EMS Magazine October 2011 by Michael Dominguez

MAINTENANCE BEST PRACTICE

THE LATEST INDUSTRY NEWS

PRODUCT SPOTLIGHT – HEAT EXCHANGERS

5-7 9 & 10 38 & 39

5-7

9 - 10

Maintenance Best Practice

Latest Industry News

11 - 17

Pumps – Maintenance/Products/ Services

22 - 23

Energy Management

26 - 27

OEE – Carry on Kaizen

38 - 39

Product Spotlight – Heat Exchangers

36 - 37

Product Spotlight – Heat Exchangers

48 - 50

Buyers Guide.

Contacts Publisher Michael Dominguez

Editorial editors/contributing: Jon Barret, Christer Idhammar, Alan France

Advertising Paul Clappison - Magazine Paul Miles - Online Advertising

Email Info@engineeringmaintenance.info

Website www.engineeringmaintenance.info

Phone tel: +44(0)1634 731646 Fax: +44(0)1634 631644

Address MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ

engineeringmaintenance.info October 2011

MAINTENANCE BEST PRACTICE

Reliability Improvements Drive Down Maintenance Costs An organization must focus on sustainable results, not just cutting costs. The following Three case studies will illustrate. Results-oriented organizations focus first on the quality and volume of production throughput, followed closely by the cost to produce the required quality and volume. This approach will improve reliability performance, which will drive manufacturing costs down. Most organizations focus more on cutting maintenance costs, and, as a consequence, maintenance costs go down temporarily, only to increase much more than the initial savings. In addition, reliability goes down, paving the way for losses that can be substantial. This behavior and results have been proven many times, especially in economic downturns. The root cause of this phenomenon is often shortsightedness and what the late quality leader Dr. W. Edwards Deming described as one of the most serious diseases in American industry: “the mobility of top management.” The three case studies that follow demonstrate what happened in two organizations that focused on cost reductions and in a third organization that focused on Results Oriented Maintenance.

Case 1: Cost and head count reduction The accompanying graph shows a 3-year case study in a food processing organization with an aggressive cost reduction program. A key measure used in maintenance benchmarking exercises was the number of maintenance crafts people and first line managers such as planners and supervisors. The head count reduction was done through attrition and layoffs. The major mistakes by this organization were: • To cut costs by reducing only the number of employees and not considering reducing the need for maintenance or improving work processes. • To focus on number of employees, instead of hours of maintenance work, including overtime and contractor hours.

Case 2: Aggressive cost reduction The graph for this case shows results at a chemical plant, a high-cost producer in its market, where management decided to do whatever it took to cut costs, mainly in maintenance. When the cost-saving initiative started, market prices for the plant’s products were low and profitability in a shortterm perspective was low compared to other plants in the corporation. The fast-paced cost reduction actions included: • • • •

•

• • •

Operations took over maintenance and only did maintenance work that was judged absolutely necessary. Planners were laid off and planning of work was discontinued. Scheduling was discontinued. Maintenance prevention activities such as shaft alignment were abandoned and lubrication was handed over to operators without training and implementation of a documented program. The preventive maintenance program was handed over to the operators, without training in what to do or how to inspect. The preventive maintenance inspectors were laid off. Shutdown crews were merged with another plant about 1 hr drive from the subject plant. Painting programs were abandoned. Training of crafts people was discontinued.

After realizing the catastrophic consequences of what had happened, the mill took initiatives to bring maintenance to world-class status. Results are very encouraging and the mill is today one of the top performers. Reliability is approaching 94 percent. Maintenance costs have gone up, so has quality production throughput, and manufacturing and maintenance costs per ton are lower. The actions taken to bring maintenance to world-class status included: • • • • • • •

Reinstating preventive maintenance inspectors and revising the preventive maintenance program. Bringing maintenance back to a central maintenance function. Developing a partnership between maintenance and operations instead of a customer-supplier relationship. Focusing on planning and scheduling and front line implementation of these practices. Developing employees’ capabilities toward joint goals. Making capital investments in new equipment and restoration of worn out equipment. Implementing front line management action indicators.

Case 3: Reliability improvements first, costs second This plant manufactures the same product as the plant described in the previous case, but it decided to focus on reliability improvements instead of only cost reduction. This included: • A clearly outspoken and established partnership between operations, engineering, and maintenance was forged.

engineeringmaintenance.info October 2011

MAINTENANCE BEST PRACTICE •

• •

• • • • • •

A change was made from a reactive to a planned and scheduled maintenance organization. Less than 10 percent of all maintenance work was planned when the initiative was launched. Ten years later more than 85 percent of all work is planned and scheduled. A strong vibration analysis program was implemented. When it started, the average vibration level was 0.23 in./ sec. Today it is down to 0.11 in./sec. Lubricators were professionally trained. This resulted in better filtration and water removal, better seals, oil testing, and fewer types of lubricants. Cost for lubrication was reduced by 60 percent. All rotating equipment above 1000 rpm is balanced dynamically before it is put into service. Many equipment bases were improved and equipped with jack-bolts to improve alignment precision. Electric motors and rolls in storage are marked and rotated twice a month. Alignment training, standards, and execution were implemented. Stores inventory and services were analyzed and improved. Service level now stands at 96 percent and stores value has been reduced by more than 30 percent. Adherence to preventive maintenance schedules was increased to over 90 percent.

Case 2: Lingering effect of 2 years of cost cutting In the first 2 to 3 years maintenance costs dropped from $35 million/yr to $27 million/yr and results were hailed as good. However, reliability started to decline. When beginning this initiative, overall production reliability (OPR)—the product of quality performance, time performance, and speed performance—was 93 percent; it bottomed at 78 percent 6 years after the start of the initiative. At this time the market price for the plant’s products had doubled. The drop of 15 percent in OPR and quality production output corresponded to a loss of over 300,000 tons during some very good years when product could be sold at top prices. Financial losses because of low OPR resulting from shortsighted maintenance cost savings are conservatively estimated to exceed $1.2 billion over a 3-yr period.

Reliability pays Reliability improvements increase production throughput and drive down maintenance costs. Maintenance cost reduction is a consequence of reliability performance; it is never the other way around. Case 1: Moving maintenance resources to operations and cutting craft personnel The number of crafts people was reduced by 14.3 percent the first year. After 1 year, 6 percent were hired back. In the same period, contractor spending went up 88 percent. Total maintenance hours including overtime, contractor hours, and in-house hours went up 10.5 percent. Total maintenance costs went up 29.2 percent. On top of that, reliability and production throughput decreased 6 percent. This plant is now investing in hiring and training more maintenance people, implementing lost maintenance practices, and moving all maintenance resources back to professional maintenance management after initially decentralizing maintenance to operations.

Case 3: Focus on reliability During the first 3 years, maintenance costs increased 8 percent (2.5 to 3 percent/yr). During the same period, reliability as measured by OPR, and consequently also production throughput, increased steadily from a low of 83 percent to 90 percent. Reliability continued to increase to 92 percent. In financial terms, a short-term increase in maintenance costs of about $3.3 million resulted in savings of $17 million annually. The value of increased and sold production represented $18 million annually. Total maintenance costs were reduced by 40 percent. Today this plant survives another economic downturn because of the reliability initiative it initiated and implemented.

Article supplied by : Christer Idhammar Founder and Executive Vice President IDCON, INC For further information please contact us on: Tel: +1 919 723 2682 Email: info@idcon.com Or visit www.idcon.com

engineeringmaintenance.info October 2011

LATEST INDUSTRY NEWS

Buck & Hickman’s Tooltastic celebrates with nationwide trade days Two years after first launching its ‘Tooltastic’ trade counter service for tradesmen and serious DIY enthusiasts, Buck & Hickman is celebrating with trade open days across its nationwide network of branches. A brand new catalogue has been launched to give customers top deals on leading brands of Power Tools, Hand Tools, Workwear and Safety Equipment. The Tooltastic open days will offer exclusive promotions to customers and the chance to talk to the Buck & Hickman branch teams. Promising that “if it’s in the book then it’s in stock”, Tooltastic trade counters offer excellent stock availability and a fantastic product range

with virtually everything featured in the new catalogue stocked at the branch and available for same day collection. For further information log on to www.tooltastic. com or call 08450 510150 for further information.

