ems nov/december 2007 by Michael Dominguez

NOV/DEC 2007 INDUSTRY NEWS GUIDE TO BUYING IMPROVING RELIABILITY ISSUE 2

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

Powering the RAF PAGE 24

Maintenance Scheduling

Condition Monitoring

Environmental Management

Reach for the skies Pneumatics

www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 101 on IBC

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INDUSTRY NEWS Highlighting what’s happening in maintenance

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CALIBRATION Calibration frequency? Let analysis decide

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PLANT Roundup of the latest plant product announcements

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CONDITION MONITORING

Insurance against expensive machine breakdowns

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FACILITIES MANAGEMENT Tracking down the hidden costs of WEEE

19 PAGE

HEALTH AND SAFETY ATEX dust zones: check motor compliance

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RUMBLE, HISS, RUMBLE, HISS, SILENCE I’ve lost count of the number of factories I’ve worked in or visited over the last two decades. What I will never forget is the noise and smell. Luckily, for the employees, both noises and smells are diminishing due to legislation, modern machinery, improved processes and better working practices. Regarding noise, common sources included the rumble of air compressors and hiss of leaking pneumatic circuits. When the cost of oil was a fraction of today’s record breaking price and the only footprint discussed in magazines like this related to steel toe-capped work boots, such noise was tolerated. Things have changed. Questions need to be asked. Given the financial and environmental cost of compressing air, is that hiss an air cylinder venting or a damaged pipe joint? Turn to page 30 for advice on improving the efficiency of pneumatic systems, from listening for leaks with the latest instrumentation to feeding waste compressor generated heat back into the facility’s central heating system. Staying with compressed air, I recall a customer asking me to visit a robot that was performing erratically. I had helped design the machine and was worried about its welfare. On inspection I was concerned by the water venting from the pneumatic solenoid valves. The lessen learned was simple. If a compressor fails and you hire a temporary replacement, make sure it is piped-in before, not after, the water trap. Otherwise, like magic, your pneumatics will become hydraulics. Expensive!

Jon Barrett, EDITOR

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Why do many reliability and maintenance improvement initiatives fail to deliver expected results. Hedgehog or Fox? Christer Idhammar, president Idcon Inc It is not uncommon for reliability and maintenance improvement initiatives to fail to deliver: but why? Common causes include: Lack of top management understanding, leadership and long term support Mobility of management Short-sighted, cost focused initiatives, instead of long term, reliability focused Politics and disjointed organisational goals and objectives Confusing the organisation with new names on well known concepts Not understanding improvement initiatives are processes without end Process driven by disciplined thoughts and actions by people Technology is secondary to behaviour In his book Good to Great (ISBN 0-06-662099-6), Jim Collins uses the famous essay ‘The hedgehog and the fox’ by Isaiah Berlin as a comparison between good companies and great companies. The book investigates what great companies share in common. In summary, great companies knew one thing they can be the best in the world at. Then they did this for a long time. The study was based on a 30-year period. All great companies made breakthrough improvements in financial performance and sustained their results. Great companies are described as hedgehogs, good companies as foxes. Fox companies often changed plans and tried to outsmart the market with short term initiatives. Their leaders were glamorous and well known. Leaders of great companies had much lower visibility.

Great companies typically worked with disciplined implementation for fifteenyears before making a significant positive financial breakthrough in performance and sustained this performance for fifteen years and beyond. So how does this relate to reliability and maintenance improvements? The following graph describes the difference between the hedgehog and fox approaches. The majority of organisations I know are foxes, the most successful are hedgehogs. A Tappi Solutions magazine survey showed only 16 per cent of companies viewed maintenance programs as long term improvement programs (hedgehog). Hedgehog organisations find things they need to execute well. They spend time identifying best practices. Then they execute disciplined thoughts and actions according to their best practices. For a long time (typically three to seven years) they implement and execute best practices in a disciplined manner and come to a point when significant results are generated after a breakthrough. Some organisations see this breakthrough after three to seven-years. A key is that new managers are requested to continue implementing the best practices, not new ideas. The fox approach confuses organisations and people don’t believe the latest initiative is for the long term. The consequence is lack of true, enthusiastic commitment: vitally important for success. The hedgehog approach stabilises organisations to focus on continually improving the right things. An organisation must focus on long-term

Fox organisations try new tricks. Perhaps it started when a new manager implemented ‘planned maintenance’. This lead to short term improvements so the next manager implemented ‘predictive maintenance’. Again, the results were short term. This caused the company to skip to ‘total productive maintenance’, then ‘condition based maintenance’ (CBM), then ‘asset management’ (AM), then ‘reliability centred maintenance’ (RCM), then ‘value driven maintenance’ (VDM). Most initiatives were initiated by management changes.

sustainable results (not just cutting costs) and see what results it achieves. In results oriented organisations, results are prioritised as follows: 1. Quality, volume, production, throughput 2. Cost to manufacture this quality volume This focus improves reliability performance, with the increased reliability reducing manufacturing costs. Reliability performance is defined as ‘overall production efficiency (OPE) which includes Total: Quality Performance, Time Performance and Speed Performance. Most organisations do not do this. Instead they focus on cutting maintenance costs. Consequently, maintenance costs temporarily go down, then increase more than the

earlier savings. Also, reliability drops and losses can be substantial. This has been proven many times, especially in economic down turns. The root cause is often short-sightedness and, what Dr Deming described as one of the most serious industrial deceases: ‘the mobility of top management’. Reader Reply Number: 300 Christer Idhammar is a world renowned expert in reliability and maintenance management best practices. He started the Idhammar group of companies in Sweden in 1972 and Idcon Inc in USA in 1985. In 2002 he received the Euromaintenance Incentive award (EFNMS) for outstanding international contributions to improve reliability and maintenance in industries world wide. He is the author and co-author of several books and hundreds of articles. He can be reached at info@idcon.com

3 www.engineeringmaintenance.info Nov/Dec 2007 EMS

INDUSTRY NEWS

ONE SPANNER, MANY USES Something Available exclusively from Buck and to celebrate Hickman, Roebuck's new universal spanner set is claimed to fit all known nuts and bolts including spline,12 point, square, star Roebuck's Uniwrench is claimed and six-point. The to be the only set of combination Uniwrench set is spanners required for any job manufactured from polished chromemolybdenum steel, featuring one straight U grip with a non-slip surface and a 15deg angled ring grip. Its open-end, non-slip design also allows users to remove damaged fasteners including nuts and bolts that are up to 70 per cent rounded off. The metric set includes: 8,10, 11, 12, 13, 14, 15, 16, 17, 18 and 19mm sizes, all with a lifetime warranty from Roebuck. www.bhinone.farnell.com Reader Reply Number: 301 CML's environmentally-friendly LEDules are now manufactured in Europe, cutting air miles and lead times

LED lighting goes green CML Innovative Technologies (CML-IT) is now manufacturing its LED light engines in Europe, reducing both the lead time and the number of air miles required for shipping. Production of the LEDule product has moved from Costa Rica to plants in Germany and Czech Republic, with local manufacture significantly shrinking the carbon footprint of the LED devices. Shorter lead times for European customers could also help to encourage the switch away from incandescent lamps, which have already been banned in Australia and California. Designed to offer a low power, long life replacement for incandescent lamps, the LEDules feature one, three, four, eight, nine or 14W power with a consistent unit-to-unit colour temperature. Colours include cool white, warm white, blue, cyan, green, amber and red, with a new RGB version, featuring red, green and blue LEDs, for subtle mood lighting applications. Units are supplied with LED, lens, driver circuitry, heatsink and packaging, with several different fitting options available. Suitable for general lighting applications, LEDules can be used as spot-lights for point-of-purchase and display case lighting or for general illumination applications such as architectural, landscape or task lighting. LEDules can also be customised for specific applications. www.cml-it.com Reader Reply Number: 303

