SEPT/OCT 2008 BUYERS GUIDE RECRUITMENT CONDITION MONITORING ISSUE 7
THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS
PUMP UP
the volume
INDUSTRY NEWS
TURN TO PAGE 32 FOR THE FULL STORY
LEAN MAINTENANCE
BEARINGS
PLANT EFFICIENCY
www.engineeringmaintenance.info
Complete confidence with CompleteCARE™
Atlas Copco’s Seven Year Warranty Service centres and authorised distributors
Atlas Copco’s Authorised Distributor Network now offers CompleteCARE™ Seven Year Warranty, to give you complete confidence and complete peace of mind. Available on all oil-injected screw compressors up to 90kW. So confident are we of the reliability of our compressed air equipment that all you need do to take advantage of this offer is to have your compressors serviced by one of our authorised distributors in line with our preventative maintenance recommendations. And complete peace of mind is yours. For more information and details of your nearest local authorised distributor call 0800 181 085 or e-mail gba.info@uk.atlascopco.com Committed to your superior productivity
Atlas Copco Compressors Ltd Swallowdale Lane Hemel Hempstead Herts HP2 7HA Phone: 01442 261201 Fax: 01442 234791 e-mail: gba.info@uk.atlascopco.com
www.atlascopco.co.uk For more information quote EMS Enquiry No. 101 on IBC
PAGE
MANUFACTURING RELIABILITY Lean on me
3 PAGE
LIGHTING Illuminating hidden costs
25 PAGE
WATER MANAGEMENT Water tight maintenance
27 PAGE
PUMPS AND VALVES
28
ExCel with your energy costs
PAGE
MANUFACTURING EFFICIENCY
33
Increase turnover by 100 percent
PAGE
MECHANICAL ENGINEERING
35
Maintenance goes supersonic
MAKING maintenance valuable We read and hear the "R" word just about everywhere we turn lately, but what impact might a recession — if we're in one or if we slide into one — have on the maintenance sector? Well, in any economic slowdown engineers might evaluate equipment purchases more closely, try to stretch equipment use with duct tape and baling wire, and hope to get by a little longer with what they already own. But research shows that industrial personnel are often more productive and more efficient — that means more profitable — when working with a newer technology and equipment that doesn't break down. Plus, if you're an engineer who borrows to buy, you might take a closer look at current interest rates. Recession or not this might be the perfect time to replace or upgrade. Industry does not stop working, and this is more true now than it was 10 or even five years ago. Unlike many other industries, maintenance is recession resistant because the work is always out there. Equipment faults don't go away, they continue to cost money and deteriorate. Plus many industry managers, and public agencies have grasped the concept of preventive maintenance, and they understand that pennies spent now could be a pound saved later. So your company is still going to need their equipment, repaired, and upgraded. Recession or not you can still use your expertise and your service to make an impact on your company’s productivity. PUBLISHER’S COMMENT
EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer Idhammar Alan France, Mark Haarman editorial@engineeringmaintenance.info
WEB MANAGER: Oliver Gibbs info@engineeringmaintenance.info DATABASE MANAGER: Steve Hill TECHNICAL MANAGER: Igor Seke
Published six times per year by EMS Annual subscription:
EMS MSL Group Cobalt House, Centre Court Sir Thomas Longley Road Rochester, Kent ME2 4BQ +44 (0)1634 731646
ADVERTISEMENT SALES: Michael Dominguez michael@engineeringmaintenance.info Paul Miles paul@engineeringmaintenance.info Paul Reynolds preynolds@engineeringmaintenance.info
www.engineeringmaintenance.info
THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS
CREATIVE: Ric Cooper production@engineeringmaintenance.info ARTWORK PRODUCTION: Elaine Cooper production@engineeringmaintenance.info
UK FOC Rest of World £90 © 2008 EMS
Articles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every effort is made to ensure the accuracy of information published. No legal responsibility will be accepted by the publishers for loss arising from articles/information contained and published. All rights reserved. No part of this publication may be reproduced or stored in a retrieval system or transmitted in any form without the written consent of the publishers.
The Engine of British Industry
Since the pioneering days of jet propulsion, HPC has been a driving force in the design and production of air compressors that have powered the UK's most advanced and successful manufacturing businesses. Contact HPC's specialists to optimise the reliability, efficiency and economy of your compressed air systems.
Call 0845 430 0472 or visit www.hpccompressors.co.uk For more information quote EMS Enquiry No. 102 on IBC
Performance, Precision, Partnership
Reliability and maintenance management expert, president of Idcon, Christer Idhammer, explains how manufacturing reliability enables cost effective process improvements
Lean on:
MANUFACTURING RELIABILITY Lean manufacturing, including lean maintenance, is a well known concept in the United States and in Europe – one which has increased in popularity in the past five years. Simply put, the lean concept should result in products being manufactured on time and with less resources. It doesn’t always mean doing more, as that can result in waste, but it does mean that items that have been sold should be produced when they need to be delivered. To become lean it is imperative to prevent maintenance needs and to perform the remaining maintenance more effectively. If the previous concepts are implemented, then the production reliability will increase and thus the production costs, including maintenance costs and costs for storage, will decrease. In effect, all losses in the manufacturing and delivery of raw material and delivery to the customer must be eliminated. Focussing on the manufacturing phase, the biggest losses in maintenance, and therefore the biggest improvement opportunities, include: Manufacturing reliability loss in quality stop times loss in speed
Partnership between operations – maintenance – engineering reliability and maintenance related design operator based maintenance Eliminating the root cause of the problem choose problem to eliminate eliminate problems educate and teach
Storage reduce store value while preserving service level to maintenance Integrating increased knowledge and skills educate and train to enable multi craft or multi skills implement flexible work systems
IMAGE 1. It isn’t always obvious where improvements in the manufacturing chain will be the most cost effective. Flow of a product is the result of Capacity x Reliability. At first glance you could believe that C is the bottleneck in the production chain since capacity there is 316 pieces per hour compared to the higher capacity in A (356) and B (333). If you calculate the flow you will find that the bottleneck is actually at manufacturing stage B. This is compensated and hidden by increased storage of work in progress (WIP) so it can sometimes seem that throughput is not a problem. WIP is a big hidden cost for a lot of companies. With low reliability, throughput of product in the manufacturing chain takes longer and the costs are increased for WIP.
Your Inefficient Motors are Wasting Money Are your motors overrated, are they running at their most efficient, perhaps their load is adversely affecting their operation? Unless you test your motors you will not know the answers. With Baker condition monitoring equipment, data from on and off-line motors can be quickly collected and analysed and action taken to improve efficiency and avoid critical failure. The Baker Explorer on-line tester offers a comprehensive view of motor health whilst the motor is running. It will also identify rotor bar, power quality, bearing and other mechanical issues.
The AWA Winding Analyser offers an automatic testing programme enabling less skilled staff to complete tests successfully, combining surge, polarization index, DC Hipot, megohm and winding resistance tests in one field-portable unit
FREE Guide Call now for your copy of How to Prevent Motor Failure and Reduce Energy Costs
Whitelegg Machines, Dorking RH5 4LQ tel: 01306 713200 www.whitelegg.com email: sales@whitelegg.com
3
For more information quote EMS Enquiry No. 103 on IBC
EMS September/October 2008 www.engineeringmaintenance.info
International Trade Fair for Industrial Maintenance
For more information quote EMS Enquiry No. 105 on IBC
14–16 October 2008 • M,O,C, Munich
Maintenance – Your key to success. MAINTAIN is the leading marketplace for momentum, strategies and service concepts in the industrial maintenance sector. As the industry’s most important gathering, it brings together decisionmakers in the manufacturing and processing industries who use the international trade fair as a communications platform. And they have a common goal: to promote innovations and service solutions in close dialog. MAINTAIN – The trade fair for industrial maintenance.