Optima Control Solutions Meets Tough Deadline For Renolit Optima Control Solutions Ltd has successfully completed a full systems upgrade on a crucial printing press in just two weeks for a major international manufacturer of plastic films. Leading drives and controls experts Optima was under pressure to meet the tight deadline when it was tasked by Renolit Cramlington Ltd to refurbish the control system on the five-colour Cerutti Printing Press at its plant in Cramlington, Northumberland, during the machine’s scheduled downtime for maintenance.

Brian Hesler Joins Draeger Safety

Cerutti Printing Press control systems was a key factor in Renolit’s decision to choose Optima to carry out this critical task. It was the first time Renolit had used the Blackburn-based company, but the decision paid off handsomely as the refurbishment of the Cerutti Printing Press was completed within the two-week deadline and on budget.

Mr Milne said: “We recognised Optima as a very capable outfit but it was a tricky project and the pressure was on them to get the machine up and running as soon as possible. Optima did a great job and provided an excellent back-up service. They coped really Renolit’s engineering project and maintenance manager, John Milne, explained well and I would certainly use them again.” that the press was vital in the making Optima Control Solutions Ltd | Tel: 01254 of decorative laminates for kitchen and 272829 | Fax: 01254 272828 bedroom doors and UPVC windows. Any Email: michael.hill@optimacs.com | Web: www. interruption to the printing operation hits the optimacs.com whole production line at the factory. Optima’s previous experience of refurbishing

Brian Hesler, former Fire Chief at Northumberland Fire and Rescue, has joined Draeger Safety as Head of Service and Training UK. Based at the company’s head office in Blyth, Brian is no stranger to customer requirements for high quality service having served 33 years in the Fire Service. He will now be heading up Draeger’s extensive training, after care and support service across the UK. He comments, “Draeger not only manufactures a high quality range of products but it also offers excellent training, service, maintenance and support via experts from all areas of industry. I am delighted to join the company and to bring my knowledge of the emergency services as well as industrial hazards to the service and support team. I am looking forward to developing our new Safety Centres in Surrey, Aberdeen and Plymouth to maintain and improve our service,

Anderson Thermal Devices, Inc. Appoints New Regional Sales Representative Firm Hawthorne, N.J., September 26, 2011 Anderson Thermal Devices, Inc., headquartered in Hawthorne, New Jersey is pleased to announce the appointment of Instrumentors Supply, Inc. of Oregon City, Oregon as their representatives in Washington, Oregon, Idaho and Utah. For three decades Instrumentors Supply has provided quality industrial heating, controls and sensors to the process heating industry.

According to John McKechnie, National Sales Manager of Anderson Thermal Devices, “We are excited to have Instrumentors Supply work with us. Their engineering and technical ability will provide complex, custom solutions for our customers’ process heating and control needs.”

Instrumentors Supply will be responsible for increasing sales of infrared quartz halogen bulbs and infrared heater panels to OEMs and industrial manufacturers.

Call the Infrared Hotline 800-720-5256 for more information or contact us via:

Anderson Thermal Devices has designed process heating solutions since 1995. In addition to custom offerings, they provide direct replacement lamps for all major manufacturers.

training and support across the UK. We are considering the development of further local Safety Centres across the UK in support of our expanding business. We want to be more local to our customers to help us be more responsive.”

For further information contact Customer Service, Draeger Safety UK Limited, Tel: 01670 561200, fax: 01670 356266, www.draeger.com.

info@AndersonThermal.com.

engineeringmaintenance.info October 2011

LATEST INDUSTRY NEWS

Haydon Kerk Motion Solutions Introduces the IDEA™ Stepper Motor Drive Module with RS485 Communication Protocol

This allows IDEA devices to communicate over a network of 1000ft without the need for termination resistors. The system architecture

Rating Plate Labels for Heavily Textured Surfaces – Now Straight from your

WATERBURY, CT – The IDEA stepper motor drive platform now has the capability of communication using an RS-485 data protocol. The RS-485 protocol overcomes the limitations of other drive communication methods making the RS-485 IDEA drive module perfect for industrial applications. The main advantage of using the RS-485 protocol, especially for industrial equipment such as stepper drives, industrial motor drives, and servo systems, is the ability for long data transmissions while exhibiting excellent immunity to electrical noise. The RS-485 protocol utilizes “differential” signal lines for limiting common mode noise coupling and twisted pair cabling for cancelling out induced noise current.

NEW! CILS Industrial

Desktop Printer!

also allows up to 256 addressable device nodes. An industrial controller can send commands to all the drives at once, or each drive can be controlled separately when assigned a unique identifier, a number between 0 and 255. To download the entire IDEA Drive Communications Guide, visit: www.idea-drive.com.

Kawasaki Cleans Up Pump Finishing Operation with AirBench Kawasaki Precision Machinery have solved a persistent dust issue with a major AirBench installation. As part of their production process, KPM use air tools to finish aluminium pump bodies,

Designed for heavily textured, powder-coated and cast-aluminium surfaces, the new CILS-9100HD high-performance heavy-duty label range provides an immediate, permanent bond to the most difficult surfaces, providing failsafe product identification that lasts the lifetime of the product. Variable data (barcodes, serial numbers etc) can be added in minutes straight from an existing PC and standard Laser or Thermal Transfer printer, saving time and additional cutting hardware costs.

producing excess dust and leading to an uncomfortable working environment. AirBench was identified as a potential solution and following successful on-site demonstrations and testing KPM procured 5 units in a range of sizes. Operators are now able to work with minimal PPE creating a more effective working environment.

Visit www.AirBench.com or www.kpm-uk. co.uk for more information.

Eriks ‘Superbranch’ To Launch In Leeds ERIKS is to move operations from two separate centres in Leeds to a purpose built 15,000 square foot ‘superbranch’ in the city, providing its customers with an even more integrated and extended service, and boosting the local economy by generating new jobs. ERIKS’ Industrial Distribution Service Centre will combine with the company’s Electro Mechanical Service Centre at the new operating site in October. The move will allow ERIKS to expand its wide range of services for the provision and maintenance of machine parts, such as motors, bearings and fans, and to broaden its capability in other areas,

engineeringmaintenance.info October 2011

for example, in the supply and maintenance of pumps. The latter will include a dedicated pump service, with the new Leeds facility becoming a Core Competence Centre for pump repairs. The distribution service at the new centre will launch on October 3rd, with the repairs and maintenance operation following later in the month. For further information, please contact: Robyn Bradley, Marketing Executive, ERIKS UK T: +44 (0)121 508 6219 robyn.bradley@eriks.co.uk

The unique CILS-9100HD toner receptive surface coating ensures printed data remains sharp, legible and permanent even when exposed to extreme temperatures (-80°C to +388°C), harsh chemicals/solvents, abrasion, oils/ fuel etc. Manufactured to any size, shape and full colour pre-printed corporate design, CILS-9100HD provides the ultimate labelling solution to the most challenging industrial surfaces. For more information and samples please contact: CILS International Tel: +44 (0)1903 219000 Fax: +44 (0)1903 219111 Web: www.cils-international.com Email: info@cils-international.com