4 EMS Nov/Dec 2007 www.engineeringmaintenance.info

To celebrate 25 years of innovation in infrared The Thermoteknix team celebrate 25 years in technology, Thermoteknix business as well as being named small innovative company of the year at the iDEA awards Systems hosted a two day sales meeting at its headquarters in Cambridge. Sales agents from Egypt, India, Philippines, Singapore, China, Indonesia, South Korea, Lebanon, South Africa, Pakistan, Malaysia and Hong Kong attended the event, which included product presentations and demonstrations from key Thermoteknix personnel. The conference culminated in a gala dinner to which all sales agents, staff, key customers and suppliers were invited. In addition to its silver anniversary celebrations, Thermoteknix was also celebrating being named as small innovative company of the year at the Innovation and Design Excellence Awards (iDEA). www.thermoteknix.com Reader Reply Number: 302

Packaged for reliability Two new MIG/MAG welding packages have been introduced by Esab, comprising the Origo Mig L305 or L405 stepcontrolled power sources and the Origo Feed L302 or L304 wire feed units. Each package includes a PSF welding torch and a 1.7, 5.0 or 10m connection set with three wire feeder mounting options: wheel kit, suspension bracket, or mast and counterbalance. Typical applications will be in the vehicle industry, household and furniture industry and general steel fabrication. Both the Origo Mig L305 and L405 casing offers protection to IP23 for indoor or outdoor use. The L305 offers ten voltage steps and a 60 per cent duty cycle of 190A/24V, while the L405 has 40 voltage steps and

Esab's new welding packages feature an IP23 casing for reliable operation indoors or out

a 60 per cent duty cycle of 365A/32V. Voltage settings and inductance adjustments are made on the power source, with controls for wire feed, 2/4 stroke and burnback time located on the wire feeder for easy access. The Origo Feed L304 has additional controls for creep start, spot welding, inching and gas purge. Various accessories are available for the MIG/MAG welding packages including a digital V/A meter and a transformer for CO2 heating. www.esab.co.uk Reader Reply Number: 304

ON WINNING FORM Last month's EMS prize draw winner is utilities operations and maintenance manager at GSK Dartford, Del Pailes, who has received ÂŁ100 in Argos vouchers. The prize was sponsored by Holroyd Instruments, which manufacture a range of condition monitoring instrumentation for use by maintenance personnel. These are in use both in the UK and overseas and said to offer ease of use as well and effective operation, even on machinery rotating as slowly as 0.25rpm.

MD of Holroyd Instruments, Trevor Holroyd, prepares to send the Argos gift card to last month's winner Del Pailes of GSK

INDUSTRY NEWS Esab's Origo Feed 302, 304 and 484 units feature grooved-wheel feed mechanisms for reliable wire feeding

Get in the groove for rugged wire feeding COOLING FREE THERMOMETERS REACH 250°C The new non-contact Optris CT hot sensor allows temperature measurement from –40 to 975°C in ambient temperatures up to 250°C, without cooling

A new infrared thermometer has been launched which can operate at ambient temperatures up to 250°C without cooling. The non-contact Optris CT hot sensor, developed by Micro-Epsilon, is said to represent a genuine leap forward in its sensor class, allowing temperature measurement from –40 to 975°C. This performance is made possible with new detector materials, mechanical design and high temperature cabling. Potential applications include ovens, dryers, heat treatment lines in the metal and glass industries, paper, plastic, textiles and semiconductor manufacturing. The technology can help process engineers optimise energy consumption, speed and product quality, by reducing process temperature once products reach their desired temperature. The CT hot’s narrow beam optics enable oblique aiming, which means users can measure thick or light fabrics using the same sensor without calibration adjustment. New treatment lines are often built inside compact machines to optimise process efficiencies. In such applications, sighting tubes for temperature sensors can no longer be positioned outside the process chamber. Compact, non-contact, infrared sensors are thus required inside the chamber itself. The CT hot, with its compact head and cooling-free design, is engineered to fit such restricted spaces. Micro-Epsilon Optris’ general manager, Ulrich Kienitz, said: “In textile or fabric drying processes, for example, companies can position multiple CT hot sensors along the inside of an oven or drying machine, which is typically around 30m in length. The sensors are able to monitor the temperature of a complete sheet or strip of fabric. By analysing the data from the sensors and looking for unusually high temperature gradients and fluctuations, operators can gauge the humidity of the material and change the process operating conditions such as speed.” www.micro-epsilon.co.uk Reader Reply Number: 305

Tooling change in five Mecaplastic, the Midlands-based supplier of tray sealing and thermoforming machinery has launched a new partial tooling concept designed to let customers change tray sealer tools in less than five minutes. The partial construction allows 80 per cent to remain in situ, with only four key elements changed during the process. The mechanism comprises lightweight, easily manageable pieces, with all tooling accessible for cleaning and maintenance. The only equipment needed for tool changing is a standard screwdriver. The system is interchangeable between the semi-automatic S1000 and in line S2000/S3000 tray sealers. It is also modified atmosphere packaging (MAP) compliant. www.mecaplastic.com Reader Reply Number: 330

Rugged construction makes Esab's latest wire feeders suitable for harsh industrial environments. Suitable for use with stepcontrolled welding power sources, the Origo Feed 302, Origo Feed 304 and Origo Feed 484 all feature galvanised steel housings as well as electronic controls and grooved-wheel feed mechanisms for superior welding. A choice of feed roller diameters means the units can be used with welding wires up to 1.2, 1.6 or 2.4mm diameter. The smallest rollers offer a two-wheel configuration, while the two larger rollers feature a four-wheel configuration. Flexible mounting options mean the feeders can be mounted on a mast with a counterbalance, on wheels or on a hanging bracket.

When the feeders are used with a water-cooled gun, the Esab LogicPump (ELP) automatically prevents overheating. Feeders can also be connected to Esab's Miggytrac and Railtrac kits through a remote outlet, for simple mechanised welding. To keep ownership costs as low as possible, units are designed for simple maintenance with an accessible feeding mechanism so worn parts can be exchanged easily. Customers can purchase adapters to allow wire spools of 440mm diameter to be used, or the feeders can be used with Esab's Marathon Pac bulk cable drums. Interconnection cables are available in 1.7 to 35m lengths. www.esab.co.uk Reader Reply Number: 306

Elga Process Water was called in to refurbish the boiler make-up water treatment plant at E.ON’s Isle of Grain power station

Makeover for tired plant At 30 years old, the boiler make-up water treatment plant at E.ON’s Isle of Grain power station was beginning to look its age so E.ON appointed Elga Process Water to refurbish the equipment. The station hosts two oil fired 690MW units giving a total generation capacity of 1,380MW. High purity water is supplied to the boilers by an ion exchange plant, consisting of two streams of cation exchange, anion exchange and mixed bed polishing, each capable of delivering up to 400m3/h of boiler make-up water. The three metre diameter vessels are fabricated from carbon steel and lined with rubber to protect them from the acidic conditions inside. Grain’s plant chemist, Pete Kingbrooks, said: “Between May and September the demand for electricity is lower and the station output is reduced. That means we can run with only one of our ion exchange streams available, carrying out planned maintenance on the other.” Both the cation and mixed bed exchange units, were scheduled for re-lining and Elga Process Water’s task was to remove the ion exchange resins to a temporary store, clean and re-line the vessels with rubber, spark test to ensure the integrity of the lining, reload the resins, hydraulically test and re-commission the units. www.elgaprocesswater.com Reader Reply Number: 307

5 www.engineeringmaintenance.info Nov/Dec 2007 EMS

For more information quote EMS Enquiry No. 103 on IBC

The History Trend Option lets users analyse an instrument’s drift over time

CALIBRATION

In this article, Beamex demonstrates how plants can improve their efficiency and reduce costs by performing calibration history trend analysis