Order your ticket online now and save up to 50%!
www.maintain-europe.com Hotline (+49 89) 9 49–5 53 68 Pattern Ltd., Richmond, Surrey TW9 2LL Phone (020) 8940 4625, Fax (020) 8948 1442, info@pattern.co.uk
For more information quote EMS Enquiry No. 104 on IBC
For more information quote EMS Enquiry No. 106 on IBC
IMAGE 2. By raising the reliability in step C to 83% the increased throughput is 260 per hour. WIP is reduced since the manufacturing steps are now balanced. Other solutions include increasing capacity by investing in a parallel machine for C. However, this would lead to unnecessarily high capacity in step C. Moreover the cost of buying more capacity is about ten times higher than investing in measures that will increase reliability.
Over manufacturing making more than has been sold manufacturing too early Over maintenance perform too much and incorrect preventive maintenance perform preventive maintenance before it is needed incorrectly prioritise corrective maintenance Use new technology less maintenance required better maintainability smart tools and methods All these areas need to be examined in detail, kicking off with the fundamental concepts behind manufacturing reliability. The sub-target behind lean manufacturing is to reduce WIP and speed up throughput in the manufacturing chain. This can be achieved by addressing reliability, which includes quality, time and speed. Lean maintenance therefore has a crucial role in improving the reliability of manufacturing equipment and with the manufacturing process ever more dependent on automation, good maintenance is increasingly important. Availability or reliability? Many organisations use availability as a key measurement for manufacturing efficiency, however availability encompasses only the percentage of planned time, or available time, that a production process produces. Availability excludes the quality of that which is produced. In fact, producing something that isn’t up to standard is often more expensive than producing nothing at all. Conversely, to slow down a process because, for example, a part of the production process can’t operate at full speed, is also expensive. For this reason, it is important to focus initiatives on all aspects of manufacturing reliability: quality, time and speed.
Manufacturing reliability can be measured in various ways and can be expressed simply as: how much is manufactured at the right quality divided by how much could have been manufactured at the right quality. Or, % Quality x % Time x % Speed. Overall nothing should be manufactured before it has been sold and is to be delivered. In many heavy process industries it is still common practice to produce as much as possible. Lean thinking on the other hand teaches that nothing should be produced until it needs to be delivered because it has been sold. Computer companies present a good example. When you order a computer from Dell, for example, the order is sent to production planning, which assembles the computer ready to deliver within a few days. Instead of having all types of computers in storage, the whole company’s economy including cash flow, liquidity, costs for materials and material storage and capital costs are affected. Automation equals maintenance Producing things just in time via a lean production process is impossible if production reliability requirements are very high. With a raised automation level the company becomes more dependant on reliable equipment - in other words maintenance. Reliable production equipment is the most important result of the maintenance operation and it can be seen as the maintenance department’s route to income generation. To become lean it is important to identify where the greatest savings could come from. What is the worth of reducing the difference between how good you are and how good you could be? In a market situation where you can sell everything you can produce, the equation is simple. In certain industries the sale price of what you are selling can fluctuate
drastically. In that case calculations should be based on the average sales price and variable cost over, for example, five years. Average sales price five years - £510/unit Average variable cost five years - £340/unit Benefit per produced, sold and delivered unit - £170/unit The value of producing and delivering a sold unit is £170. If you currently produce and deliver 25,000 units per year and your production reliability is 88% but it is possible to reach 94% then the value of increasing production reliability is 6%. 1500 units x 170 = 255,000 £ per year. The next question is whether it is possible to reach even better results by focusing on lowering maintenance costs. Could it be more beneficial to lower maintenance costs if manufacturing reliability is maintained at 88%? The answer seems obvious, but it isn’t unusual that economists are so focused on lowering visible costs that they don’t see the invisible opportunities that are concealed in increased production or faster product throughput. A concept worth repeating many times, is that by increasing manufacturing reliability, manufacturing costs, including maintenance costs will decrease. If you can’t sell the increased volume that you can reach with the higher manufacturing reliability, then the savings most often lie in more reliable and faster delivery of goods sold, less energy expenditure, better safety and less overtime. www.idhammarsystems.com Reader Reply Number: 300
Christer Idhammar, president Idcon Inc President of Idcon in the USA and founder of the Idhammar group of companies, Christer Idhammar, will address further steps to lean manufacturing in the next issue.
5 EMS September/October 2008 www.engineeringmaintenance.info
INDUSTRY NEWS
FAST INSTALLATION, FASTER REACTIONS Reduced air losses and faster reaction times are two of the benefits claimed for IFM's latest AirBox, which is available in nine variants. A new design means the AS-i AirBox is also easy to install, clipping onto the base with no need for tools, while the cable can run in three directions for neater installation. New non-overlapping solenoids offer additional air switching options of two 3/2-way valves, one 5/2-way valve or one 5/3-way valve with blocked centre position. Pressure resistance is enhanced up to 12 bar and the new AirBoxes have extended addressing. A fault LED and LEDs for indication of the logical state of the PLC outputs are standard for all versions.
IFM's AS-i AirBox clips onto the base unit with no tools
www.ifm.com Reader Reply Number: 301
A thrilling performance Equipment from Ashtead Technology Rentals is set to appear in a television adaptation Ashtead's Olympus Iplex FX videoscope is to feature in TV thriller, Above Suspicion
of Lynda La Plante’s latest thriller. The production company hired an Olympus Iplex FX videoscope to portray authentic crime investigation scenes when filming Above Suspicion, which will air in November. The videoscope is designed for industrial inspection, providing portable and intelligent remote imaging with an internal battery providing two and a half hours operating time. Head of research at La Plante
Productions, Cass Sutherland, said: “The police use remote visual inspection equipment to investigate crime scenes without interfering with potential evidence so we needed an instrument to be used by the characters on screen. “Ashtead not only helped us decide which videoscope would be most appropriate, they also delivered the device quickly and efficiently.” www.ashtead-technology.com Reader Reply Number: 302
WATER GOOD SOLUTION Predictive maintenance is proving increasingly popular in the water industry where it helps improve asset performance. One solution is the Artesis motor condition monitor (MCM), said to provide traditional condition monitoring benefits at a fraction of the complication and cost. Using a model-based approach, Artesis MCM provides complete monitoring and diagnostic capabilities for most electric motor driven equipment. Installation costs are said to be low, with no need to access the driven equipment for sensor installation. Once installed, the system trains itself to recognise normal performance, following which it continuously monitors the equipment for possible faults. When a fault is detected, the system
provides a diagnosis and indicates severity so the user decide on the most appropriate intervention. Artesis MCM is particularly good for inaccessible equipment like submersible and borehole pumps and has already been installed by one company providing water services to a major city. In the first year of operation, the system reduced maintenance costs by around 10 per cent by avoiding breakdowns and reducing spare parts. After three years, no unpredicted breakdowns had occurred, leading to the inclusion of Artesis MCM units as a standard element in all new build specifications. www.artesis.com Reader Reply Number: 303
6 EMS September/October 2008 www.engineeringmaintenance.info
Service standards flying high Aircraft equipment manufacturer, Messier Dowty, is to install five new ovens fitted with ABB instrumentation, including temperature controllers and videographic data recorders. The order expands ABB's 50-year service and support contract with the manufacturer of aircraft landing gear, which currently sees ABB take responsibility for around 200 temperature instruments across the site. Instruments in the new ovens will be used to measure the performance of processes such as heat treatment and surface finishing to ensure they remain within strict tolerances. ABB’s service engineer for Messier Dowty, Bob Clow, said: “Inaccurate temperature measurement during the heat treatment process could result in components not being properly treated, potentially leading to failure during operation. Predictive maintenance ensures optimum instrument performance from routine checks through to installation, commissioning and equipment upgrades.” As part of its service contracts, ABB also calibrates and certifies its temperature equipment to the AMS2750 standard covering thermal processing equipment used for heat treatment processes. www.abb.com Reader Reply Number: 304 Predictive maintenance keeps ABB instruments at optimum performance throughout their service life
CONDITION MONITORING
Protect your critical rotating plant
SENSONICS predictive maintenance systems are used and appreciated around the World, providing cost-effective, monitoring for all types of critical rotating plant. O Vibration O Turbine
For more information quote EMS Enquiry No. 107 on IBC
Monitoring
Supervisory
O
Displacement Measurement
O
Overspeed Protection
O
Bearing Condition
O
Seismic Monitoring
O
API 670 Compliance
O
ATEX Hazardous Area
O
IEC 61580 SIL
Maintenance software just got easier
G
G
G G G
Delivering maintenance software benefits since 1990 Proven by hundreds of customers in a wide range of industries Flexible system to meet your needs Now even simpler to buy, implement and use. Fully feature systems start at £1490
Don’t taketake our our word for for yourself. Don’t word it. Call us now, and find out for yourself. Call us now, and find out for yourself.