PUMP MAINTENANCE

Sealless Pumps Help To Solve â&#x20AC;&#x2DC;Stickyâ&#x20AC;&#x2122; Problem Pumping resinous glue at high temperatures presents a sticky problem for certain types of pump, especially when there is an added complication of the glue containing particulates. This challenging pumping application is part of the process of manufacturing Oriented Strand Board (OSB) a timber based building product which is similar to plywood. However, Hydra-Cell sealless positive displacement pumps, available from MICHAEL SMITH ENGINEERS have proved to be successful on this application, where other types of pump have failed. OSB is recognised as an innovative, environmentally sustainable timber-based material for both structural and non-structural building applications and is manufactured by compressing strands of wood with resins at high temperature to create strong and versatile panels. Originally gear pumps were being used to deliver the resinous glue into a mixing chamber, where it is sprayed onto wood fibres in the early stages of the manufacturing process. Chosen for their high pressure capability, these pumps leaked persistently through their mechanical seals causing damage to them when hardened resin became trapped between closely meshing gears. This resulted in the need for the pumps and gearbox to be replaced three times on one month. The installation of a HydraCell pump at this stage of the process immediately solved the problem by providing reliable, high-pressure pumping of the resinous glue. The sealless design of these pumps means no dynamic seals to leak, wear, or replace and their spring-loaded, horizontal disk check valves enable the pump to process liquids which contain particulates up to 500 or greater microns in diameter

engineeringmaintenance.info October 2011

without problems. Following 6 months of trouble-free operation, the second pumping system was installed on the process with the same successful results for the Oriented Strand Board manufacturer. The range of Hydra-Cell pumps covers flow rates from 0.4 lit/min up to 128 lit/min and pressures up to 172 bar, providing repeatable and accurate output. They can handle dirty liquids and liquids with particulates and because they are sealless by design, leak-free, self priming and can be run dry, they are also ideal for cleaning (CIP) applications. Other applications include; machine tool cooling, reverse osmosis & separation, spray drying & abrasives, paper mill applications and oil production and refining. Further details are available from: Mr. Sam Smith, Michael Smith Engineers Ltd, Oaks Road, Woking, Surrey, GU21 6PH, UK Tel: 0800 316 7891 Fax: 01483 723110 Info@michael-smith-engineers.co.uk

PUMP MAINTENANCE

Turning Old Into New It is inevitable that over the long term pumps will display signs of wear because it is almost impossible to design a pump that is free from operational deterioration. Wear will have an adverse influence on the performance of the pump, causing mechanical losses, leakage and energy (hydraulic) losses. Components most likely to be affected are bearings, mechanical seals, wear rings, rotating elements and the shaft. Then there is the matter of the internal surfaces which can be subjected to corrosion and erosion by the pumped fluid (Fig. 1).

typically this will involve identifying the problem if there has been a pump failure. Externally the pumps may look to be either in a reasonable state or not worthy of being rescued. A thorough examination of the pump in its operating environment will reveal the cause of the failure and establish whether or not the pump can be repaired in-situ. AxFlow’s engineers have a check list of actions that are adhered to during the disassembly process and it is this procedure that is crucial to identifying where problems lie. The Company goes as far as to photograph every action of the stripping down procedures as this allows component appraisal. Using this visual data is deemed essential when it come to making recommendations as to the best course of action to be taken. According to Tom Cooper, Service Base Manager, the goal is to get the customer’s plant back up and running as quickly as possible, but not at the expense of creating further problems that might arise in the future. Pump replacement may at first seem the easiest option, but this can be costly for the customer and may not always be the best long term solution. This approach is illustrated by projects undertaken where the actual pumps in service were no longer manufactured. Two of the latest restoration projects have involved a 42-year-old Allen Gwynnes 36” intake/33” discharge cooling water make-up pump for a power station in the East Midlands and a 46-year-old Vickers impounding pump in Hull docks. Weighing in at around 5 tonnes, including the 600kg 30” impeller, the Allen Gwynnes DESC pump was installed when

Above: Figure 1

the power station was first constructed in the 1960’s and is one of three pumps extracting water from the adjacent River

Pump servicing, repair and refurbishment is a mainstream

Trent. The scope of the service work included stripping the

activity for AxFlow (www.axflow.com) and through its

pump down and performing a complete dimensional check.

Service Base in Huddersfield it provides pump users with

Remedial work involved replacing the impeller wear rings

a wide range of facilities, including supplying and fitting

and rebalancing the whole rotating assembly.

mechanical seals and the specialist Belzona coating service. When called in to provide both on-site or off-site

AxFlow also took the opportunity to convert the upper

maintenance and repair, it is standard procedure to examine

stuffing box to a split semi-cartridge mechanical seal in

the pump in detail and to discuss with the customer the

order to allow easy replacement without there being a need

application and operating conditions. In this way the

to remove the motor, bearing and coupling. The lower

Company’s engineers are able to provide a wholly effective

stuffing box was also converted to an un-split cartridge seal.

solution to the problem regardless of the age of the pump

and to give a guarantee on its work. Where feasible,

“Historically, the gland leakage led to bottom bearing failure

remedial work is carried out at the customer’s premises and

and required constant maintenance to keep the bearing in a

engineeringmaintenance.info October 2011

PUMP MAINTENANCE

Above: Figure 2 usable condition,” reports Mark Redgrove, AxFlow Technical Support Manager. “We reassembled the pump with new bearings, casing wear rings, fasteners and gaskets before filling it with (a lot of) water to check the integrity of the seals. Once all the tests were complete we painted the pump and organised a fast delivery to site (Fig. 2).” At Hull docks, the Vickers pump is employed around high tide to maintain the dock water level. Having removed the

Above: Figure 3

pump from service, it was clear that a full overhaul would be required, this necessitating the replacement of the cutlass bearing and shaft sleeve, refurbishing the mechanical seal, reconditioning the Michell bearings and installing a new GRP bell mouth because the original one had suffered severe damage from cavitation. In addition, the impeller was re-tipped, machined and balanced and all the internal surfaces coated with Belzona to stop corrosion (Fig. 3). “Having the facilities to apply Belzona coatings provides us with a considerable advantage when we take on challenging pump refurbishment projects,” comments Mark Redgrove. “These coatings not only give excellent protection against corrosion, erosion and cavitation, but enhance the hydraulic performance of the pump which in turns leads to higher levels of operating efficiency. As a result, our coatings service is now becoming an integral part of the AxFlow proposition.”

For further product information, contact: Tony Peters AxFlow Ltd Orion Park Northfield Avenue Ealing London W13 9SJ Tel: 020 8579 2111 Email: info@axflow.co.uk www.axflow.co.uk

engineeringmaintenance.info October 2011

PUMPS

Saving Water In The Process Of Brewing Vacuum pumps within the brewing and bottling process are often far too greedy where water is concerned.... When challenged with this imposition, Shaun Hampson gave his view from the

So, is there a real solution? Ultimately, the answer to this question lies with System Life-Cycle assessment following the common theme:

Global vacuum brand of Sterling-SIHI. Brewing processes, are actually quite demanding, which takes away some of the simplicity associated with the selection process. Foaming and product carry-over are common-place in such a process that often attracts a sanitary/hygienic classification.

Generally, it is energy and waste that feature heavily in the total costs of ownership (and operation). Consequently, it is these aspects which ought to be at the centre of all brew-house, and bottling vacuum. Although this may seem obvious, the reality is sometimes different when brewers are faced with multiple equipment suppliers each offering varying technologies at a broad range of prices. Ejectors, eductors, liquid-ring vacuum, lobular-roots, totally dry vacuum, and other products are only the start of product choice. Their integration together with vital ancillaries makes all difference to operational performance alongside reliability, waste, and energy efficiency. For instance, basic separator design based on operational experience can have a dramatic influence on water saving. For almost 100 years, SIHI have been developing, manufacturing, and supplying the spectrum of vacuum and centrifugal pump equipment destined for some of the World’s biggest breweries, distilleries, and contract bottling sites.

To find out more about improving water consumption, power, and reliability with existing vacuum systems, simply contact Sterling-SIHI UK. When process efficiency is added to the equation, then the criteria issued to the vacuum equipment suppliers surrounds:

e-mail: uksales@sterlingfluid.com Telephone: +44 (0)161 928 6371 Visit: www.sterlingSIHI.com to download your

• • • • •

30mbara - 1014mbara pressures Tolerant to foaming and liquid carry-over Highly reliable Efficient, and NO water consumption

engineeringmaintenance.info October 2011

Brewing Application Guide. Visit SIHI at Brau Beviale, Nuremberg, 9th-11th November 2011 (Hall 6, Stand 6 – 109).

PUMP MAINTENANCE

Richter Launch New Mid-Range Corrosion Resistant Pumps range of mechanically sealed process pumps has therefore been developed to meet the standard needs for highly corrosion resistant PFA lined pumps at a competitive price.”