Calibration frequency? Let analysis decide Manufacturing plants need to be confident their instrumentation products, like temperature sensors and flow meters are performing correctly. If sensors drift, the consequences can be disastrous. Most plants have a maintenance plan which ensures all instruments are calibrated appropriately. However, with increasing demands and cost issues, the time and resources required for calibration checks can be scarce. This may lead to instruments being prioritised for calibration, with those deemed critical receiving regular checks, while those deemed less critical, calibrated less frequently or not at all. Plants can improve their efficiencies and reduce costs using calibration history trend analysis, a function available in Beamex’ CMX calibration software. Using this function, the plant can analyse whether it should increase or decrease the calibration frequency for all its instruments. Cost savings can be achieved in several ways. First, by calibrating less frequently where instruments appear stable according to their calibration history. Second, by calibrating critical instruments more often, ensuring they are checked and corrected before drifting out of tolerance. Beamex’ area sales manager in Finland, Pertti Mäki, said: “The largest savings from using the History Trend Option are in the pharmaceuticals sector, without doubt, but all

industry sectors can benefit from using the software tool, which helps companies identify the optimal calibration intervals for instruments.” The trick, said Mäki, is determining which sensors should be re-calibrated after a few days, weeks or even years and which can be left for longer periods without sacrificing quality or safety. Doing this, he said, lets maintenance staff concentrate their efforts where they are needed, thus eliminating unnecessary calibration effort and time. Mäki continued: “When an engineer buys a particular sensor, the supplier provides a technical specification that includes details on what the maximum drift of that sensor should be over a given time period. With CMX’s History Trend Option, the engineer can now verify that the sensor he or she has purchased, actually performed within the specified tolerance over a certain time period. If it hasn’t, the engineer now has data to present to the supplier to support his findings.” The History Trend function also means a plant can compare the performance of different sensors from different manufacturers. Thus, setting up a new line, maintenance personnel can use this functionality to select the sensor that best suits the process. Calibration software like CMX can also help when planning calibration operations. Calibration schedules account

for a sensor’s required accuracy and the time during which it previously maintained that accuracy. Sensors found to be highly stable need not be re-calibrated as often as sensors that drift. The History Trend Option, available as standard in CMX Enterprise and as an add-on in CMX Professional, is a utility designed for viewing calibration history data. Data is displayed graphically and is available in numeric format. The function helps users plan optimal calibration intervals. Once implemented, maintenance personnel, for example, can analyse an instrument’s drift over a certain time period. History Trend displays numerically and graphically the instrument’s drift over a given period. Using this information, engineers can make decisions and conclusions regarding optimal calibration intervals and

instrument quality regarding measurement performance. Users already familiar with CMX may confuse the function with the standard Calibration Results window. However, the History Trend window lets users view key figures of several calibration events simultaneously, letting them evaluate the calibrations of a position or device for a longer time period compared with the normal calibration result view. For example, users get an overview of how a particular device drifts between calibrations and also whether the drift increases with time. Also, the engineer can analyse how different devices are suited for use in a particular area of the plant or process. Reporting is straightforward and the user can tailor reports to suit their individual needs, using the Report Design tool. www.beamex.com Reader Reply Number: 309

History Trend user-interface

7 www.engineeringmaintenance.info Nov/Dec 07 EMS

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PLANT MANAGEMENT

STICKY MAINTENANCE SOLUTIONS Eurobond Adhesives claims Penloc thread lockers, retaining compounds and structural adhesives are essential tools in a maintenance engineer’s tool box. The range offers anaerobic and two-part toughened acrylic bonding solutions for maintenance tasks. ZT Threadlocker is a low strength yellow acrylate designed to work in temperatures from -55 to 15°C. It cures to handling strength in five to 20-minutes and be fully functional in 45-minutes. Breakaway torque is 12Nm. VF is the high strength grade with 30.5Nm breakaway torque. R2 is a self-hardening resin retaining compound, designed to secure bushes, bearings and other cylindrical parts. Interference fits can be strengthened or

replaced by slip fits without loss of strength. Mechanical locking devices such as wedges, pins and adjusting springs can also be eliminated. R2 has a medium shear strength allowing dismantling with ordinary tools. It can withstand temperatures from 55 to 200°C. Typical uses include bearings, splines, keys and oil seals. 1-1 is a two-component toughened acrylic structural adhesive. It cures to handling strength in five-minutes, with full cure in one-hour. It resists temperatures from -55 to 125°C. Typical tensile shear strength values of 276kg/cm2 can be achieved on steel to steel applications. www.eurobond-adhesives.co.uk Reader Reply Number: 310

Remove the drudgery of sludge Fluid Dynamics International states that downtime and maintenance costs associated with sludge formation in zinc phosphate-based paints have been reduced by installing Magstream magnetic fluid conditioners. Magstream has also minimised problems with clogged spray nozzles and reduced flow rates due to pipe encrustation. Consequently, the consistency of phosphate coating has improved. The company claims Magstream’s effectiveness has been proven in paint spraying plants for over 20-years, with companies such as Jaguar, Hoover, Servis and Massey & Ferguson, Sanyo, Brother and General Motors. The product uses rare earth magnets encased in a stainless steel

tube and orientated to optimise polarity. The financial savings from installing Magstream are also said to be significant. In one automotive application, sludge formation and disposal was reduced by 75 per cent, while the spraying system cleaning frequency was extended from six weeks to 12-weeks. Pipe work no longer needed caustic cleaning to remove sludge encrustations and the electrical consumption of pumps reduced accordingly. Resulting efficiency improvements in heat exchangers also enabled more precise control of phosphate temperature. www.treatwater.com Reader Reply Number: 311

SMOKE FREE LUBRICANT RW Greeff has introduced Dow Corning’s Molykote L 1428, a new synthetic lubricant formulated to resist oxidation and thermal degradation, while maintaining stable performance and lubricity over a wide temperature range and under heavy loads. It also suits high temperature bearing applications. L 1428 is designed to help lower maintenance costs, reduce chain drag and wear, extend oil-drain intervals and

prevent process interruptions. The oil is kosher approved and NSF F2 designated (certified for food-grade applications where no contact is expected with foodstuffs). The company states the product has extremely low volatility and will not form carbon deposits or smoke. www.rwgreeff.co.uk Reader Reply Number: 312

9 www.engineeringmaintenance.info Nov/Dec 2007 EMS

PLANT MANAGEMENT

SMALL BUT PERFECTLY FORMED Abbeychart’s new Nuert Mini-Pump is designed to provide a compact, quiet and reliable solution where space limitations prevent standard pumps and a lower flow rate is required. Technically similar to standard models, the pump boasts fewer components and lower cost. The company states it can be matched with a small motor to replace vibration pump units, while offering higher performance and long service life. Measuring 49 by 75 by 86mm the pump can be installed in any position. These self-priming rotary vane pumps are offered with five flow rates between

Remote machine monitoring

50 and 270 lit/min at 1,400rpm, with or without normal or balanced by-pass for adjusting maximum pressure. An optional built-in 100 mesh stainless steel filter removes particles down to 150μm. Working life is further extended with self-lubricating internal components, low start-up torque and a one-piece polished stainless steel rotor shaft. Specifications include 18 bar maximum working pressure and maximum fluid temperature up to 50°C (standard) and 90°C (special). www.abbeychart.co.uk Reader Reply Number: 313

That sinking feeling How much oil?

The efector octavis bearing condition monitor from ifm is now available as a master unit which can monitor up to four separate locations. The central unit can also now be programmed via Ethernet. The stainless steel vibration pickups (placed up to 30m away) feature IP69K for arduous environments. Efector octavis continuously monitors a machine’s operating condition. It is designed to detect rolling element bearing failures and shaft imbalance conditions on critical plant equipment such as pumps, motors, mixers, compressors, fans and spindles.