keeping industr y turning Tel: 0191 2963816 email: sales@cayman.co.uk Web: www.cayman.co.uk For more information quote EMS Enquiry No. 108 on IBC
T: +44 (0) 1442 876833 - sales@sensonics.co.uk
www.sensonics.co.uk
Northridge Road, Berkhamsted, Herts HP41EF
For more information quote EMS Enquiry No. 109 on IBC
INDUSTRY NEWS
FLOW METER CUTS ENERGY COSTS Suitable for use in gas, steam and liquid applications, Deltaflow flow meters from Flowline are said to offer precise and economical performance to achieve energy savings. These differential pressure probes measure flow in pipes and conduits and can be used in a variety of industries. In power plants, for example, Deltaflow can meter all gaseous media including feed air, preheated air, recycled stack gas and flue gas. It can also meter media with high particulate content, less than 200g/m2, live steam, low/mediumpressure steam and feed water, all tested per PED97/23/EG with CE certification. Exact measurement of combustion exhausts means efficiency levels can be adjusted for optimum performance and because pressure loss levels are low,
Deltaflow probes measure flow in gas, steam and liquid applications
users can specify pumps, blowers and compressors with narrow profiles, resulting in further energy savings. The meters can also be used in chemical and petrochemical industries for metering products, exhaust or flue gasses, inert or aggressive media as well as for measuring biogases and sewage gasses in the water and wastewater treatment industries. The Deltaflow series can be used on pipe diameters from three to 15,000mm and pressure ranges span zero to100 bar, up to zero to 690 bar. Temperature range is from -200 to 1240ยบC and the unit is available with a weather-proof casing for outdoor applications. www.flowline.co.uk Reader Reply Number: 305 Highlighting kerbs and steps reduces accidents such as slips and trips
Transforming oil management One of five HSL workstations supplied to EDF featuring reservoir tanks for oil extraction during transformer maintenance
Surface coatings and fabrication specialist, Hi-Tec Spray (HSL) has provided a spray booth, test booth and a full transformer oil management system to EDF Energy Networks. The equipment, supplied in partnership with Unipart, will be used by EDF as part of its ongoing substation maintenance programme. Within the oil management system five, temporary, reservoir tanks with integral workbench tops enable the extraction of oil from the transformers to facilitate repair work. Each tank houses various level switches to assist controlled removal.
Each station also has a Graco air operated Husky 1040 double diaphragm pump that can transfer oil to or from any of the 500l stainless steel reservoir tanks. To safeguard against leaks or major spillage all are mounted on a fail-safe bund. For straightforward oil changes, two 800l intermediate bulk containers, also with Graco 1040 pumps are used to vacate all oil from the transformer. As no repair work is necessary, these skid modules have no need for a benchtop facility, using a forklift truck instead to enable oil changeover in a more convenient environment. Two custom built booths complete the project, including a spray booth equipped with an airless manual spray unit and a smaller test room enclosure.
Slips, trips and falls can be reduced using Watco high visibility paint to highlight hazards such as kerbs or steps. Suitable for use on concrete, stone, brick, masonry, asphalt and similar porous surfaces, the paint contains fluorescent pigments to improve visibility. It can be applied by brush or roller to damp surfaces and only one coat is normally required. The paint is also ideal for line marking and walkways and offers resistance to UV and weathering.
www.hitecspray.co.uk Reader Reply Number: 306
www.watco.co.uk Reader Reply Number: 307
BRIGHT IDEAS ON SAFETY
Forces attracted to fuel savings Magnetic fuel conditioning units supplied by Magnatech Fuel Conditioning have been installed across five MOD bases in England. Magnatech installed the units on all types of gas and oil burners from a single domestic to a large CHP unit or main boiler room. Previous MOD technology trials
indicated that the units achieve payback within a year, with the installed units now saving more than their purchase price every year with no maintenance or running costs. This figure is rising as fuel prices soar. To realise these savings, the Magnatech units are fixed to the
outside of the gas train or oil line, while the boiler remains in full operation. No pipes are cut and there are no fees for third party assessment. According to Magnatech, fuel consumption is reduced by as much as 10 per cent with magnets losing just one per cent of their power in 100 years.
8 EMS September/October 2008 www.engineeringmaintenance.info
www.magnatechfuel.co.uk Reader Reply Number: 308 Five MOD bases in the UK are now equipped with Magnatech fuel conditioning units
For more information quote EMS Enquiry No. 110 on IBC
For more information quote EMS Enquiry No. 112 on IBC
Dust and fume extraction hoses from Masterflex
Temperature range -260°C to +1100°C Size range 38 mm to 900 mm Very flexible, small bend radius Long service life, low operating costs
•• Visual Planning for Save money by planning Maintenance and Health work more efficiently & Safety • Spend more time being productive at a glance • Information
• Keep track of parts • Complete system + P&P and VAT • £150 Reduce Paperwork
Suitable installation and connecting systems
Tel: 01732 871417 Fax: 01732 840470 sales@tcardsdirect.com
For more information quote EMS Enquiry No. 111 on IBC
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 on IBC
For more information quote EMS Enquiry No. 114 on IBC
INDUSTRY NEWS
Standing the test of time UNDER PRESSURE
WORKING
ABB's ABB's gas gas detection detection system system replaces replaces aa 30-year 30-year old old ancestor ancestor product product at at Snowdonia's Snowdonia's underground underground substation substation
When the Dinorwig hydroelectric substation in Snowdonia needed to replace its 30-year old gas detection system, engineers chose an ABB AK100 gas analyser to do the job. Interestingly, the technology at the heart of the new katharometer is exactly the same as its predecessor because the essential approach has not been bettered. Designed to check for leaks of sulphur hexafluoride (SF6) from high-voltage contactors, the katharometer detects the presence of a gas by comparing the thermal conductivity of a sample with that of a reference gas – in this case air. Any leaks could lead to both suffocation and arcing in the switchgear. The £17k Dinorwig system therefore monitors six sample points using a common katharometer and a stream switching unit comprising a timer and valves. ABB product systems manager, Andy Jones, said: “The AK100 uses established technology. The peripherals may have changed, but the basic technology is so robust that no-one has ever come up with a better alternative.” www.abb.com Reader Reply Number: 309
Teseo has extended its modular aluminium pipeline system with a new DT drilling jig, which allows use of a 19mm drill bit, the correct bore size for an outlet plate that carries 3/4inch treaded connectors. In addition a new outlet plate with 11/4 inch thread is now available for use with the HBS 80 and 110 pipeline profiles. As ever, there is no need to turn off the compressor to expand the system using the new equipment. To open a new air point on an established system under full pressure, users fix the outlet
plate on the pipe run, screw a ball valve to the outlet plate, screw the Teseo drilling jig to the ball valve, open the ball valve to allow the drill bit through and drill the aluminium extrusion piping. Swarf is collected in the drilling jig. Remove the drill bit and shut the ball valve, remove the drilling jig, couple up the additional airline to the ball valve and the new air point is installed. Users experience no loss of pressure, no down time for the rest of the plant and an instant delivery for a new workstation.