Richter Chemie-Technik GmbH, the German pump and valve manufacturer and part of the USbased IDEX Corporation, has launched a new range of PFA lined, mechanically sealed pumps specifically aimed at the mid-range of the process industries market. Colin Simpson, Sales Director at UK distributors, Billingham-based Tomlinson Hall Ltd, commented, “Richter Pumps are renowned for their innovative magnetic drive and mechanically sealed, plasticlined pumps for difficult corrosive and hazardous fluids and have become the standard within the European chemical, petrochemical and pharmaceutical industries.” “However, they have identified a gap in the market for mid-range pumps which previously would have necessitated the use of a higher specification model than was actually necessary. The new RSI and RSA

Both the RSI (ISO/DIN code compliant) and RSA (ASME/ANSI code compliant) pumps incorporate PFA lining to provide the highest chemical resistance at temperatures from -30° C to 150° C and full FDA conformity. These mechanically sealed process pumps can also handle liquids containing solids and have flow ranges from between 0.1 - 120m3/hr with delivery heads up to 100m. A major feature of the pumps is their low life cycle costs, designed specifically for ease of maintenance with a wide open lantern design for full visibility and easy access to the mechanical seal area. The pumps are considerably cheaper than mechanical seal pumps made of corrosion resistant metals (titanium, nickel etc) and have a larger pressure and temperature range than full plastic or partially armoured pumps. Lutz Rosin, Marketing Executive at Richter Chemie-Technik GmbH, commented, “The new range compliments rather than competes with Richter’s existing range - for larger flows, higher temperatures and specific applications, the Richter SCK or mag-drive MNK series may well be more appropriate, but the market’s reaction to these mid-range pumps has been very positive as they incorporate all the high quality design that Richter’s products are known for, but at a more economic price that offers superb value for money.”

For more information please visit: www.richterpumps.co.uk or contact Tomlinson Hall on: (01642) 379500.

engineeringmaintenance.info October 2011

RESISTANCE TEMPERATURE DETECTORS

Resistance Temperature Detectors: Back To Basics Chris Chant, Business Development Manager at Okazaki Manufacturing Company (OMC), discusses the basic principles of a resistance temperature detector (RTD) and the technical advantages they offer in industrial applications. Resistance Temperature Detectors or Resistive Thermal Devices (RTDs) are wire wound and thin film devices that incorporate pure metals or certain alloys that increase in resistance as the temperature increases, and conversely, decrease in resistance as the temperature decreases. RTDs are similar to thermocouples in that they convert changes in temperature to voltage signals by the measurement of resistance. As an RTD becomes hotter, the resistance measured on its element becomes larger. As the RTD cools, the resistance becomes smaller. The Platinum Element RTD The most commonly used type of RTD element is Platinum. These versions are often referred to as PRTs or PRT100s. Platinum elements are popular because they can be used over a wide range of temperatures and also provide fast response times. Platinum’s coefficient of resistance is almost linear, which means that by using a platinum element, resolutions of +/- 0.1 deg C or better are possible. PRTs are gradually replacing the use of thermocouples in many industrial applications below 600 deg C, due to their higher accuracy and repeatability. The current international standard which specifies tolerance, and the temperature-to-electrical resistance relationship for platinum resistance thermometers is IEC 60751:2008. By far the most common devices used in industry have a nominal resistance of 100 ohms at 0 deg C, and are called Pt100 sensors (‘Pt’ is the symbol for platinum). The sensitivity of a standard 100 ohm sensor is a nominal 0.385 ohm/°C. RTDs with a sensitivity of 0.375 and 0.392 ohm/°C as well as a variety of others are also available. Other Elements Other more cost effective elements can be used in RTDs. The most common of these alternatives are copper and nickel. The advantage here is that the RTD will have a reduced manufacturing cost and will have a lower replacement value. However, the drawback is that these elements have more restrictions on the range over which they can be used due to non-linearities in the Resistance versus Voltage curve. Also, problems of wire oxidation are known to occur when copper is used as the element. Why choose an RTD? One of the technical advantages of using an RTD is that it provides a very stable output for long period of time. Other benefits include ease of recalibration and accuracy of readings over a relatively narrow temperature range. When compared to thermocouples, the disadvantages of using RTDs are: higher sensitivity to vibration, smaller overall temperature range, and a greater initial cost.

To eliminate measurement errors, it is necessary to compensate for the length of lead wire used to connect the RTD to the readout. The calculations to correct this are relatively straightforward. Three-wire and four-wire designs are also available that help to minimise these types of errors. Laboratory Accuracy with Industrial Ruggedness Platinum resistance temperature detectors are used for interpolation between the IPTS-68 fixed temperature points of ice and antimony (0 deg C to 630.74 deg C). They are generally used where accuracy and stability are most important. OMC’s approach to RTDs will bring +/- 0.05 degrees laboratory accuracy to the toughest industrial processes – without any special handling considerations. OMC has combined the inherent accuracy of a precisely wound Platinum resistance element with AeroPak® compacted ceramic insulated cable. The result is a low cost yet rugged sensor that will withstand factory handling, whilst retaining the stability required for today’s precision process control environments. Time response characteristics The response of an OMC Resistance Temperature Detector is defined by two noticeable characteristics when exposed to an instantaneous (step) change in environment temperature. These are: (a) Time Constant: The time to reach 63.2% of the complete step change in temperature. (b) Response Time: Time to reach within 0.5% of the final temperature in a step change. This is approximately equal to 5 times the time constant. The response of a temperature sensor to a step change in environment temperature tends to follow a second order differential equation. However, this is approximate, since if the mass of the sensor is small in relation to the mass of the fluid passing over it (as is the case with a liquid), the response may approach a first order differential equation. Selection/Matching Completed probes can be matched in pairs to the nearest 0.01 ohm at 0 deg C for differential temperature measurements to 0.05 deg C. Completed probes can be supplied with selected ice point resistances within a narrow band to eliminate the need for compensation in indicating circuits. Latest development In the last few months, OMC has completed the development of a brand new high temperature platinum resistance thermometer for industrial applications. The new Ceracoil W86 is able to measure very high temperatures of up to 660 deg C using a platinum RTD element.

Prolonging Life and Eliminating Measurement Errors To achieve the maximum life from a Resistance Temperature Detector, it is recommended that a protective well and terminal head be used. The well serves to protect the RTD from damage by the gas or liquid being measured. Protecting wells are typically manufactured in stainless steel, carbon steel, Inconel or cast iron. The wells are designed to operate in temperatures up to 1,100 deg C.

engineeringmaintenance.info October 2011

For more information on OMC’s range of RTDs and thermowells, please visit the website at www.okazaki-mfg.co.uk or contact the sales department on 02920 814330 or email: info@okazaki-mfg.co.uk

engineeringmaintenance.info October 2011

LATEST PRODUCT NEWS

New Norbar Multi Channel Lubro Air Pressure Regulator Norbar Torque Tools has launched a new Multi Channel Lubro for regulating air pressure when using pneumatic torque multipliers and other pneumatic tools. This device allows the operator to undertake multiple applications without having to continually refer back to air pressure graphs and without then manually adjusting the pressure setting. Up to 15 programmable channels are available for multiple applications and settings are protected by supervisor key control. A useful write-on label located on the front of the Multi Channel Lubro can record up to 15 air pressures in psi/bar together with job references and torque measurement settings in Newton metres. These features ensure consistency when different operators have set a particular pressure. The Norbar Multi Channel Lubro can be operated from mains or battery. The internal rechargeable battery pack offers a 16 hours ‘2-shift’ battery life and includes monitoring to show the state of charge. The battery can be fully recharged in 4 hours.