Sensitive applications such as food, electronics and medicine, require pure compressed air. Activated carbon filters and adsorbers have a limited capacity to remove oil and it can be difficult to decide when to change elements. Oil vapour concentration in suction air is subject to considerable fluctuations and overloading can damage filter elements. Sudden oil break-through can cause high consequential costs. For higher process security in compressed air treatment, Beko Instruments has developed measuring instruments for supervising the oil content. Oil Control reacts to the changed remainder oil rates in the streaming compressed air. Residual oil content is measured using ion exchange. The solution is unaffected by moisture content, is independent of changing flow conditions and features adjustable alarm values. Centralised and decentralised compressed air monitoring, shut-off and bypass is possible with Oil Control, with users able to verify oil content in any part of system. Using Oil Control, factories can protect production processes against high oil entry, thus avoiding repair and waste costs while guaranteeing compressed air quality.

www.ifm-electronic.co.uk Reader Reply Number: 314

www.bekotechnologies.com Reader Reply Number: 315

10 EMS Nov/Dec 2007 www.engineeringmaintenance.info

A new Multikwik utility sink, launched by Hunter Plastics, is designed to provide a functional solution for providing practical hand washing facilities for workplaces. The sink is a single piece moulding making it easy-to-clean, hygienic and virtually maintenance-free. The sink eases the task of installing hand washing facilities required by the Health and Safety Executive. This requires every workplace to provide washing facilities with hot and cold water close to all workstations. With a ten-year strength guarantee, the company states the sinks will withstand the rigours of continual use without deteriorating, even when sited outside. Chip-proof and resistant to boiling water, frost and most chemicals, the sinks are tested to 150kg and will not rust due to their plastic construction. Two versions of MultiKwik utility sinks are available. The cleaner station features an integral splash panel, while the wash station also has a grid, drainer, soap dish and hooks. Both are available in a granite finish and are supplied with plug and chain, waste fittings and overflow. www.hunterplastics.co.uk Reader Reply Number: 316

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

There is, however, an alternative way to maintain constant vigilance. Proactive preventive condition monitoring from INA FAG – it’s just as sensitive inside an industrial environment as the Meerkat is out in the wild.

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

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

For more information quote EMS Enquiry No. 107 on IBC

For more information quote EMS Enquiry No. 108 on IBC

For more information quote EMS Enquiry No. 109 on IBC

Beamex® MC5 Multifunction Calibrator Beamex® CMX Calibration Software

Save costs and improve quality of calibrations. The Beamex® calibration system improves the quality and efﬁciency of the entire calibration system through faster, smarter and more accurate management of all calibration assets and procedures. Beamex calibrators, workstations, calibration software and professional services form an integrated, automated system. ister to dow n

m/ca

libratio

ion

B CMX Leamex ® ight d emo x.

FREE

w w w. b e

Try m e for

loa

R eg

info@beamex.com www.beamex.com

For more information quote EMS Enquiry No. 110 on IBC

Portable calibrators Workstations Calibration software Professional services Industry solutions

MAINTENANCE SCHEDULING

A workshop has been organised to show how scheduling and optimisation tools can help ensure the right person, does the right job, at the right time

Meeting service level agreements Maintenance professionals have, for many years, accepted their responsibility to ensure the assets they are responsible for are available when needed and meet necessary compliance standards. Increasingly, however, the world of maintenance organisations is shifting from asset centric to service centric, with performance based contracts and service level agreements that can be difficult to meet or even measure. Also, in recent years, industry has seen increasing workforce mobilisation and an adoption of mobile technology. In the maintenance arena, companies are now seeing technicians with PDA-based work instructions, using telecoms and wi-fi

network communications to receive work and feedback completion. Meeting these new developments and changing environments results, most of the time, in more pressure on maintenance processes, labour productivity and ultimately profitability. Fortunately, organisations do not have to solve this problem alone. Resource scheduling and optimisation tools are available as complimentary solutions to support maintenance management systems. Macs EU has organised a free workshop (5 December) to introduce maintenance professionals to Smart Schedule, a resource scheduling and optimisation tool from Syclo

Delegates to Mac EUâ&#x20AC;&#x2122;s workshop will see how resource scheduling and optimisation tools can benefit their organisations

designed to help maintenance organisations allocate the best person, to perform the most critical work, within prescribed SLA timescales. In scheduling resources to work assignments, Smart Schedule can be configured to consider a wide range of factors including work criticality, work/resource locations, resource skills requirements, existing workload, holidays and others. The weighting given to these during optimisation can be tailored to suit particular environments and maintenance management systems. Smart Schedule has a visual user interface that supports the automatic colourcoding of tasks as they are assigned, started and completed. Alerts can be configured to flag where tasks are reaching their SLA commitments and their colour changed accordingly. The dispatcher or supervisor can then intervene and re-schedule or re-prioritise work though a simple drag-and-drop process, thus maximising the opportunity to meet the SLA. During the workshop, attendees will be shown how a resource scheduling and optimisation tool can benefit an organisation and how it works. Further, delegates will see how the tool can interact with asset management systems such as IBMâ&#x20AC;&#x2122;s Maximo Asset Management system. To attend the workshop, register by email at enquiries@macs.eu or the web www.macseu.co.uk. After successful registration, delegates will receive further information. The workshop starts at 10am and will be held at Mac EU, 45 to 47 Station Road, Gerrards Cross, SL9 8ES. Spaces are limited. www.macseu.co.uk Reader Reply Number: 317

13 www.engineeringmaintenance.info Nov/Dec 07 EMS

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

ULTIMATE LUBER More Adaptability Can be used in single or multi-point configurations.

More precision. Sensors and systems for temperature, displacement and position measurement. optris CT IR temperature sensors Non-contact temperature measurement from -40 to 900°C One of the smallest sensors worldwide with optical 20:1 resolution Analog and digital interfaces Installation of up to 32 sensors Options: Very high speed version

optoNCDT

500cc

More Power Up to 900 PSI lets you lubricate up to 8 bearings using a distribution block.

250cc

125cc

Available in 3 sizes

More Versatility Runs off internal battery pack or optional external power sources. Now custom programmable Ask us for more details.

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

BLE REFILLA

Available in 4 sizes

Jumbo 475cc

Budget 250cc

Mini 125cc

Micro 60cc

ELECTRO-LUBE (UK) LIMITED INC. A.T.S.A.T.S. ELECTRO-LUBE INTERNATIONAL TOLL FREE 1-800-663-8141 FREETEAM FAX VALLEY 1-800-663-8140 www.atselectrolube.com 383L JEDBURGH COURT, ELEVENTHTOLL AVENUE, TRADING ESTATE, GATESHEAD NE11 0BQ TELEPHONE: 491 4212 FAX: 0191 491 4224 email: info@ats-electro-lube.co.uk OVER 25 YEARS OF 0191 MANUFACTURING RELIABLE LUBRICATION PRODUCTS FOR AN INDUSTRIAL WORLD OVER 25 YEARS OF MANUFACTURING RELIABLE LUBRICATION PRODUCTS FOR AN INDUSTRIAL WORLD

For more information quote EMS Enquiry No. 112 on IBC

Laser-Triangulation sensors Measuring ranges 2 - 750 mm Resolution 0.2 μm Linearity 2 μm Measuring rate 2.5 kHz Compact - no external controller Analog and digital output

Dust and fume extraction hoses from Masterflex

Perfect for both OEM and user

wireSENSOR Draw-wire position sensors High precision and accuracy Different series with measuring ranges from up to 30 m Customer-specific OEM’s For harsh industrial environment

Temperature range -260°C to +1100°C

Different analog and digital output options

Very flexible, small bend radius

www.micro-epsilon.co.uk MICRO-EPSILON UK Ltd. 105 Boundary Lane · Liverpool · L5 9YJ Phone +44 151 482 5545 · Fax +44 151 482 5501 me.uk@micro-epsilon.com For more information quote EMS Enquiry No. 111 on IBC

Size range 38 mm to 900 mm Long service life, low operating costs Suitable installation and connecting systems Masterflex Technical Hoses Ltd GB-Oldham OL1 4ER Tel: 0161 626 8066 www.masterflex-uk.com PU / FABRIC HOSES