Teseo's drilling kit enables new connectors to be fitted to a live aluminium pipeline system
www.teseo.net Reader Reply Number: 310
GO WITH THE FLOW A robust, stainless steel design means IFM's new SM series magmeter can be mounted inline, with a low-profile installation for process control applications. The magnetic inductive flow meter is designed to detect the flow rate of conductive media up to 25l/min. Users can view the flow rate, total volume and temperature of all conductive media with simple programming to establish application parameters. The
The SM series magmeter can detect flow rate, total volume and temperature
sensor has a response time of less than 0.15 seconds and a repeatability of ±0.2 per cent. Typical applications include: flow and temperature monitoring through heat exchangers, monitoring cooling water on welding machines, batching applications, totalize flow of process water and pump run dry protection. www.ifm.com Reader Reply Number: 311
Fulfilling growth predictions
Artesis UK manager Joe Barnes will extend the company's support for key sectors
With responsibility for all UK sales operations, Artesis' new UK manager, Joe Barnes, is tasked with building and developing relationships with the maintenance and plant engineering sector. He will also extend the Artesis distributor network, supporting expansion in key sectors such as water, marine, oil and gas, power, renewables, chemicals and manufacturing.
Joe brings experience from previous sales and technical support positions, most recently at Proctor and Gamble. Director at Artesis, Geoff Walker, said: “Joe’s technical capabilities and industry experience are a powerful addition to our team. His work will accelerate our growth in the UK market.” www.artesis.com Reader Reply Number: 312
11 EMS September/October 2008 www.engineeringmaintenance.info
Precision shaft alignment pays
1.5
MILLION
INSTALLED WORLDWIDE EFFICIENCY AND RELIABILITY ARE THE BASIS OF OUR SUCCESS. For more than 25 years, compressed air users throughout the world have trusted BEKO’s competence in compressed air and condensate technology. Perfectly understandable. Because as far as innovation, energy saving and dependability are concerned BEKOMAT® has, and will continue to be, THE name in cost effective condensate discharge.
1.5 MILLION
WORLDWIDE
BEKOMAT ® CONDENSATE DRAINS
Accurate shaft alignment extends rotating machinery lifetime and reduces maintenance expenses.
®
OPTALIGN smart For quick and precise shaft aligment Latest technology and powerful functions make OPTALIGN®smart a high performing and user-friendly alignment system. Bluetooth and USB interfaces Continuous and precise measurement during shaft rotation Automatic evaluation of the alignment condition Live correction by monitoring the machine Data security and protocols 3-machine train alignment
PRUFTECHNIK Ltd Burton Road, Streethay Lichfield. Staffordshire WS13 8LN Tel: (+44) 1543-417722
www.pruftechnik.co.uk
BEKOMAT® condensate drains. Our all-encompassing range covers pressures up to 63 bar and includes stainless steel, EX-area, vacuum and special versions for multi-stage compressors- the biggest range on the market!
BEKO TECHNOLOGIES LTD. 2 West Court Buntsford Park Road Bromsgrove Worcestershire B60 3 DX
Phone +44 1527 575778 Fax +44 1527 575779 info@beko-uk.com www.bekotechnologies.com
Contact us for more information: info@pruftechnik.co.uk For more information quote EMS Enquiry No. 130 on IBC
For more information quote EMS Enquiry No. 131 on IBC
VALUE DRIVEN MAINTENANCE Founder of maintenance consultancy, Mainnovation, Mark Haarman, asks what a valuable maintenance organisation really looks like
MAKING
maintenance valuable According to the value driven maintenance (VDM) philosophy, maintenance creates value for a company in four ways: reducing costs (cost control), improving equipment availability (asset utilisation), reducing the spare parts in stock (resource allocation) and improving compliance with regulations covering safety, health and environment (SHE). Using net present value (NPV)-formulas it is possible to calculate the value potential for every value driver. After that the maintenance organisation has to focus on the value driver with the highest value potential. The question is: what does a maintenance organisation that creates maximum value for a company look like? Is it centralised or are there decentralised maintenance organisations close to, or even under, production? Is all the work done in-house or is it outsourced to contractors? Which work processes are being applied and how are the EAM and CMMS being used? To answer those questions we first have to understand how a maintenance organisation operates using the VDM competence model. This competence model shows that there are two improvement loops - one around cost control and one around asset utilisation. A company focussed primarily on cost control will manage its improvement loop by implementing a maintenance budget, preferably per critical installation.
Within the competence of reliability engineering, the preventive maintenance program has to comply with financial targets. After that competence planning and preparation addresses preventive and corrective maintenance jobs. Once these are completed, the costs have to be registered for analysis purposes, to appreciate the cost drivers and thus initiate corrective measures to comply with the financial targets. This closes the Demming circle: plan, do, check, act. A maintenance organisation that focuses on uptime however, has to deal with a completely different Demming circle. Here the target is the service level agreement with production, in which performance targets regarding equipment availability and reliability are determined. In this case it is also important to embed these agreements in the preventive maintenance program, after which the work orders will be prepared, planned and executed. For this improvement loop it is important that production losses caused by preventive or corrective maintenance are registered to be analysed and to locate the performance killers. The VDM model demonstrates the importance of the competence reliability engineering, because it is the most important link between improving cost control and asset management. Also, reliability engineering translates the demands from safety health and environment into the preventive maintenance program and sets boundaries for the four maintenance resources: technicians, spare parts, contractors and technical knowledge. With this competence model we can determine the most valuable maintenance organisation. VDM provides best practices of leading maintenance organisations for each competence. RCM for example is known for best practice in the area of reliability engineering and TPM is mostly used to support asset utilisation improvement.
For cost control however, a method such as asset based budgeting is best suited and RBI is mostly used as best practice in the area of SHE management. Re-using proven best practices accelerates the change process and increases the credibility of changes as they have already worked for other companies. Can we conclude that there is one standard for the most valuable maintenance organisation? Yes and no. Yes, with VDM there is a standard approach for designing and building the most valuable maintenance organisation. No, because the outcome is different for every company. Whether or not to apply best practices depends on where the most value can be created. For example TPM will not be applied by a maintenance organisation that has to focus on costs. Best practices always have to be translated to a companies’ specific situation. All too often RCM or TPM implementations fail because the feasible ambition level within the maintenance organisation wasn’t taken into account. Therefore the most valuable maintenance organisation is a custom made solution by definition. One of the founders and managing partners of Mainnovation, Mark Haarman is an expert in maintenance and asset management and is the author of Value Driven Maintenance, new faith in maintenance.
www.mainnovation.com Reader Reply Number: 313
13 EMS September/October 2008 www.engineeringmaintenance.info
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.