Other benefits include: • •

Adjustable pressure control for pneumatic tools Pressure gauge recording output pressure levels up to 100psi/6.9 bar

• •

Supply of controlled oil feed to lubricate the connected tool Removes excess saturated water and foreign particles that could damage the connected tool

Philip Brodey, Director of Norbar comments: “There are numerous applications for air pressure delivery to pneumatic tools in manufacturing, assembly, transport and other areas. The new Norbar Multi Channel Lubro is safe, easy to operate and exceptionally flexible in handling a broad range of pressure settings.” For further information about Norbar products and services, contact: Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxfordshire, UK OX16 1XJ T+44 (0)1295 270333 | Email: enquiry@norbar.com

Steelman Engineering Ltd achieves ISO9001:2008 certification with SGS United Kingdom Ltd As part of its continual improvement and growth strategy, Carryduff-based Steelman Engineering Ltd has underlined its commitment to Quality Management by achieving ISO9001:2008. The standard supplies the requirements for customer satisfaction through consistent products and services and for continual improvement of a Quality Management System. “We quickly began to see how having the ISO9001 System in place would help us move forward when dealing with our customers,” says Steelman Engineering General Manager, Larry McGibbon The company chose SGS United Kingdom Ltd for the certification process. “The competition offered us a generic auditor to work with. But SGS talked our language. The auditor that was appointed to us came from an engineering background,” says Larry McGibbon.

engineeringmaintenance.info October 2011

“Having ISO9001 certification has raised our standards to the next level. Everything is documented, and we now have a controlled procedure in place that everyone can rely on,” says Larry McGibbon. Now, with the new standard in place, Steelman is realising the benefits and evolving its procedures to align them with its plans for continual improvement and growth. By achieving the new standard, Steelman also gains greater credibility in the market, whilst improving its own efficiencies. www.uk.sgs.com/ssc

engineeringmaintenance.info October 2011

Get More From Floors – Get More Safety Health and safety is paramount across the industrial sector - and Flowcrete UK’s Get More From Floors campaign is designed to show plant managers how floors can play a major role in supporting good working environments through the installation of a correctly specified Epoxy, Polyurethane or Methylmethacrylate (MMA) resin floor finish. From anti-slip surfaces, through to the use of lineage and demarcation zones to signpost people safely around a plant, Flowcrete floors are key to the smooth and functional running of manufacturing and processing areas. Now the subject is explored in detail by Flowcrete UK at the Get More From Floors online portal, available at www.flowcrete. co.uk/campaigns/get-more-from-floors Pulling together a variety of content, the Get More From Floors resource centre shares Flowcrete’s 30 years’ wide-ranging experience and flooring expertise to help plant managers make informed decisions about their flooring requirements. Get More From Floors, Get More Safety is the third of six subjects being explored throughout 2011 under the campaign, following on from the issues of floor durability and floor hygiene. Specific floor safety information is located at www.flowcrete. co.uk/campaigns/get-more-from-floors/get-more-safety Alan Dean, Managing Director of Flowcrete UK, said: “According to the HSE, one serious slip accident occurs every three minutes in the UK – most of which occur on a floor contaminated by water, grease or other substances. “Health and safety is a major concern faced by industrial manufacturers and, with this in mind, we have developed a number of flooring solutions to help reduce the risk of slips, trips and other accidents in the workplace - as well as improve workflow management to eliminate these problems at ground level.. “Our approach includes anti-slip floor finishes with an adjustable profile to suit client’s individual requirements. “Flowcrete’s team of flooring experts has developed the most advanced range of anti-slip solutions, with systems based on graded aggregates laid between coats, built into the resin matrix or scattered on to the surface of the floor. “The floor surface can be fine turned to meet the balance between slip resistance and cleanability, to ensure a fit for purpose flooring system is specified, suitable for either wet or dry processing areas. “Floors can also reduce risks within the industrial environment by being used as a platform for efficient workflow management, through the principles of 5S and lean manufacturing. “Bright signage, demarcation and instructional patterns can be incorporated at ground level to outline the different zones – marking out walkways and aisles, loading back and stacking areas, and other areas exposed to potential danger. “

Many of Flowcrete’s industrial flooring systems can be graded for positive slip-resistance - including Flowcoat SF41, Flowcoat LXP, Deckshield, Flowfresh HF and Flowcrete HF - to ensure a safe platform underfoot. Flowcrete UK’s latest innovation, FloorGraphix, allows the rapid installation of floor signage through the use of a printed graphic mesh sealed into the floor using a fast cure MMA resin. Colourful demarcation and signage can also be created through virtually all of the industrial flooring specialist’s systems, with a colour palette including a number of vibrant, high visibility shades to achieve maximum impact. Flowcrete’s extensive product offering also includes the industry-leading Industrial Floorzone concept, unique to Flowcrete UK. This system delivers the damp-proof membrane and high strength Isocrete floor screed, topped off with a performance resin floor finish – all from a single source and installed by Flowcrete’s approved contractor network. Flowcrete has vast experience within the industrial flooring industry - carrying out projects for Blue Chip clients including Bentley Motors, the RAF and BAE Systems - backed up with best in class customer and technical support services. For further information please contact uk@flowcrete.com Or visit us on the web at www.flowcrete.co.uk

engineeringmaintenance.info October 2011

EDITORS CHOICE

A Plan For Breaking Out Of Budget Jail I wrote this column for those who want to improve equipment reliability but feel as if they are stuck in “budget jail”. Assuming your fiscal year starts January 1, November and December is the time to plan your jailbreak! Most of you understand what I mean by budget jail. In fact, you are probably in the process of trying to pick the lock. For those who don’t know what I mean, I’ve listed some signs of what a budget jail look likes: 1. The maintenance budget isn’t built from scratch (zerobased budgeting) each year to consider all major expenses for the coming year. 2. The maintenance budget is, more or less, an arbitrary number (often last year’s budget less X percent) that must be reduced each year regardless of equipment condition. 3. Top management has little understanding for equipment overhaul and major maintenance cycles. Many cycles aren’t annual or more frequent. The cycles for equipment repair and overhaul are often two, five or 10 years. This can create performance spikes. 4. You never break the budget for planned investments, but the budget is often broken due to so-called unforeseen equipment repairs. The plant culture seems to indicate that equipment breakdowns are a valid excuse for breaking the budget, but investments are not. 5. If an investment creates a significant profit for the company in the long term but it breaks the budget for the current year, the investment will be denied. Do you recognize your plant in the points above? If so, I can tell you that it shouldn’t be that way, and that we must convince top management how to improve reliability. Continuing to preach the reliability gospel is good. But, is there something we can do to break out before we get the whole company sold on reliability? I think so.

In November/December, you will start performing detailed equipment inspections of your plant and/or area with your best maintenance people using basic inspection tools - flashlights, infrared temperature guns, stroboscopes, vibration pens and industrial stethoscopes. If you can, create a team of the best operator and maintenance technician you can find for the inspection rounds. Have the inspectors report back in a meeting where both operations and maintenance management are present. This action alone has merits. The found problems need to become work requests and prioritized. Work closely with operations to establish a meaningful priority system. The total cost of the potential breakdown must be considered, not just the maintenance cost. The key parameters to consider are the same as with any maintenance job: 1. Failure developing period: How long will the equipment last before breaking down? 2. Consequence of potential breakdown (safety, environmental, lost production, damages, repairs, etc.). 3. Risk that the breakdown actually will happen.

BREAK-OUT STRATEGY If you are in budget jail and have tried to get out by preaching reliability to the people above you but have made little headway, I have a plan. It will test your belief in that a focus on reliability works. Please note that if you are well on your journey into reliability excellence, this plan will not be as useful to you, but it may still work in focused areas. The idea is simple but requires courage. There is a budget allotted to your plant and/or area for the year. The plan is to break the maintenance budget (assuming it is needed) in the first quarter but regain the lost money with better reliability by the end of the year. You must be the judge in how much you can break the budget in the first quarter and still sit in your chair!

engineeringmaintenance.info October 2011

Along with the inspections, try to stop all break-in work that isn’t an emergency. A maintenance department can free up 10 to 30 percent of its resources by stopping these honey-do jobs.

SUMMARY Start doing detailed inspections in late 2011 . Prioritize the problems found and fix them even though you may have to break the budget early in the year. Work with operations and maintenance to get rid of non-critical break-in work to free up resources and/or save money on overtime and contract work. If you prioritize the repairs correctly early in the year, you will reduce maintenance cost through better reliability later in the year.