CONNECTIONS

TUBE PROTECTION

For more information quote EMS Enquiry No. 113 129 on IBC

CONDITION MONITORING

By using the latest condition monitoring systems and services, manufacturing companies can reduce unforeseen breakdowns. Schaeffler UK’s managing director, Kate Hartigan, explains

Condition monitoring:

insurance against breakdowns

Schaeffler UK’s managing director, Kate Hartigan, argues condition monitoring should be considered as insurance

When owning and managing high value items like cars or homes, most people are comfortable paying insurance premiums. So, surely manufacturing companies need to ensure their high value capital goods are adequately insured against unforeseen breakdowns? After all, lost production could equate to tens of thousands, even hundreds of thousands, of pounds per day. Although the cost of machine components like bearings and motors is small compared with the total machine price, the cost of production downtime and consequential losses resulting from a component failure, are often significant. Take a steel or aluminium manufacturing plant. The typical cost of production downtime is £100,000 per day. Similarly, lost production in a paper mill equates to around

company’s assets are protected. Risk £15k per hour. Total maintenance costs for a assessments should be carried out typical food or beverage manufacturer are regularly to see what effect breakdowns around 15 to 20 per cent of total costs. The would have on critical, bottleneck pharmaceutical sector spends similar machines and equipment. The severity and amounts on maintenance. Naturally, every manufacturing company likelihood of breakdowns on particular machines are assessed and given a has a maintenance department. However, corresponding risk value. Those with the due to time and resource constraints, the highest risk scores are given priority by the maintenance team may become reactive, fire fighting problems as they occur, with no maintenance team and should be protected by condition monitoring. predictive maintenance systems, little Companies can protect plant without preventive maintenance and often no condition monitoring or predictive maintenance strategy at all. maintenance systems by, for example, There should be no excuses for this today. There are many technology safeguards holding stock of components such as gearboxes and bearings. When a breakdown which, when compared with the cost of lost occurs, the component is immediately production, are relatively inexpensive. More available. However, as Hartigan points out: enlightened manufacturers are using “As well as the obvious increase in stock condition monitoring and predictive holding costs, the company also runs the maintenance systems, including bearing risk of the stock deteriorating or becoming vibration monitoring, acoustic emissions obsolete over time. We would recommend monitoring and thermography, to protect plant and machines. Schaeffler UK’s managing director, Kate Hartigan, said: Schaeffler's new FAG ProCheck condition monitoring system “Manufacturing or maintenance managers need to justify any expenditure on condition monitoring systems and services, to their finance director or MD. We would suggest using a risk management approach with questions like ‘what will it cost the company in lost production if I lose that critical machine for five hours?” One of the finance director’s responsibilities is to ensure the

15 www.engineeringmaintenance.info Nov/Dec 07 EMS

CATIV 600 V

True RMS voltage measurement

Combined dual digital and analogue display

PI, DAR and timed testing

Capacitance measurement

Result recall

Bluetooth速 download capability

And much more

Find out more ask your instrument supplier, or call 01304 502101 The Bluetooth word mark and logo are owned by the Bluetooth SIG, Inc. and any use of such marks by Megger is under license.

WWW.MEGGER.COM

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

Megger Limited Archcliffe Road Dover CT17 9EN UK T +44 (0) 1304 502 101 F +44 (0) 1304 207 342 E uksales@megger.com For more information quote EMS Enquiry No. 130 on IBC

CONDITION MONITORING

that customers reduce the risk of unexpected failures, by implementing suitable condition monitoring systems on rotating plant and machinery. Don’t think of this as capital outlay, but as insurance against the risk of possible lost production. “By installing a predictive maintenance system, the customer picks up a problem early. During the next convenient downtime period, the maintenance team can then remove and replace a bearing with minimum disruption costs and also avoid the risk of breakdown damage to the equipment.” Condition monitoring also helps prevent maintenance teams replacing components unnecessarily and possibly introducing new, unrelated problems. Manufacturing maintenance staff can use CM systems to predict when failures are likely to occur and plan replacement during production shutdowns. Hartigan continued: “In too many companies, parts are changed on a time basis rather than on a condition basis because the maintenance team considers this to be the safest option. However, this introduces a further risk, because whenever there’s human intervention, problems can occur. “Most companies work in a breakdown culture which is reactive rather than proactive. Rather than boasting about how rapidly they can repair or replace components and get a machine back into production, maintenance teams need to be asking themselves ‘how can we prevent the problems occurring in the first place?’ CM is the most effective solution.” If a manufacturer plans to achieve 100 per cent production schedule adherence, predictive maintenance is critical. Unforeseen machine breakdowns simply cannot be tolerated. Similarly, overall equipment effectiveness (OEE), total productive maintenance (TPM) and theory of constraints (TOC) performance will suffer if unforeseen breakdowns occur that disrupt production. Praxis, a partnership between Schaeffler UK’s maintenance and condition monitoring specialist FAG Industrial Services (F’IS) and Corus Northern Engineering Services, gives customers access to a range of condition monitoring products and services. The range of handheld and fixed systems includes: vibration monitoring systems; acoustic emissions monitoring; endoscopy; thermal imaging equipment; and contract patrol monitoring services. Training services are offered so customers

can understand equipment, analyse results and take appropriate corrective action. The focus is on training customers to take complete ownership of condition monitoring strategy and implementation. Steel and aluminium production In one materials production application, extreme operating conditions associated with hot wide strip mills resulted in a short service life for the work roll bearings. Unexpected shutdowns and costly resulting damage had to be avoided. Schaeffler’s F’IS team installed permanent condition monitoring of the work roll bearings using its FAG DTECT X1 vibration monitoring system. This included integration into the customer’s software, remote monitoring, data evaluation; customer training; and the identification of bearing defects.

As a result, the customer prevented unforeseen breakdowns and the cost of consequential damage. Less than a year after installing the new systems, the customer projected the following results: Annual costs before introducing condition monitoring: Five chock/roll neck repairs, each costing €21,000 = €105,000 Five unscheduled roll changes, each taking 7 minutes: €35,000 Total: €140,000 Total CM project costs by comparison: €100,000 Total savings from condition monitoring system, around €40,000. www.schaeffler.co.uk Reader Reply Number: 318

17 www.engineeringmaintenance.info Nov/Dec 07 EMS

Your plant maintenance picture isnâ&#x20AC;&#x2122;t complete without us Condition monitoring helps maintain output, efficiency and profitability by providing a detailed and accurate assessment of plant assets

For more information quote EMS Enquiry No. 115 on IBC

For more information, contact: Ian Taylor, Business Development Engineer Corus Northern Engineering Services T: +44 (0) 1642 498041 F: +44 (0) 1642 483376 cnes@corusgroup.com www.corusnes.com

For more information quote EMS Enquiry No. 114 on IBC

For more information quote EMS Enquiry No. 116 129 on IBC

FACILITIES MANAGEMENT

WEEE may be touted as a supplier cost, but unless organisations get their asset registers in order, it will also create a significant cost for UK business, insists Real Asset Managementâ&#x20AC;&#x2122;s managing director, Keith Dolby

Hidden costs of WEEE The implications of the Waste Electrical and Electronic Equipment (WEEE) Directive seemed to have passed unnoticed by the majority of UK businesses. And why not? The legislation states firmly the onus of disposal rests with suppliers and distributors. However, endemic poor asset management means this burden will pass directly to the bottom line. With upwards of 10 per cent of registered assets no longer in existence and the lack of component level recording of electrical and electronic assets, businesses will struggle to identify original suppliers and provide a full audit trail to disposal. The result will be expensive WEEE compliant disposal, potential fines for failure to provide an audit of asset disposal and attendant negative publicity. Supplier burden The green bandwagon is rolling strongly across the UK and Europe, with politicians of all parties united in their bid to attract How many UK businesses can accurately identify the location of their WEEE equipment?