DTECT X1
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.
DETECTOR III
For further details of our condition monitoring products and services call 0121 351 3833 or visit our web site at www.schaeffler.co.uk and click on the Condition Monitoring and Maintenance Products link.
EASY CHECK
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. 128 on IBC
15 EMS September/October 2008 www.engineeringmaintenance.info
16 EMS September/October 2008 www.engineeringmaintenance.info
Smile...
Replacement condensate filter cartridges to fit CF1000 & CF200 by Denco Limited
Now cost less! Made here in the UK to fit the Denco Ltd CF range of separators, available from stock for next day delivery our replacement filters are guaranteed to perform to the original manufacturers specification.
Tel: +44 (0) 1543 379212 www.bowmanstor.com For more information quote EMS Enquiry No. 115 on IBC
For more information quote EMS Enquiry No. 116 on IBC
New! The rugged Ti25 and Ti10 thermal imagers help you identify the exact problem area The Fluke Ti25 and Ti10 make thermal imaging easy to understand and help you solve problems in industrial applications. With patent-pending IR-Fusion® you can view a full thermal image, or one combined with a visual image, to identify the exact problem area. Full IR
• See small temperature differences and fine details on the wide, full VGA display
• Engineered and tested to withstand a two metre drop • Voice recorder simplifies adding comments to each image (Ti25) Blended
• Store over 1,200 IR-Fusion •
® thermal images with temperature data and voice comments Measure up to 350°C (Ti25)
Prices start from £2,986 for the Fluke Ti10 Picture-in-Picture
IR-Fusion®: Now put problems clearly in the picture
Fluke. Keeping your world up and running.®
Order your Ti25 or Ti10 now! Check www.fluke.co.uk/ti for your nearest distributor
020 7942 0700
For more information quote EMS Enquiry No. 117 on IBC
18 EMS September/October 2008 www.engineeringmaintenance.info
For more information quote EMS Enquiry No. 118 on IBC
Get Shear Mode Technology for Less Than ÂŁ100 Compact, Durable, Industrial Vibration Sensors Now Direct in the UK Quality Products: I Advanced shear mode construction for improved measurement stability I Half the footprint size of a conventional industrial accelerometer I Hermetically sealed housings; case isolated I Hazardous area approved models I Ideal for use with permanent installations and continuous online monitoring systems I Full line of handheld calibrators, armoured and conventional cables & accessories
Models Availa in Stock ble fo Fast Deli r very!
Actual Size
PCB Piezotronics Limited 7 Paynes Park Tel: 01462 429710 Hitchin, Herts SG5 1EH Fax: 01462 429798 Email: info@pcbpiezotronics.co.uk
For more information quote EMS Enquiry No. 119 on IBC
Š 2008 PCB Group, Inc. SensorLine is a service mark of PCB Group, Inc. PCB, ICP and IMI with associated logo are registered trademarks of PCB Group, Inc.
LOW-COST INDUSTRIAL VIBRATION SENSORS
For more information quote EMS Enquiry No. 120 on IBC
20 EMS September/October 2008 www.engineeringmaintenance.info
CONDITION MONITORING
The Acoustic Emission (AE) technique is based on the detection of the high frequency component of naturally occurring stress waves (or structure borne elastic waves)
CONDITION MONITORING
based on acoustic emission comes of age There was a time when AE was regarded only as a means of monitoring defect growth in stressed materials and structures. Despite numerous instances of its successful application to machinery condition monitoring since the 1960’s these successes tended to be dismissed by the Condition Monitoring (CM) community as being oneoffs and not relevant to main stream applications; a fair comment in its time since the AE equipment used was seldom suited to use by shop-floor personnel. Today, however, the situation couldn’t be more different; interchangeable AE sensors are available and easy to use signal processing routines have been developed which make interpretation straightforward. As a result, AE is positioned as one of the four principal CM techniques alongside Infra-red Thermography, Lubrication Management & Analysis and Vibration Analysis as specified in ISO 18436. Furthermore, AE has its own CM standard ISO 22096 (Condition monitoring and diagnostics of machines – Acoustic emission) and ISO traceable certification of CM practitioners is available to Levels 1, 2 & 3. Whilst these developments represent the culmination of much hard work undertaken by key AE practitioners over recent years they have only been made possible by the unique attributes of AE in the CM role which deliver important practical benefits for industrial use :a) A high Signal to Noise Ratio (SNR), which means that the presence of a small fault gives rise to a large change in the detected signal, giving AE the
following inherent benefits : sensitive to faults at an early stage the presence of a fault can be detected without having to first do a frequency analysis very slowly moving machinery can be monitored a broad range of fault types can be simultaneously detected b) It is based on the omni-directional detection of propagating high frequency waves, which simplifies AE detection and sensor installation in the following ways : there is no need for sensors to be mounted in specific orientations there is no need for sensors to be mounted in the same plane as bearings it is not necessary to consider the possibility of the sensor being mounted on a node or anti-node on the machine surface cross-talk or interference from adjacent machinery is seldom an issue it can be applied in noisy and high vibration environments The many benefits of AE listed above have underpinned its success as a routine CM method to assist maintenance personnel and not surprisingly it is incorporated in both portable CM instruments and permanently installed monitoring systems. A key to the continued growth of permanently installed monitoring systems in industry is ease of integration into existing shop floor monitoring and control systems. Because of the high frequency nature of AE sensors, in the past this has necessitated the use of an AE instrument
to pre-process the signals. However as an example of the growing maturity of AE technology in the CM role, recent development have led to smart AE sensors (such as the MHC-DS1 - see photo) in which the entire AE instrument is integrated within the sensor itself. Such a smart sensor approach overcomes the difficulties for the end user of having to deal with high frequency signals and coaxial cables but instead has preprocessed DC and switched outputs on twisted pair cables for direct connection to PLC, SCADA etc. In terms of machinery protection (i.e. detecting gross mechanical failures as they happen) rms responding and switched output Vibration sensors are a familiar site on the shop floor but such sensors are not suited to the CM role. This is because the benefits of CM, maximising machine utilisation and minimising maintenance costs, rely upon an early warning of degradation in order to allow the timely planning of appropriate service and maintenance activities. It is in this CM role that smart AE sensors look set to play an important part as a natural compliment to machinery protection sensors; in the foreseeable future they may even become as ubiquitous. Trevor Holroyd is the Managing Director of Holroyd Instruments Limited and has been continuously active in the development and use of AE for industrial monitoring since 1974.
www.holroyd-instruments.com Reader Reply Number: 314
21 EMS September/October 2008 www.engineeringmaintenance.info
MANAGING RISK
Make complex stuff simple. Reduce Maintenance Costs Automate Preventive Maintenance Improve Asset Reliability Reduce Breakdowns Manage Spare Parts Ensure Regulatory Compliance Paper-free PDA Work Orders
I I I I I I I
Operations director of Idhammer Systems, Alan France, reviews the themes covered during the company's Manufacturing Performance Masterclass 08
GETTING
MEAN ON LEAN Affordable and easy to use maintenance software • Browser-based Fresh innovative design • • Completely configurable • Simply great value
It’s maintenance. Managed. To discover more agile maintenance management visit www.getagility.com or call 01924 200344
22
With many companies adopting lean manufacturing techniques, it seems that real risks are being taken. It stands to reason - if you cut down your spare capacity, remove your buffer stores and most of your WIP, your plant must be reliable and very well maintained in order to operate effectively. Leaving major disasters, such as fire aside, a staggering 70 per cent of companies without effective risk management and business continuity plans suffer unplanned plant downtime at least once a year. As ever, maintenance is fundamental to plant availability or uptime, so effective maintenance is an essential part of strategic risk management. Good maintenance is also a critical component of the lean ethos. Traditional manufacturing had lots of slack in the system however, as buffer stores are removed to improve flow through the plant, the ability to recover
from a breakdown also disappears. Lean may be the ‘in thing’ but it’s not effective unless you improve your maintenance methods at the same time. Employee engagement is also vital within the lean maintenance mix. During loss management for example, you need to know what’s failing, when and for how long. A well trained operator is a mine of information who can provide much of the information needed to analyse performance issues. If the process can offer some real-time information in return, this will drive improvements at all levels. It makes sense to keep the technology simple: sense when the machine stops electronically and record the stoppage time automatically. Ask the operator to identify the reason for the stoppage at the time the event occurs and provide them with facts such as current performance, time to finish and worst stoppages.