Steel Plant Back On Line With Belzona Wrap Pipework suffers from many different problems including erosion-corrosion, impact damage, adverse weather conditions and abrasion. Conventionally, problems such as these may lead to the entire system having to be closed down and drained before any repair process or replacement can begin. With the high cost of downtime, more and more companies are looking for time and cost-saving alternatives to replacing damaged assets. Belzona offer a simple, cost effective solution to securing leaking pipes. In September 2011, application services division, Belzona Technosol Limited successfully stemmed a gas leak on a 24 inch cast iron pipe at a steel works in Teesside. The pipe was the gas main between the coke ovens and the power plant and required an immediate solution. The leak was detected and once excavated a crack of 25cm length was found to be the cause. Belzona 1121 (Super XLMetal) was selected due to its extended working life, to pack the gasket and to create fillets on either side of the flange. A three layer wrap repair was then completed using Belzona

1121 and Belzona 9341 (Reinforcing Tape), ensuring a long lasting and reliable repair. The preparation, application and cure were completed within 2 days. The gas main was then reopened and tested at full pressure to the absolute satisfaction of the client. For further information on the products and services available from Belzona please visit www.belzona.co.uk or contact us on 01423 57641.

New Harsco Guide Takes Safety To A Higher Level A new publication issued by Harsco Infrastructure has been designed to help construction industry professionals re-appraise their safety procedures for operations which involve working at height. Intended for use by client and contractor staff at all levels, the new Harsco Infrastructure Guide to Working at Height is set to become an invaluable source of relevant information and best-practice guidance. The new 34-page document is believed to be the most up-todate, comprehensive and authoritative of its kind and draws on Harsco Infrastructure’s experience as a world-leading supplier of access, formwork, shoring and maintenance services and products to the construction and industrial markets. Its contents have been designed to help the reader understand the many implications of working at height, adopt best practice procedures, select the most appropriate equipment and access and offer guidance on its safe use. “Today more than ever, markets are converging rapidly to create an increasingly universal standard of safety,” comments Harsco’s Health and Safety SHEQ Director, Tony Horsfall. “Our aim in creating the new guide has been to help people understand the many issues which surround working at height

engineeringmaintenance.info October 2011

- a common, everyday situation which can have dramatic consequences unless it’s managed properly.” Included in the new publication is information on the selection of different types of access, collective fall and personal protective equipment, plus references to examples of site equipment and operator-related hazards. This is complemented by principal design standards for different types of access equipment, and explanations of the variations in safety requirements that exist between different European markets. Copies of the new publication are available by emailing info@infrastructure.com or visiting our members’ area at www.harsco-i.co.uk/register

INDUSTRY RECRUITMENT

New Emea Sales Manager IRISS, the leading infrared window specialist, has a new man at the top in EMEA sales. He is Patrick Christie, whose extensive experience in the facilities management industry and practical engineering skills eminently qualify him for his new role. Patrick’s career has been centred on the built environment for more than twenty years during which time he has managed critical facilities such as data centres and their infrastructures. An impressive range of electrical engineering, power electronics and HVAC qualifications underpin Patrick’s CV. This knowledge has allowed him to add considerable value to the management positions he has taken with various service providers. Patrick’s most recent appointment was with MITIE Facilities Limited where, as Account Director, he managed the corporate office facilities of Transport for London, a multi-million pound contract with a portfolio comprising 53 buildings. Services covered ranged from electrical distribution systems to building fabric maintenance. “I have been associated with Martin Robinson, the founder of IRISS, for several years and share his enthusiasm for creating a safer working environment for thermographers,” Patrick explained. “I have always taken a keen interest in infrared technology, it is an ideal method for cost efficient condition based monitoring. IRISS IR windows allow thermographers to perform routine, non-invasive surveys without having

any impact on operation or production and I welcome the opportunity to be part of a team whose business it is to maximise the safety and accuracy of this process.” IRISS inspection ports and infrared windows are becoming immensely popular in the UK and naturally Patrick is looking forward to working with UK customers to create new and safer inspection routines. He is also responsible for market development throughout the EMEA region which is served by a comprehensive network of IRISS distributors and agents. Patrick is now based at the new IRISS headquarters building in Chelmsford and may be contacted on T: +44(0) 1245 399713 | E: p.christie@iriss.com

Mutech’s Md Appointed By Abmec To National Safety Committee The Association of British Mining Companies (ABMEC) has recently appointed Colin Cameron as a representative on the UK national L6/10 committee. The Committee reports to the British Electrotechnical Committee (BEC), the UK Committee for IEC and Cenelec. Managing Director of leading UK electronics design and manufacturing consultancy, Mutech Ltd, Colin Cameron is one of only two ABMEC representatives on the prestigious committee. Colin Cameron explains: “As part of the IEC the L6/10 is responsible for issues relating to the safety of electrical and mechanical equipment used in hazardous areas (the IECEx scheme) across a wide range of industries, from oil and gas to mining and landfill.”

wealth of electronics expertise, particularly with intrinsic safety. He continues: “I want to take an active role, principally by looking after the interests of equipment manufacturers. My long term goal will be to contribute to the development of international standards and to work towards global harmonisation.” L6/10 balances the needs of various vested interests. On the one hand it prevents dangerous products from entering the market, whilst recognising the legitimate needs of manufacturers and users to introduce new products and techniques. Colin Cameron’s selection by ABMEC closely follows Mutech’s appointment of Mark Pitts as Design Manager at the Manchester based company. Mark also has extensive experience in participating in committees responsible for international standards for electronics.

L6/10 is the sole route for UK input into the IECEx scheme. In addition it is a forum for interaction with BIS etc on European concerns on ATEX and similar issues. Colin Cameron continues: “It comprises manufacturers, users, certification and government bodies, offering the UK perspective to the international committee.” The nomination is an acknowledgement of Colin Cameron’s

More information is available from Mutech Ltd, tel: 0161 872 0400 email: sarah.varney@mutech.co.uk www.mutech.co.uk

engineeringmaintenance.info October 2011

COMPRESSED AIR

The Best Just Got Better! BEKO TECHNOLOGIES are pleased to announce the launch of the new range of DRYPOINT RA compressed air refrigeration dryers with flow capacity from 20-9000m³/hr and pressure from 4-14 bar(g) and retaining the high inlet temperature capability of the existing range. UK Service Manager Chris Norris said “We have been very successful with the product claiming a significant market share for the free standing sales. We took advantage of the very low warranty defect rate and offered a simple “no quibble” warranty extension to 3 years and of course we hoped that the designers would not get over zealous about value engineering and replacing what I regard as key components in the product’s reliability with lower cost items which might affect the product’s integrity. We have all seen this happen!” Norris goes on to describe the changes made, “The product only needed some tweaking and we were pleased to see that the controllers were brought up to a high standard, the smaller units having a relatively simple display but doing all the necessary tasks including controlling the BEKOMAT level sensing drain, also allowing the drain test to be carried out from the control panel. Obviously I am always pleased to see service indication on products particularly very reliable products which can get abused because of this virtue. On the 3 phase line we have

scroll compressors fitted from RA1080. This helps keep noise and vibration down and allows a simpler connection, all helping to keep costs down. We have some new features such as Advanced Service Warning, Advanced Fan Control which allows the fan to run at 50% speed saving energy and helping to keep a constant dewpoint. All alarms and operating data are stored in the system to help prevent failures and if they occur to quickly diagnose the cause of the problem. The refrigerant has also been changed to R407C which has a significantly lower GWP (Global Warming Potential) than R404a. Chris Norris summarises by saying “We in the UK are very satisfied with the new range. We believe that we will get even stronger in the market by offering what customers want, reliability, performance to the specification, connectivity, and ease of maintenance via good information from the control system. We are confident that our DRYPOINT RA range will give customers the lowest cost of ownership and publish our pressure drop and total power input for customer scrutiny. It’s a pity not all do this. In fact some of our competitors publish neither and some just the power. It is really important to understand that the upfront cost of the product is only half the story! BEKO stock these products and offer them at a price that is good for such a quality product. The best just got better! BEKO Technologies Limited, 2 & 3 West Court, Buntsford Park Road, Bromsgrove, Worcestershire, England, B60 3DX. Tel: 01527 575778. Fax: 01527 575779 E-mail: info.uk@beko.de Website: www.bekotechnologies.com