the environmentally sensitive voter. Businesses too are keen to publicise their green credentials, from carbon offsetting to organic goods. Such policies have a firm economic footing. Green strategies appeal to voters and consumers alike: but only if the potential cost is viable. Over burden the general public with cost or expectation and it will take more than a picture of an endangered polar bear to reenergise widespread environmental concern. So, it is no surprise that the WEEE Directive was carefully framed to place responsibility with suppliers and distributors of electronic and electrical equipment. The directive aims to minimise the impact of electrical and electronic goods on the environment by increasing re-use and recycling and reducing the amount of WEEE going to landfill. It seeks to achieve this by making producers responsible for financing the collection, treatment and recovery of waste electrical equipment, while obliging distributors to allow consumers to return their waste equipment free of charge. However, such policies assume a level of asset management far beyond that achieved by the majority of UK business. Unless supplying a like-for-like replacement, suppliers will only remove and dispose of equipment they delivered in the first place. How many UK businesses can accurately identify the location of their WEEE equipment within the organisation, let alone confirm when it was purchased and from whom? Yet without such information, just which company do they expect to handle the disposal for free? Lost assets The asset registers of most UK businesses are appalling. In many cases, a full physical audit not only reveals that at least 10 per cent of recorded assets no longer exist but only 40 per cent of registered assets can typically be easily identified. The rest have been moved and/or upgraded without record. This means that on an average 2,000 item asset register, around 200 items have been disposed of but are still recorded as in use. While this may not matter to the finance team which has

19 www.engineeringmaintenance.info Nov/Dec 2007 EMS

FACILITIES MANAGEMENT

already depreciated these assets to zero, it will certainly matter when the organisation is asked to prove the items were disposed of in line with the WEEE Directive. The figures are worse for WEEE equipment. With prices for such equipment currently so low, few individual items reach the typical £1,000 to £1,500 minimum capitalisation threshold, so are not required to be held individually on the asset register. Instead, finance departments opt to consolidate such purchases into one single entry. Furthermore, most companies typically switch supplier regularly to reflect changes in pricing and availability. Yet, while these items are recorded as one bulk purchase they are highly unlikely to be disposed of simultaneously. Equipment breaks, is refurbished and moves locations: information that cannot be recorded without an individual asset number. So, when disposal is due, just how is a company going to identify and prove the original supplier? Without such knowledge,

Upwards of 10 per cent of registered assets no longer exist

the liability will be on the organisation to arrange and pay for WEEE compliant disposal. Asset management Penalties for failing to meet the WEEE Directive are not insignificant. If found guilty of an offence, producers, distributors and operators can be liable to a fine of up to £5,000 per offence on summary conviction in the Magistrates Court or an unlimited fine imposed by the Crown Court. Company directors and managers can also be prosecuted, in addition to the company itself, if they consent to, or participate in the offence, or if their neglect led to the commission of an offence by the company. If organisations are to avoid the two fold costs of fines and/or expensive WEEE compliant disposal with one of the multiplicity of firms recently set up to

support this burgeoning market they need to create an accurate, detailed asset register. First step is a full audit. It is likely any company conducting a full audit during 2007 to identify missing assets will be given leeway by the authorities. After that date any ‘missing’ assets will be deemed to have been disposed of without following the proper procedures since the company will have no valid certificate. The finance director will be faced with the unpleasant choice of admitting the

For more information quote EMS Enquiry No. 117 on IBC

EMS Nov/Dec 2007 www.engineeringmaintenance.info

How to reduce your customers’ cooling carbon footprint

ICS are specialists at providing chillers and air conditioning. Although we can’t claim to being able to cool a whole metropolis, we are rather good at supplying energy efficient chillers and equipment from our 170 strong UK manufacturing facility. Whether you need to provide reduced costs or new HVAC equipment offering the latest elevated efficiency rates (EER) – ICS have a wealth of experience and a proven track record to recommend the most resilient and climate conscious equipment for your client. We can help you to specify and supply the correct components including the latest Turbocor, free cooling and Class A equipment. So, if you have no idea about how to reduce your customers’ carbon footprint, don’t worry because we can help. Call ICS free on 0800 169 3861 or log on to www.industrialcooling.co.uk

Chillers are our business For more information quote EMS Enquiry No. 118 on IBC

ICS chillers and air conditioning – helping you create a reliable, efficient and comfortable environment for your clients.

For more information quote EMS Enquiry No. 119 on IBC

FACILITIES MANAGEMENT

company has no accurate picture of its own assets or accepting a fine. Neither option will amuse the shareholders. Once the full physical audit has been conducted, organisations then need to put in place strong procedures for asset disposal. Linking the asset register to a document management system will ensure a scanned WEEE certificate can be linked to a disposed asset, providing the required audit trail. Each asset can be recorded alongside the supplierâ&#x20AC;&#x2122;s name and email address, enabling swift supplier contact when disposal is due. Critically, the creation of an accurate, up to date asset register can also deliver an immediate return on investment, including a reduction in insurance premiums. Recording the cost of asset disposal will also improve a companyâ&#x20AC;&#x2122;s understanding of the total cost of each asset and the true financial implications of the WEEE Directive. Compliance overload UK business is already complaining about excessive red tape, which is perhaps one

of the reasons that the introduction of the WEEE Directive in July 2007 has been so effectively downplayed. However, a belief that the onus of WEEE is firmly on equipment suppliers could be an expensive mistake. There are many reasons for an organisation to clean up its asset register,

but without doubt those organisations that persist in inaccurate and bulk recording of WEEE assets will rapidly discover the true cost of this green initiative. Real Asset Management www.ramplc.com Reader Reply Number: 319

Equipment breaks, is refurbished and moves locations

DURA TREAD Anti-slip Fibreglass Floor Grating

BS EN 124 APPROVED

Prevents trips, slips and falls in the workplace Applications:

Benefits:

Range includes:

Stairs Industrial Flooring Walkways Platforms Assembly Lines Wash Bays Work Stations

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

For more information quote EMS Enquiry No. 120 on IBC

Light weight High strength Easy installation Anti-Slip Surface Corrosion/Fire resistant Impact resistant Zero maintenance

Standard Grating Covered Grating Pultruded Grating Structural Stair Treads Tread Covers Solid Fibreglass Plate

FIBREGLASS GRATING LTD High Performance Composite Construction

For more information quote EMS Enquiry No. 121 on IBC

www.engineeringmaintenance.info Nov/Dec 2007 EMS

ENERGY MANAGEMENT

Fuel efficiency, reduced cycling and extended life are three of the stated benefits of Wellman Robey’s Ygnette boilers, recently selected for an RAF replacement and upgrade project

Take-off for boiler upgrade A UK Royal Air Force base has ordered nine Ygnette hot water boilers from Wellman. The boilers will replace and upgrade existing Wellman Robey Ygnette boilers originally installed in 1977. The order comprises three 2,500kW LPHW (4.5 bar g) and six 800kW LPHW (10 bar g) boilers, all fitted with dual-fuel modulating burners supplied by Wellman’s burner company, GP Burners. The manufacturer states its Ygnette boiler is known for its performance on all fuel types. The horizontal, three-pass, wet-back, reverse flame design features a large furnace for efficient combustion. Combustion products are reversed to pass through convection tubes forming the tube pass and then discharged into a rear

outlet box provided with chimney connection for horizontal or vertical outlet. The stated benefit of this design is near perfect combustion with maximum fuel utilisation, high operational efficiencies and low running costs. Modulating burner controls help improve boiler operation by monitoring water temperature to produce a continuous control signal that determines fuel input. Reductions in water temperatures trigger an increase in firing rate, which helps optimise efficiency and minimise emissions. Precise air/fuel ratio control is essential to minimise excess combustion air and reduce heat losses in exhaust gases. Modulating burner output helps

The RAF boiler order comprises three 2,500kW and six 800kW systems

24 EMS Nov/Dec 2007 www.engineeringmaintenance.info

improve boiler temperature or temperature control, thus increasing fuel efficiency. Additional stated benefits include higher turn-down ratios, less plant cycling, extended boiler life, extended refractory life and less burner downtime. Wellman Robey’s Mike Winnall said: “We are delighted to be awarded the order for the replacement boilers by the RAF and we are confident that the Ygnette range of boilers fitted with modulating burners will offer the client maximum energy savings and a system to serve them well for the next 30 years and beyond.” www.wellman-robey.com Reader Reply Number: 320

Get your energy costs under control!