For more information quote EMS Enquiry No. 121 on IBC
EMS September/October 2008 www.engineeringmaintenance.info
When the operator begins to point out long-standing minor stoppages and the true effects on performance the process is really working. It’s worth mentioning that a push button, two line LCD screen is unlikely to enable this effective two-way information sharing. In order to engage with operators, we need to provide them with quality touch panel PCs for data capture and operator feedback, as well as single point lessons, standard operating procedures and fault diagnostics, to help the operator improve performance. Improved measurement can also dramatically enhance performance. Good maintenance relies on an effective system that understands, and preferably talks to, the OEE management system. The key is to make every asset, every unit of energy and every second, count.
www.idhammarsystems.com Reader Reply Number: 315
INDUSTRIAL PROTECTIVE COATINGS
Belzona Polymerics Ltd has a solution for improving the efficiency of pumps, significantly reducing operating costs
INCREASED
pump efficiency Belzona has seen pump applications increase dramatically of late, as companies seek to minimise running costs by tackling issues of reduced efficiency. According to National Sales Manager, Gordon Cairns, the number of repairs undertaken by the group has nearly doubled in the last two years, more than any other type. He commented: “Many companies are now working hard to reduce energy consumption, which forms the major part of a pump’s running costs.” Independent testing from the Department of Trade and Industry at the National Engineering Laboratory, in Glasgow, has backed up Belzona’s claims of increased efficiency as a result of applying a smooth
hydrophobic coating system. Tests showed efficiency increases over new pumps of more than 5%. This, supported by industry knowledge that efficiency losses due to erosion corrosion can be 12 or more percent certainly substantiates the argument in favour of a Belzona coating solution. Belzona’s partner contractor, SPP Pumps, has passed on the benefits of applying a Belzona efficiency enhancement coating system to its many customers. SPP Pumps Business Manager, Martin Bagg, explained: “For a number of years, we have used Belzona 1341 (Supermetalglide) as an internal coating for split case pumps. The coating is generally utilised for efficiency enhancement where experience
has shown that an improvement of around 2% can normally be achieved”. In addition to the initial efficiency enhancement, the coating also assists in maintaining the condition of the pump over time as it acts as a barrier to erosive and corrosive deterioration of the casing’s internal surface.The coating has also been recognised due to its ease of application and its certified approval for use in contact with potable water. Contact Blake Simms on
T: +44 (0)1423 726103 E: bsimms@belzona.com W: www.belzona.com Reader Reply Number: 316
23 EMS September/October 2008 www.engineeringmaintenance.info
INDUSTRIAL PROTECTIVE COATINGS
Belzona Polymerics Limited has introduced a scheme to differentiate and reward specialist service centres that invest heavily in surface preparation equipment and are dedicated to maintaining high levels of application procedures and customer service
NATIONWIDE NETWORK
of authorised coating centres launched To receive recognised status as a Belzona Authorised Coating Centre (BACC) service centres must first win the endorsement of a ‘Belzona Champion’, who nominates the company for assessment. Here, they will demonstrate up-to-date equipment and facilities, a dedicated coating room and temperature controlled area and, crucially, ongoing staff training in Belzona approved application techniques. Steve Cooper, Commercial Manager for Belzona said, “The BACC concept was created to distinguish between regular machinery and equipment contractors and a specialist group of service centres that go the extra distance”. BACC certified centres receive valuable sales and marketing support from Belzona, including referrals, lead and appointment generation and integration to national advertising and PR campaigns. They also
have the benefit of sales and technical training that keep them at the forefront of product and application breakthroughs; invitations to leading industry seminars; access to more ambitious contracts and a relationship with an industry leading international company. The BACC network allows Belzona to broaden its service offer and reach. Customers receive a full turnkey repair service on rotating equipment, such as pumps, fans, blowers, screw conveyors and agitators. This covers mechanical repair and replacement, as well as preventative long term coating protection. Steve Cooper further commented, “This gives us the platform to target key industries that require a “total service”. These include Petrochemical, Power, Paper and Water”. BACC status has already been granted to four companies. One of the latest to be presented
24 EMS September/October 2008 www.engineeringmaintenance.info
with an Authorised Coating Centre certificate is Hertel, Wilton Workshops, Teesside. Hertel is an international industrial services company, which builds, maintains, modifies and dismantles plants and installations for the (Petro) chemical, Process and Power industries. Annette Salter, Workshop Manager said: "We have built up an excellent relationship with Belzona sales and technical people over the last 10 years, both at the Harrogate headquarters and across the UK. This partnership has allowed us to enter accounts together and secure business that, individually; we would have been unable to win”. Contact Blake Simms on
T: +44 (0)1423 726103 E: bsimms@belzona.com W: www.belzona.com Reader Reply Number: 317
LIGHTING
Oil and gas giant Shell UK Limited has just completed an extensive lighting upgrade programme across twelve of its North Sea oil platforms, which involved the removal and installation of several thousand explosion-proof fluorescent lighting units
FLUORESCENT LIGHTING CUTS
maintenance and installation costs The programme is part of a much larger Enhancement & Rejuvenation project at Shell, which in-volves not only emergency lighting, but also other types of electrical equipment located in hazardous areas, including pumps, generators, switchgear, motors and control equipment. The programme is currently being expanded to include Shell U.K.’s onshore facilities. For the lighting units, the original supply agreement between Cooper CrouseHinds (UK) and Shell U.K. Exploration and Production Europe, was made back in 2005. The eight-year contract involves the supply of lighting to both onshore and offshore installations, from Cooper CrouseHinds’ CEAG eLLK 92 range of fluorescent light fittings. The lights have been fitted to both indoor and outdoor locations across the12 Shell North Sea oil platforms. As part of the contract, technical support and installation training were also provided by Cooper Crouse-Hinds (UK). John Ferguson is Senior Electrical Engineer at Shell U.K. He works in the Project Engineering de-partment and is also Technical Authority for Electrical Discipline Support at Shell U.K. Exploration and Production Europe. He comments: “In 2005, we evaluated three suppliers of explosion-proof fluorescent lighting. We needed to replace most of the fluorescent lights across twelve of our off-shore oil platforms, for obsolescence and other agerelated reasons. In awarding the contract, the key drivers for us were cost of ownership of the lighting and a range of other factors that were weighted and