“ Hertz Kompressoren has tailored its HSC Frecon Series Screw Compressors, the ideal choice for all kinds of industry and applications. Every screw compressor model is equipped with an exclusive screw block, constructed with the strongest materials and each compressor ensure exceptional performance, efficiency and long lasting maintenance life. Standard air compressors are designed to operate continuously at full capacity. However depending on the application, the need for compressed air varies significantly. Research has shown, that on average, only 50-70 % of the Compressor capacity is utilized. HERTZ FRECON models within the Variable Speed Controlled Compressor Series, give you the advantage to reduce energy costs by up to 35 %. Figures show a comparison of energy consumption between same sized ON/OFF-load compressors and HSC FRECON Compressors. This consists of cost in 5 Years, compressors running 4000hours/year with an average load ratio of 60% “on load” and 40% “off load” with today’s high energy costs.

engineeringmaintenance.info October 2011

Frecon shows remarkable savings in energy and also in total costs of the compressor. The payback time of the FRECON unit could be between 1 - 2 years. Hertz Kompressoren Limited - UK Tel : 0161 764 4160, Fax: 0161 764 2890 e-mail : meltem@hertz-kompressoren.co.uk Web Address : www.hertz-kompressoren.co.uk

Visit: www.engineeringmaintenance.co.uk

engineeringmaintenance.info October 2011

PRODUCT SPOTLIGHT – HEAT EXCHANGERS

Ultrasonic Cleaners for Intercoolers and Heat Exchangers Hilsonic announces a Bumper year for their range of Ultrasonic Cleaners specifically aimed for the cleaning of large scale Intercoolers, and Heat Exchangers. we are prowd to announce that our range of ultrasonic cleaners have proved to be a very popular solution to the problem of dirty heat exchangers and intercoolers, this interest has been increased significantly with our unique ability to offer custom built cleaners to meet specific requirements. Traditionally the approach was to replace a Heat Exchanger and Intercooler as there was no effective method of cleaning them. Our range offers a solution to this, effectively allowing our customers to clean and reuse existing Heat Exchangers and Intercoolers as opposed to replacing them. This offers a significant cost saving to the client as well as the obvious environmental benefit. Furthermore all our Equipment is built to last with an estimated twenty year life span and has easily serviceable components which we can provide as required. Since our launch we have received

orders from as far afield as Brazil, Tahiti, South Africa, as well as Europe and of course the UK. Industries that have been particular interested in this range include the Shipping Industry, Dry-docks, Shipyards, Power Stations, and Engine Refurbishes.” For further information contact: Darren Pyke - Technical Director, Hilsonic Tel: +44(0)151 639 6020 Fax: +44(0)151 334 7407 Email: sales@hilsonic.co.uk

PRODUCT SPOTLIGHT – HEAT EXCHANGERS

Fast And Competitive Service For Your Plate Heat Exchangers With regular pro-active maintenance, control of your heat exchanger’s condition and performance can be optimised. Tranter provides you with a safe, fast and competitive service for your plate heat exchangers, no matter which brand, including anything from programmed inspection to full annual overhaul. As an OEM manufacturer of heat exchangers for over 70 years, coupled with having the largest range of plates available in the market, Tranter can offer more than the usual service, with global resources and logistic support that can be used to your advantage. The Tranter service centre is available 24/7, has a vast range of stocked spares to suit a variety of brands and can manufacture complete replacement units if required.

engineeringmaintenance.info October 2011

Contact information: Tranter International AB Sales Representative Grosvenor House, St. Thomas’s Place Stockport, SK1 3 TZ, United Kingdom Switchboard +44-161 429 5680 Telefax +44-161 429 5681 sales@uk.tranter.com

PRODUCT SPOTLIGHT – HEAT EXCHANGERS

Easy To Clean All Welded Plate Heat Exchangers The Company Barriquand is specialized in the design and the supply of Easy to Clean All Welded Plate Heat Exchangers called PLATULAR® and patented by our company since many years. The PLATULAR® is of a robust construction manufactured from either stainless steel or higher alloys. To enable it to be broadly used with all different types of media, an independant and generous spacing can be provided between the heat transfer plates, whilst removable access covers and optional wash systems simplify routine cleaning and maintenance. The availability of PLATULAR® models, in a variety of length and flow configurations means that there is a

More information are directly available on our website at the address: http://www.barriquand.com

PLATULAR® for almost any application. PRODUCT SPOTLIGHT – HYDRAULIC REPAIR

Shepcote Engineering Is The Uk’s Leading Repairer Of All Types Of Hydraulic Cylinders, Sliding Piston Accumulators And Rotary Distributors. Housed within 25,000 sq ft premises with a 50 tonnes lifting capacity, is a specialist team with over 30 years experience, providing hydraulic solutions to industry. Our aim is to minimise your downtime by providing a comprehensive and cost effective repair service for the following: •

• • • • • • • •

Repairs to all types of cylinders with bore sizes up to1600mmand strokes of 20metres, back to or exceeding manufacturer’s standards. On site advice on repairs and modifications to your existing cylinders. On site removal, refitting and commissioning of cylinders. Fully equipped machine shop to enable repairs to all types of plant and equipment. Welding and Fabrication Services. Grinding and recoating of piston rods. Hydraulic testing up to 800 bar. Hydrostatic testing up to 1000 bar. Collection and delivery service.

Shepcote Contact details – Unit B Fabrication Building, Davy Industrial Park Prince of Wales Road, Sheffield, S9 4DZ Tel: 0114 2562505 | Fax: 0114 2611910 Email: enquries@shepcote-eng.com www.shepcote-eng.com

engineeringmaintenance.info October 2011

PRODUCT SPOTLIGHT – ELECTRICAL TESTING/HANDHELD INSTRUMENTS

Durabook U12C – Affordable Tough Technology The Durabook U12C is tough, light and slim with an integrated ergonomic handle, shock resistant LCD & HDD mounting, smart battery protection, integrated stylus and OSD Quick Menu. The convertible Touchscreen that twists from normal laptop to easy to hold tablet within seconds gives you the best of both worlds with the normal keyboard layout of a Laptop but the ease of use of a tablet. Tested to MIL spec. 810 G, the magnesium alloy case helps to protect the vital components of the notebook such as the motherboard, hard drive and memory module, the keyboard is waterproof and the ports protected by dust covers. With a 12.1” Touchscreen, Windows 7 or XP Pro, latest Intel 5 Dual core processor, 2GB RAM & 320 GB hard drive, Durabook is the obvious choice of platform for any Windows based program. Designed for use on site or in the office with 3 USB ports, Bluetooth, WiFi and a built-in True RS 232 9 pin serial port.

For further information visit: www.mavericktechnology.co.uk or call 01280 816 333

engineeringmaintenance.info October 2011

PRODUCT SPOTLIGHT â&#x20AC;&#x201C; DATALOGGERS

Which Grant Squirrel Portable Data Logger? To determine the most suitable Squirrel data logger for your application, ask how many inputs are required and which type; how often are readings required; how much data needs to be stored; how will the data logger be used; how will you communicate with it; and any other special requirements the application might have. to 100 readings per second (on up to 4 channels). For

Grant data loggers offer various types of signal inputs:

more information visit www.grantinstruments.com.

Voltage, Current, Bridge, Strain, Load, Pressure, Level, PH, Relative Humidity, Dew Point, Temperature (RTD, thermistor or Thermocouple), Event or State and pulse count. Communication with the data logger for set-up, monitoring and downloading data can be done using a serial RS-232 connection, USB or Ethernet interface or a Wi-Fi connection. Grant`s Squirrel data loggers offer

Contact details: Grant Instruments (Cambridge) Ltd. Shepreth Cambridgeshire SG8 6GB Tel. +44 (0) 1763 260 811 Email: acquisitionsales@grantinstruments.com www.grantinstruments.com

up to 32 universal channels with logging speeds of up PRODUCT SPOTLIGHT - HAZARDOUS LIQUID CUPBOARDS

Improve Health And Safety In A Multitude Of Operations! Fume filtration hoods from Esco GB greatly increase operator protection by creating a safe working environment when using solvents, acids, adhesives, fuels, organic compounds and other volatile chemicals across a multitude of applications. Air containing fumes from the working area and surrounding environment are controlled by regulatory airflow patterns and passed through active carbon filters

If you have an application which you think may require

(specific to your application). Following which, safe clean

containment, give us a call or drop our applications

air is recirculated back into the working environment.

consultant Dr Einesco an email and he will happily advise further.