EXPERIENCE ENSURES OUR COMPETITIVE EDGE OIL / WATER SEPARATION WITH THE NEW ÖWAMAT® GENERATION. • Performance higher by up to 90 % • Easier servicing due to the cartridge technology • Longer service life of the filter units • Type approval with and without separation of free oils ÖWAMAT® devices made by BEKO are made for the most difficult of condensates

Reduce energy costs by as much as 30% with the new GD Belliss & Morcom range of oil-free compressors for PET applications.

and are superior in costeffectiveness and function.

Now with new optimised designs, the GD Belliss & Morcom VH, WH and VST ranges of speed controlled PET compressors can reduce energy costs by up to 30%, while offering improved levels of efficiency when generating high pressure air for PET bottle blowing. With over 25 years experience in PET applications, GD Belliss & Morcom are the recognised industry leaders and customers worldwide enjoy greater productivity and lower operating costs from these key features:

• Advanced new VH, WH and VST ranges improve cost

efficiency to both low and high volume users, delivering 125-3200, m3/hr FAD @ 40 barg.

• Intelligent Monitoring – smart technology gives greater •

operational control and even lower cost, through Air PET™ Control and CCS Energy Saver Systems. Highly compact footprint for ease of installation and space saving.

• Improved valve and cylinder design increases parts life and minimizes service times.

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Gardner Denver worldwide sales and service teams.

With the completely new development of the ÖWAMAT

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experienced provider. Go and see for yourself.

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Phone +44 1527 575778 Fax +44 1527 575779 info@beko-uk.com www.bekotechnologies.com

SEE US IN HALL 08B, STAND A40

COMPLEX NEEDS – SMARTER SOLUTIONS™ Gardner Denver Ltd | Chequers Bridge Gloucester | GL1 4LL | England Tel +44 (0) 1452 338 338 Fax +44 (0) 1452 338 317

glo_sales@gardnerdenver.co.uk www.gardnerdenver.com

For more information quote EMS Enquiry No. 122 on IBC WAMAT Anzeige 03-2007 UK.indd 1

For more information quote EMS Enquiry No. 123 on IBC 30.03.2007 14:40:51 Uhr

BOILER PROJECTS WHERE WILL YOUR FOCUS BE?

CAPITAL COST

LIFETIME RUNNING COSTS

With capital cost on average less than 1% of lifetime running costs, fuel efficiency must be the main focus when specifying industrial steam boilers. The new Yorkshireman 2 is the most fuel efficient boiler of its type, mainly by the incorporation of unique X-ID boiler fire tubes, only available from Byworth Boilers.

Web: www.byworth.co.uk Tel: 01535 665225 Email: sales@byworth.co.uk

FOCUS ON EFFICIENCY

Parkwood Boiler Works, Parkwood Street, Keighley, West Yorkshire BD21 4NW For more information quote EMS Enquiry No. 124 on IBC

ENVIRONMENTAL MANAGEMENT

Virtual Energy Manager is designed for organisations of all sizes, equally at home managing one site or hundreds

It is claimed smart technology that converts complex data into plain English can cut a company’s energy bill by a guaranteed 30 per cent

Cutting carbon footprints According to system developer, Manchester-based Ener-g Efficiency, its new Virtual Energy Manager will give a big boost to bottom line performance, while cutting carbon emissions. The company’s managing director, Paul O’ Brien, said: “The technology can help organisations of all sizes, from SMEs to multi-nationals, to manage and take control of their energy use and begin evaluating their carbon footprint. “Crucially, it uses plain English and ‘dashboard’ visual displays that everyone in the workforce can readily understand. It’s simple to use, yet the technology is so advanced that it automatically manages the optimum energy output to suit various areas – from warehousing to offices.” The Virtual Energy Manager is said to be the first system to combine automatic meter reading and a building energy management system. It is backed by an energy savings guarantee, which provides money back should consumption reduction not reach agreed efficiency targets. The powerful internet-based system is designed to managing every part of an organisation’s energy use 24/7. It

provides: actual consumption metering (day-by-day and hour-by-hour); instant saving assessments; quick, easy calculations of emissions performance; optimum comfort levels; integrated control of plant services; and an alarm to report issues such as unusual energy usage peaks. Mr O’ Brien added: “The need to manage energy and reduce carbon emissions is increasing. The display of energy certificates will shortly be needed in public buildings, and other proposed legislation includes the introduction of a Carbon Reduction Commitment that will see many public and private sector organisations needing to calculate their carbon footprint and manage their energy use to reduce their footprints. “In both cases the need for high quality, accurate energy data and effective energy management is clear. Virtual Energy Manager is designed for everyday use and will quickly tell users the status of their site and their performance against target. Within a few seconds the energy ‘dashboard’ provides easy-to-understand information at a glance. Interactive maps help

identify and locate sites needing attention and simple icons quickly highlight actual performance.” Designed for organisations of all sizes, the system is equally at home managing one site or hundreds, automatically adjusting as a business changes. Sites can be added or removed, while individual meters and sites can easily be benchmarked against each other. Paul O’ Brien concluded: “Knowledge is power and empowering managers is a key feature, with customers choosing who has access. Experience shows that waste can be driven out more effectively by providing knowledge about energy use to mangers throughout an organisation, from directors to shift supervisors. “When it comes to managing energy, different people are also interested in different things. Some need to know financial data, others more technical information. Virtual Energy Manager provides it all from a single, easy-to-operate platform.” www.energ.co.uk Reader Reply Number: 321

27 www.engineeringmaintenance.info Nov/Dec 2007 EMS

Maintenance software just got easier

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

G G G

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

Tel: 0191 2963816 email: sales@cayman.co.uk Web: www.cayman.co.uk For more information quote EMS Enquiry No. 125 on IBC

For more information quote EMS Enquiry No. 126 on IBC

High quality compressed air in accordance with ISO 8573.1:2001 The first range of filters to comply with the NEW ISO 12500-1 international standard for compressed air filter testing The most energy efficient compressed air filters in the world

email: dhindsales@parker.com For more information quote EMS Enquiry No. 127 on IBC

www.domnickhunter.com

HEALTH AND SAFETY

While industries like petrochemical are used to ATEX conformity, Deritend is warning that motors without correct certification are likely to be used in the recently defined ATEX zone 20 to 22 dust conditions

ATEX dust zones:

check motor compliance General manager of Deritend’s Wolverhampton motor repair and rewind workshops, Dave Hawley, takes up the story: “There are many companies that are now subject to ATEX regulations for the first time, due to the inclusion of dust laden atmospheres. They may be aware that explosions and fires caused by dust can be equally as devastating as those caused by explosive gases and vapours, but not what constitutes a risk and how to address it. Compliance as far as dust and electric motors are concerned is actually relatively simple and the motor parameters required are not extreme, but there is a genuine need to know within industry.” Previous regulations for explosive atmospheres did not account for risk of explosion created by dust. There have been several large explosions investigated in recent years in areas such as crop storage, food processing, coal processing and plastics that are now attributed to dust. Both atmospheric and settled dust can pose a problem and are now included in the new regulations. Most industries used to dealing with explosive gases and vapours (typically petrochemical) are unlikely to need to make many, if any, changes regarding the new directives. Companies in this sector will also know what

type of new motor they need and that an approved repairer should be used to certify a repaired motor. Companies not using motors certified by the supplier or repairer are liable should anything go wrong, under ATEX 137. Industries such as paper, processing, food preparation, textiles, woodworking, plus companies supplying machines into these sectors, are likely to be included for the first time and require the most information. Zone classification is the responsibility of the company on whose premises machinery is operating. It is also the responsibility of any company manufacturing machinery or repairing machinery that may create a risk or is designed for use in a risk area. Zone classification depends

on the type of hazard present and duration that machinery is exposed. For examples, explosive gases such as hydrogen and vapours produced by petrol are zoned 0, 1 or 2 based on the frequency of presence and concentration. Dust laden atmospheres created by activities such as composite woodworking and flour production are zoned 20, 21 and 22 based on level of exposure. Settled dust is also included, which depending on type and amount, can fall into any of the three categories. Areas to look out for where motors are at risk of causing a problem in the new dust zones are: conveyors, mixers, extractors, fans and pumps. Atmospheric dust is the most dangerous,