scored accordingly. These factors included ease of installation and maintenance, warranties and innovation – the most important factor being ‘Product Reliability’. This, in the end, led us to choose Cooper Crouse-Hinds UK, who scored very well in all these areas.” Quality and reliability of the lighting were key factors for Shell. As Ferguson recalls: “Since 2005, in excess of 10,000 light fittings have been supplied to us and only around 20 fittings have had to be returned to the supplier. However, only two or three of these were due to design or technical faults with the product – the rest were because of incorrect installation on our behalf. Overall, we are very satisfied with the quality and reliability of the lights.” Ease of installation and maintenance of the light fittings were also critical factors in selecting the lighting supplier. As Ferguson explains: “Cooper Crouse-Hinds went the extra yard for us by pro-viding a handy, pocket-sized reference guide for all our maintenance engineers and technicians. This includes important installation and maintenance information and is very easy to use. In fact, most of our technicians now carry a copy in the pocket of their overalls.” Cooper Crouse-Hinds UK also provided on-site installation training. “On the technical support side, Cooper CrouseHinds reacted very quickly to any queries that we had. In one particular example, the company modified the design of its light fitting ballast by incorporating new circuitry that detects the early stages of the tube ‘end-of-life’ phenomenon and
shuts down the fitting, thus avoiding a potential overheating problem with the fluorescent light. We were very pleased with such a fast response from their R&D team on this matter.” The eLLK 92 range of fluorescent lighting units are available for ATEX Zone 1, Zone 2, Zone 21 and Zone 22 hazardous areas. The lighting units come in 2, 4 or 5 feet lengths, with twin lights. The 2 and 4 feet versions can be supplied as emergency lighting. These versions have an ‘intelligent’ NIB battery fitted, which monitors the lighting, providing onboard maintenance with LED indication for ‘capacity’ and ‘faults’. The eLLK 92 fluorescent lighting units are designed with a glass fibre-reinforced plastic enclosure and a polycarbonate protective bowl. The units are protected to IP66 (EN 60529). Permissible ambient temperatures are from –20°C up to +50°C. This emergency light unit formed the bulk of the supply for the Shell offshore refurbishment project. www.ceag-crouse-hinds.co.uk Reader Reply Number: 318
25 EMS September/October 2008 www.engineeringmaintenance.info
BEARINGS
Robin Kyte, Sales Manager at The Barden Corporation (UK) Ltd, explains why bearing obsolescence is so important when it comes to safety-critical applications such as aircraft systems and nuclear power plant applications
The problem of
OBSOLETE BEARINGS Locating and sourcing a supplier of an obsolete mechanical component such as a bearing, is a growing concern for many organisations, particularly if the component is part of a safety-critical system on an aircraft or nuclear power plant application. Sourcing a bearing for a mechanical system on a military aircraft, for example, can be a challenging process, particularly if the system is an ageing one. The aircraft itself may have been in operational service for more than 40 years and may also be projected to remain in service for many more years to come. However, if the operator needs replace the original bearings, the original supplier of the component may have ceased to exist, is now re-located overseas, or perhaps is no longer willing to manufacture the equivalent bearing in such small volumes (less than 1,000 units). This means that many aircraft (and other mechanical) system operators and managers are now facing significant bearing obsolescence issues, particularly if the quantity of bearings they require is relatively low. In addition, there may be other design features about the bearings that make it equally unattractive, or even impossible, for a supplier to adhere to. For example, the bearing may require special materials, special lubrication, certification, special features such as tapered outside diameters, or may need to fit an Imperial chassis size.
There are similar issues in the nuclear industry too. Bearings are commonly found in nuclear power plants as part of actuation systems, which position the control rods into the fuel bundle. In an emergency situation, the control rods are dropped into the fuel bundle to absorb the reactor heat, which dictates that the bearings must not, under any circumstances, fail. This means bearing suppliers must offer full manufacturing traceability, controlled lubrication and complete retention of records, similar to the aerospace and defence industry. The solution for the system operator is to find a bearing supplier who is able to manufacture the specified bearing to the same (or higher) quality standards as the original and who is also willing to supply in small batch sizes, anything between 10 and 500 units. Robin Kyte is a Sales Manager at Plymouth-based bearings manufacturer The Barden Corporation (UK) Ltd. The company manufactures a range of super precision angular contact and deep groove ball bearings. The focus is on special configuration bearings that add value and provide engineered solutions for the customer. As Kyte states: “In the UK and most of Europe, the problem of obsolete bearings is predominant in the military aerospace and nuclear sectors. The problem usually arises when the mechanical system is very old, usually more than 25 years. In this scenario, many
26 EMS September/October 2008 www.engineeringmaintenance.info
customers approach Barden because we are willing to manufacture direct replacement bearings in relatively small batch sizes and we have the manufacturing capability to produce special engineered bearings. Barden also have a strict non-obsolescence policy.” Barden bearings are manufactured and controlled under strict aerospace procedures that the company employs, providing full traceability, controlled lubrication and complete retention of records. “Often the bearing drawings on such legacy products will define only the chassis size, with little or no information regarding the internal design, materials or tolerances. With such a basic specification, a wide range of bearings could meet the requirements, ranging from low precision, commercially-produced bearings to high precision bearings with full traceability and inspection,” says Kyte. “Some of these bearings may be relatively inexpensive to buy, but they were never designed to operate in these types of environments or applications. Often, the buyer doesn’t actually realise that the bearing they have just purchased is not a like-for-like replacement. Certification, full traceability and quality should be the key issues here,” he advises. www.bardenbearings.co.uk Reader Reply Number: 319
PREDICTIVE MAINTENANCE The water industry is increasingly turning to predictive maintenance as it addresses the challenge of improving asset performance. Artesis has successfully combined advanced technology with a cost-effective implementation to meet their current and future needs
simplified predictive maintenance
FOR WATER INDUSTRY The nature of the challenge There is an increasing pressure on water companies to maximise the performance of their physical assets, a critical factor in optimising shareholder value and customer service. The water industry regulator (Ofwat) reviews the prices that companies charge, and takes into account the benefits of the capital investments planned and improvements in operating efficiency. This approach has forced water companies to focus on asset effectiveness in order to find the right balance between replacing existing equipment and developing new maintenance strategies. The scale of the challenge is huge. United Utilities, for example, provides water and wastewater services to 7 million people in the North West of England. To achieve this, it maintains an asset base of more than 120,000 pieces of equipment on 3,540 sites, requiring an annual operating budget of ÂŁ371 million. Adopting predictive maintenance Predictive maintenance initiatives in the water industry have become more accepted and widespread with the increased use of Reliability Centered Maintenance (RCM). This provides an analytical framework for the selection of maintenance strategies based on the identification of failure modes, their effects, and their impact on the business. For each asset, the most appropriate strategy might be to run to failure, to maintain based on fixed time or operating intervals, or to predict future failures based on measurements. Although run to failure is a common strategy, both in the water industry and elsewhere, it can lead to high costs resulting from loss of availability, secondary damage, and excessive spares inventory. Planned maintenance is recognised as more cost-effective than run to failure for a wide range of equipment but often results in unnecessary maintenance interventions that can themselves introduce problems.