Whether you require a small one man area of containment or a multi-person process, Esco GB can offer a solution within a reasonable budget, while helping you provide safer working conditions for operators.

Tel: 01725 514555 Email: dreinesco@escogb.com Web: www.escogb.com

engineeringmaintenance.info October 2011

PRODUCT SPOTLIGHT – CONDITION MONITORING

SIHIdetect – The Innovative Sensor Different from other devices, the SIHIdetect has the ability to combine high frequency noise data (up to 5600 Hz) with conventional vibration values in order to reveal the true condition of rotating machinery. This very small Condition Based Monitoring component can be conditioned remotely and simply left to transmit the on-set of upset conditions before any machine damage occurs. Centring on the highly sensitive three-axis accelerometer, this unique device has the capability to identify: hydraulic cavitation, bearing wear, impeller wear, misalignment, detrimental pipestress, end of curve turbulence and magnetic-drive problems. Standard software provided with the SIHIdetect enables users to navigate through a simple computer interface, allowing them to calibrate the system or change the threshold values of allowable vibration velocity. Available as an optional extra, SIHIvibrosoft software has been developed purposely for professional analysis of data generated by the SIHIdetect sensor. Detailed evaluation of the data can subsequently be made in order to reveal very specific aspects of vibration encountered.

Main Features of SIHIdetect • • • • • •

Cavitation and process turbulence Simple to connect LED display Available Ex All rotating machinery DCS integration and continual monitoring Sterling Fluid Systems (UK) Ltd Tel: 0161 928 6371 Fax: 0161 925 2129 Internet: www.sterlingSIHI.com

PORTABLE TESTING

ChlordioX™ Plus - New Digital Instrument for Portable Testing Of Chlorine Dioxide, Free Chlorine and Chlorite The ChlordioX™ Plus builds on Palintest’s innovative sensor technology, providing a new portable testing solution for Chlorite. The ChlordioX™ Plus is ideal for applications such as drinking water, produce washing and paper/pulp bleaching. Using the company’s patented disposable electrical sensor technology and a unique sequential methodology, the instrument offers superior analytical performance compared to DPD or Lissamine Green methods, while reducing the potential for user error. Palintest’s chronoamperometric method, using the ChlordioX™ Plus, quickly, accurately and precisely measures Chlorine Dioxide and Chlorite between 0.02 - 50 mg/l, and Free Chlorine between 0.02 - 10 mg/l. Results are displayed in under a minute for the Chlorine Dioxide and Free Chlorine tests, while the degassing process for determining Chlorite levels takes less than 6 minutes. The kit contains all the equipment required to start immediate testing, including degassing equipment, reagents and sensors for 100 tests of each parameter. The ChlordioX™ Plus device is battery-powered (4xAA), lightweight (975g), and portable (170x126x116mm), making it ideal for laboratory or field testing. The instrument incorporates

a backlit LCD screen and is controlled by a simple to use menu. Up to 500 readings can be stored in its on-board memory, while a waterproof USB connection enables quick downloading of results to a PC. Palintest Ltd. Tel: +44 (0)191 491 0808 Fax: +44 (0)191 482 5372 E-mail: sales@palintest.com Website: www.palintest.com

engineeringmaintenance.info October 2011

PRODUCT SPOTLIGHT – FLOW MEASUREMENT

NEW ENTF range of Flow Meters from ENVITECH LTD Envitech have recently expanded their range of both closed pipe and open channel flow measurement systems. The latest to be offered is the ENTF range of “time of flight” closed pipe meters. These meters compliment our existing range of Magflux meters by offering clamp on sensors and portable units, aswell as being able to measure non conductive liquids. Fixed site, portable and hand held units are all available, as are different sensor formats including clamp on, insertion and integral flanged systems. They are easy to fit,and offer no obstruction to flow. A similar range is available with two temperature inputs making them into energy flow meters, ideal for energy loss and efficiency studies.

Further information contact: Envitech Ltd. Unit 20 Lambourne Crescent Cardiff Business Park Llanishen Cardiff CF14 5GF Tel: 02920 337134 Fax: 02920 337137 e-mail: sales@envitech.co.uk web page: www.envitech.co.uk

PRODUCT SPOTLIGHT – DATA LOGGERS

Save money on high temperature data loggers TM Electronics now offer a low-cost high temperature data logger for harsh environments - industrial dishwashers, washer disinfectors, pasteurisation and thermal disinfection. For just £185 (including software) this compact, submersible logger is robust, waterproof and withstands temperatures of over 100°C. Each additional logger is priced at just £115. With a high-visibility case and fast-response external probe, the logger records actual temperatures achieved within the equipment being tested, which can then be downloaded to computer via a USB or serial download pad. This ‘wireless connection’ eliminates the need for sockets with waterproof caps which can easily be lost or forgotten.

Other features • • • • • • •

Waterproof to 15m 32,000 reading capacity User-programmable logging interval 2 user-programmable alarms Delayed and trigger-start options 3 stop options Low battery warning

engineeringmaintenance.info October 2011

For more information +44 (0)1903 700651 sales@tmelectronics.co.uk www.tmelectronics.co.uk

engineeringmaintenance.info October 2011

PRODUCT SPOTLIGHT – CONDENSATE SYSTEMS

Steam and Condensate Systems For more than 75 years Kadant Johnson has applied a systematic, application specific approach to solving steam and fluid handling challenges. Our extensive process knowledge in steam system engineering and the ability to integrate these systems with process equipment provides industrial process plants with cost effective solutions to steam distribution and energy conservation. The efficient integration of Kadant manufactured products into a functioning system will define the success of a capital project. Kadant Johnson’s line of steam speciality products, including steam jet thermo-compressors, direct steam injection water heaters, condensate pumping stations, rotary joints and syphons can be seamlessly integrated into the steam distribution system for thermal efficiency. To complete the integration of hardware and systems, we offer technical and mechanical services ranging from training, to installation, maintenance, troubleshooting and turnkey project management. With references across the globe, you can be confident when selecting Kadant Johnson as your integrated steam and condensate systems partner.

• • • •

Packaged steam system solutions. Fully assembled skid mounted systems. Global technical and application support. Single source, integrated systems approach. For further information, please contact; David Moss – UK Sales Manager- Fluid Handling, at Kadant United Kingdom Ltd Telephone 0161 764 9111 Email: david.moss@kadant.com

PRODUCT SPOTLIGHT

High Frequency Accelerometers From Pcb Piezotronics Operate To 30Khz For Gear Mesh And Bearing Fault Analysis PCB Piezotronics, a world leader in vibration, acoustic, pressure, force and torque sensors, has launched a high frequency industrial accelerometer that operates to 30kHz for gear mesh and bearing fault analysis. The 621B40 works with online or portable monitoring systems to provide reliable and effective vibration monitoring. It operates to 30kHz even with a magnetic mount – a feat almost unheard of in the condition monitoring industry – and captures high frequency gear mesh faults that are often missed during routine route-based measurements. Due to the sensor’s high frequency range, it is ideal for measurements on high-speed compressors, gear boxes and turbomachinery, to provide early detection of impending problems. When analysing the condition of an integral gear compressor, for example, a technician needs to be able to examine gear mesh frequency and its sidebands. The harmonics of the gear mesh and natural frequency of the gears play a significant role in diagnosing potential machinery faults. With a magnetically mounted 621B40 supplying a response to more than 30kHz, a vibration analyst can obtain precise measurements of these revealing high frequency phenomena.

For even higher frequency measurements, PCB Piezotronics can supply its 352A60 sensor that features an upper frequency range of 60kHz at ±3dB and is designed to work with a stud mount adhesive base (supplied). Principal performance specifications of the 621B40 sensor include sensitivity of 10mV/g, measurement range of ±500g and frequency range from 1.6Hz to 30kHz (±3dB). Shock resistant to 10000g peak, the 621B40 operates over the temperature range -54 to +121°C. engineeringmaintenance.info October 2011

BUYERS GUIDE 2011

engineeringmaintenance.info October 2011

BUYERS GUIDE 2011

engineeringmaintenance.info October 2011

BUYERS GUIDE 2011

engineeringmaintenance.info October 2011