Several large explosions investigated in recent years are now attributed to dust

something as simple as flour can cause powerful explosions. Extraction equipment should be used and motors working in this environment require a higher level of enclosure sealing of IP65 and a controlled maximum surface temperature of 125°C. Settled dust is a wider risk than atmospheric dust and tends to cause fires started by excessive heat, the smouldering temperature of common dust as varied as cocoa or paper is generally over 200°C and so motor sealing to IP55 and a maximum surface temperature of 125°C are adequate. It is important to note that neither of these motors are EEx type rated and thus less costly. Motors must have full certification paperwork available from the manufacturer for inspection, when requested. Also motors must carry correct identifying labelling, including a re-assessed CE mark conforming to the new regulations. This is why purchasing a quality new motor from a knowledgeable supplier or a rewind from a reputable firm is essential for peace of mind and ultimately people’s safety. Older certified motors do not need to be re-certified, but the repairer does. www.deritend.co.uk Reader Reply Number: 322

29 www.engineeringmaintenance.info Nov/Dec 2007 EMS

PNEUMATICS

The largest proportion of a compressor’s lifecycle costs is energy consumption. What’s more, 30 per cent is thought to be wasted. Thus, it is essential operators measure, control and reduce energy losses. Atlas Copco explains

Maximising energy savings System audits can include sonic leak detection

Atlas Copco offers 24 VSD stationary compressor models, ranging from 7kW to 900kW, including oil-free versions and workplace models, with integrated air and condensate treatment equipment. Energy recovery Most electrical power used by screw compressors is transformed into heat, but up to 94 per cent of heat can be recovered. A well-planned investment in energy recovery can payback within one to three-years. The available heat from a water-cooled, oil-injected compressor (preferably above 30kW) can be recovered as hot water. Connecting it to a boiler’s return circuit helps reduce heating costs of washroom supply, radiators and process operations. In the case of air-cooled compressors, hot air can be ducted for direct space heating.

Start with compressor sizing. A system’s nominal compressed air requirement is determined by all of the consumers: tools, machines and processes. Thus, compressor size should be based, not on the total air using equipment, but usage at any given time. The golden rule is size the compressor to the largest air-using equipment only. To be certain, carry out a compressed air audit, such as Atlas Copco’s AIRScan. This gives a true picture of how much compressed air is being used and how much energy is wasted producing it. The survey pinpoints areas of energy drain. Analysis of usage patterns shows where the system could be improved regarding efficiency, flexibility and costs. The audit is applied in two stages. Consultant engineers conduct an initial diagnostic check to determine the compressed air system’s efficiency, including pipework. The second phase is a complete system appraisal, which measures, audits and reviews all elements of the compressed air system. As the

procedure is non-intrusive, it does not cause shut downs or interruptions. Variable speed compressors The survey may recommend installing variable speed drive (VSD) compressors. In 80 per cent of installations, air demand shows important fluctuations, while in 70 per cent of installations, load cycle lies between 40 and 80 per cent. Energy savings averaging 35 per cent are the main characteristic of integrated VSD compressors, derived from an integrated frequency inverter that varies the compressor motor speed to match output to demand. Traditional regulators can not track demand pattern variations, wasting energy as a result. VSD smoothes a compressor’s air demand profile, eliminating pressure overshoot and saving energy. Other VSD benefits include: up to 22 per cent total life cycle cost savings: pressure flexibility; pressure stability; no starting current peaks; high power factor; and EMC-compliance.

30 EMS Nov/Dec 2007 www.engineeringmaintenance.info

Air drying Energy-efficient procedures should also be applied to producing moisture-free quality air. Atlas Copco’s MD adsorption dryer and oil-free screw compressor combination is designed to reduce demand regarding power consumption and compensation for pressure drop. Compressor heat is used to regenerate the dryer rotor, which needs only 120W for rotation. No electrical heater or purge air is involved and close coupling minimises pressure drop. Intelligent control In applications comprising multiple compressor installation, intelligent remote control and monitoring can also help reduce power costs and optimise the system for minimal pressure band and maximum energy savings. Atlas Copco’s AIRConnect is an aftermarket service that links compressed air installations to a 24/7 internet-based monitoring system. It is designed to provide increased compressed air system availability and reliability and allows service optimisation: the right service at the right interval. Hardware monitors the devices in the

PNEUMATICS

The largest proportion of a compressor’s lifecycle costs is energy consumption

compressor room and provides internet access. AirConnect software includes a configuration program for compressor room layout and measurement points during commissioning. AIROptimizer provides hardware and software for energy

optimisation. The agreement includes hardware and software, maintenance costs and an annual AIRScan compressed air audit. An initial audit is performed to determine potential savings and, as a result, many operators find the

savings exceed their previous maintenance costs. Aftermarket services The underlying principle behind all practical issues of compressed air production is management and control of air generation costs. That means

Atlas Copco 0800 18 1085 www.atlascopco.co.uk Reader Reply Number: 323

NEC BIRMINGHAM

11 - 13 March 2008

MAINTEC

l al 28 tc 4 bi 4 hi 2 ex 862 To 0 )2 (0

easyFairs®

all-embracing service contracts that extend to on-going audits of energy efficiency, air leakage and air quality. All these factors relate to the implementation of cost-effective measures to remedy problem areas the audits reveal. Atlas Copco offers a choice of service plans, with options for inspection, preventative maintenance and total responsibility. Effective, planned maintenance of a compressed air system is a major contributor to optimum performance from equipment and the control of energy costs.

Something your schedule can rely on easyFairs® MAINTEC is the most reliable way to find out about all that’s new in maintenance. Knowing when is paramount to maintaining and improving asset performance, so make sure that easyFairs® MAINTEC, 11 - 13 March 2008 is a fixed appointment in your Diary!

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For more information quote EMS Enquiry No. 128 on IBC

www.engineeringmaintenance.info Nov/Dec 2007 EMS

ANNUAL BUYER’S GUIDE

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

Website

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Byworth Boilers

www.byworth.co.uk

sales@byworth.co.uk

01535 665225

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sales@certuss.co.uk

0121 3275362

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0121 543 0000

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0191 2963816

Productivity Europe

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m.jones@productivityeurope.org

01234 215867

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info@idhammarsystems.com

0117 9309300

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gba.info@uk.atltascopco.com

0800 181085

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info.uk@gardnerdenver.com

01452 338116

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01279 503173

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01629 822060

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01777 817536

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01494 816569

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01706 835331

www.metrum.co.uk

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0118 973 3000

www.icm-uk.com

info@icm-uk.com

01779 474748

www.ats-electro-lube.co.uk

info@ats-electro-lube.co.uk

0191 491 4212

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01732 871417

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01732 221245

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industrial@uk.fluke.nl

020 7942 0700

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www.hawk-ir.com

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01642 497000

www.nfpc.co.uk

enquiries@nfpc.co.uk

01909 504700

www.hansfordsensors.com

sales@hansfordsensors.com

0845 6801957

Boilers

Boiler Hire Wellman Robey

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CMMS

Compressed Air

Condition Monitoring

Data Acquisition Metrum

Health & Safety Integrity&Compliance Management

Lubrication ATS Electro-lube (UK) ltd

Planned Maintenance T Cards Direct

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Training National Fluid Power Centre

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FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info

32 EMS Nov/Dec 2007 www.engineeringmaintenance.info

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