always be unplanned events.

Myth 02 –

OEE does not work for my industry. OEE can be applied to most industries, and no doubt works really well for your competitor.

Myth 03 –

We have a different, in-house measure. One GM told me that their internally developed measure did ignore some of the losses but also triggered his bonus, as long as it remained over 85%. Surprisingly it always did - so why would he want to measure OEE?

Myth 04 –

‘No materials’ should be considered a performance loss. If we go back in time and separate production and engineering, rather than having cross-functional ‘manufacturing teams’ - we get into arguments. Speaking as an engineer, the plant is technically available for production, but Operations has let the side down by not having the correct

EMS November/December 2009 www.engineeringmaintenance.info

materials available. Measuring engineering KPI’s is always possible by deselecting those losses outside the control of engineering. However, in terms of ‘lost plant time’, the production process is not available because there are no materials.

Myth 05 –

Breakdowns and minor stops are the same. A breakdown usually requires a careful study of circumstances and involvement from several disciplines to identify the root cause and plan resolution. For instance, a gearbox failed because we ran out of oil. Minor stops are usually those annoying conveyor jams which occur 100 times a shift and lose a total of 20 minutes. They still need to be studied and a correction plan identified, but the techniques are different.

OEE

Myth 06 –

I have a softer ‘planning department’ target speed. That’s fine as it’s a target speed used by planning to let the customer know when to expect delivery. But it’s not OEE and won’t help to discover that hidden factory – and all the potential savings.

Myth 07 –

I have lots of planned events. Be cautious, planned events will be excluded from the OEE calculation, so keep them to an absolute minimum - zero is a good start. Any activity classed as ‘planned’ is unlikely to change as there is no pressure to do so. The only planned events to consider should be ‘Plant not crewed for production’ or ‘no sales.’

Myth 08 –

World class is 85% This is correct for a machining centre, but if you’re running something like a flour mill or indeed, most continuous processes, world class performance is above 90% OEE.

Myth 09 –

We do not need any more output, so why raise the OEE? If you have a low OEE value you’re wasting energy, labour and materials.

Myth 10 –

OEE is a management tool used to benchmark and compare. It’s mainly a problem solving tool and it’s not appropriate to compare the scores of different operations, but it can be used to benchmark the improvement trend over time for different operations.

Myth 11 –

OEE data should always be captured manually. It’s always a good start, and gets everyone into the improvement mindset. However, as you improve there comes a point when most, if not all, of the availability issues and the big breakdowns have been resolved. What’s left are minor stops and slow running which are very difficult to capture manually, but still have a big impact on

performance. At that stage it’s good to consider some level of automatic data capture, at least a product count and a running/not running signal.

Myth 12 –

With automatic data capture I don’t need the operators involved. The operator is a critical element in the continuous improvement process. If they are ignored it will be difficult, if not impossible, to make real improvements.

Myth 14 –

We have an Excel wizard on-site and our spreadsheet system is fit for purpose. Spreadsheets are a very good start, but the single user nature of Excel and the large amount of data soon means that people spend more time manipulating data than working on making improvements. It’s proven that you’ll save time and money with a powerful database based solution and you can use that time to make production improvements. Oh, and I hope your Excel wizard doesn’t leave!

Myth 15 –

Productivity is a more relevant measure in our environment. Productivity is a good measure. If you flood the place with extra crew and complete a changeover in double quick time it’s possible to generate a high OEE, but the employee costs will be pretty high. As such, on its own productivity cannot discover those hidden losses, a better approach is to include a crew size for each product run and then calculate output per employee or OLE (Overall Labour Effectiveness), based on the number of people and OEE score.

Myth 16 –

Utilisation is a better measure than OEE. It’s quite a different measure. Plant employees do not have much influence on the sales force. If the plant is designed for 24/7 operation but sales can only find orders for 24/5, then asset utilisation will be low, even if plant performance when running is good and generating a high OEE. If utilisation is 20% and OEE 70% blame the sales force, not the plant operators.

Myth 13 –

We measure OEE, but ignore the quality element. Really, why? The quality element has a significant impact on the OEE score and if you don’t measure quality losses how do you know they are not considerably worse than you think?

Myth 17 –

Performance is really bad and we have to improve before we can measure OEE. How will you know what to improve if you don’t measure production performance? Use OEE as the catalyst for change. If the first OEE value is very low, say less than 10%, it’s actually good news as there are lots of improvement opportunities easily available, and look how people will feel if you move the value to 20% within a few weeks – not to mention how much money you will have saved.

Myth 18 –

A high OEE score is just that, but where is the cash value? The cash value is in reduced energy, materials and labour. If the order is 60,000 units and the target is 1,000 units per hour (OEE score of 40%) - this means an extra 34 hours are required to meet the order. If the score can be improved to 60% the extra hours required drops to just 15. Improve performance, shut down the plant 19 hours earlier and save money.

Myth 19 –

We’re not ready to measure OEE or improve? Well if not now, then when? I leave you with a final wise comment from Peter Willmott - ‘adopt OEE, but don’t corrupt it.’ 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.

www.idhammarsystems.com Reader Reply Number: 339

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