Predictive maintenance has become the preferred technique for critical assets in many industries, not only because it brings significant cost benefit advantages but also because it improves the level of control that engineers can exert over the future performance of their assets. Predictive maintenance solutions Predictive maintenance typically relies on the implementation of a condition monitoring system, used to collect and analyse the measurements that allow the diagnosis and assessment of potential failures. For machinery, vibration-based systems have successfully been used for large, critical assets but have often proved expensive and difficult to interpret when applied to wider populations of equipment. Specialist techniques like oil analysis, motor current signature analysis, and infra-red thermography have proved excellent for detailed fault analysis once a potential failure has been identified in specific types of equipment, although they are each limited by the range of faults that can be detected. Artesis MCM technology The recently introduced Artesis predictive maintenance system provides all the benefits of traditional condition monitoring systems at a fraction of the complication and cost. Originally developed under a NASA contract, Artesis MCM (motor condition monitor) uses an intelligent, model-based approach to provide complete monitoring and diagnostic capabilities for most electric motor driven equipment. Each small monitoring unit covers a complete motor and the equipment driven by it, and is typically installed in the motor control cabinet. Since connections are required only to the motor supply cables, installation costs are low with no need to access the driven equipment for any sensor installation. Once installed, the system trains itself to recognise normal performance, following which it
continuously monitors the equipment for possible faults. When such a fault is detected, the system provides a diagnosis of one of a wide range of mechanical and electrical problems, and indicates severity so that the user can make decisions on the most appropriate intervention. Artesis MCM has proved very attractive to water companies, and has also been successfully implemented in a very wide range of other industries. Because it is simple to install and requires little user intervention in operation, it combines low start-up costs with the significant benefits of predictive maintenance. Since it doesn’t require any sensor installation on the equipment itself, Artesis MCM is a particularly good solution for inaccessible equipment like submersible and borehole pumps. All diagnostic analysis is carried out in the monitoring unit itself, reducing the need for extensive communications between remote facilities and centralised control rooms. Water industry solutions In a typical water industry application, Artesis MCM has been used to monitor a wide range of equipment providing water services to a major city. The water company, faced with the need to provide water to ever-higher standards and to become more cost-effective while coping with rapidlyincreasing demand, embarked on a set of initiatives to move from breakdown to predictive maintenance. As they had little existing diagnostic expertise, they needed a system that would do most of the routine analysis for them. And because much of their equipment was located in remote sites spread out over a wide area, access problems meant that they required a permanently-installed system. Trials and operational implementations of Artesis MCM are now taking place in many water companies in the UK and around the world. www.www.artesis.com Reader Reply Number: 320
27 EMS September/October 2008 www.engineeringmaintenance.info
CONTROL AND INSTRUMENTATION Samson Controls excel in providing optimum control for temperature regulation at London’s top exhibition venue
CONTROL VALVES HELP
ExCeL minimise energy costs
Achieving energy savings at ExCeL, London’s prestigious exhibition centre has always been a key objective, but especially valid today as a result of ever-rising energy costs. Opened in 2002, ExCeL has become the established ‘home’ for some of the UK’s best known events, such as the London Triathlon and the London Boat Show. The centre has 90,000m2 of events, conference and meeting space, as well as cafes and restaurants. A typical exhibition hall would cover about 6400m2 and as a result of the flexible layout of the halls, adjacent halls can be easily joined together, with single halls of up to 3200m2 possible. As the centre is a year round venue, with almost limitless combinations of halls available, consideration was given to creating the most energy-efficient methods of heating and cooling the various exhibition spaces. Clearly, it was important that the energy costs could be optimised for a wide variety of demands ranging from only a few halls in use, to all the halls being occupied. To help achieve the key objectives, variable speed pumps for water circulation in
the extensive heating and ventilation systems, were utilised to realise the potential for significant energy savings, especially when demands were lower. To ensure that the water distribution worked as the designers intended it was important that Differential Pressure Regulators were installed as the primary balancing device. Enter Samson Controls, who provided over 225 valves ranging in size from series 45 valves, up to size 400mm series 2333 valves. The 400mm valves are some of the largest globe valves manufactured and were installed to handle flow rates as high as 375 lit/sec. The use of very large valves, which have to operate against high pump heads, requires special construction and this was a challenge which Samson was pleased to accept. The Samson valves enabled speedy commissioning of the water distribution network because each sub-circuit could be set independently of each other circuit, without the need to go back and adjust previously set circuits. The large stocks of valves held by Samson in the UK enabled the project to be completed to tight
28 EMS September/October 2008 www.engineeringmaintenance.info
deadlines, ready for the first exhibition being staged at the new centre – at which Samson was proud to be an exhibitor! www.samsoncontrols.co.uk Reader Reply Number: 321
For more information quote EMS Enquiry No. 122 on IBC
TEMPORARY BOILERS YOU’LL WANT TO KEEP!
• UK's most reliable and efficient rental boilers • Modern, fuel efficient boilers with latest technology • Plant for long term projects can be built to specification • Service back up second to none • Speedy emergency hire service • Steam boilers from 500 to 16000 kgs/hr • Hot water boilers from 250 to 5500 kW/hr • Multiple boilers installed for larger demand • Full installation, commissioning and training available
UK's leading boiler hire service from the manufacturer of the UK's most fuel efficient boilers
Call the Hire Department to discuss your project:
Tel: 01535 665225 Email:: hire@byworth.co.ukk Web:: www.byworth.co.uk
UK’S LEADING
BOILER MANUFACTURER
For more information quote EMS Enquiry No. 123 on IBC
ENERGY MATTERS
As part of a company wide energy drive, Victor Manufacturing has realised 48% energy savings per annum on their compressed air related energy costs by installing an energy efficient Boge SLF40 frequency controlled screw compressor
ENERGY SAVINGS
to catering equipment manufacturer Victor Manufacturing is a leading commercial catering equipment manufacturer. At their manufacturing site in Bradford an extensive range of food service equipment is manufactured which is used by all kinds of organisations such as hotels, restaurants, hospitals and universities to move, store and serve hot and cold foods. Compressed air is used within the manufacturing process to power various applications such as the assembler’s air tools. In recent months all areas of energy usage at the facility have been reviewed as part of a company wide energy drive. As such, Victor Manufacturing invited The Carbon Trust to audit the compressed air system and assess its energy efficiency. Amongst the recommendations made, the Carbon Trust identified that energy savings could be made by replacing the existing compressor with an energy efficient version. At this stage Bob Morris, the Production Supervisor, invited current compressed air partner Boge Compressors to review the system. Dale Cellier, the Area Sales Manager at Boge Compressors consequently conducted an audit of the existing system to provide recommendations. The audit verified those of The Carbon Trust – that energy savings would be made by replacing the existing compressor with an energy efficient compressor.
The Boge SLF40 frequency controlled screw compressor was recommended. Bob Morris said “The quantified energy savings were significant enough to convince us that investing in an energy efficient compressor would pay off in the long run. Our experience with Boge to date has been excellent. We already had one Boge compressor installed over 12 months ago to power the laser cutting application which had run satisfactorily. In that time Boge had provided us with excellent service and backup support. As a result we chose to install a Boge SLF40.” The Boge SLF series combines a direct coupled drive system with frequency control to provide the ultimate compressor for pressure control under variable output requirements. The SLF is therefore a low
30 EMS September/October 2008 www.engineeringmaintenance.info
carbon technology that works strictly in accordance with the compressed air demand by producing the exact volume of compressed air at the pressure required. Frequency control minimises idling time and evens out air demand fluctuations. For Victor Manufacturing this meant creating a 48% reduction in their compressed air energy costs per annum! Bob Morris concludes: “We have since been very satisfied with the performance of the Boge SLF40 – we don’t have to think about the compressor system anymore – it’s just doing its job, saving us money and contributing to our all up reduced carbon footprint!” www.boge.co.uk Reader Reply Number: 322
VISIT
www.engineeringmaintenance.info for the latest Jobs News Interviews Online Seminars Events Training Products White Papers Case Studies Forum For more information quote EMS Enquiry No. 124 on IBC
For more information quote EMS Enquiry No. 125 on IBC
B:I:G>C< BDC>IDG>C< HDAJI>DCH
aM&T Sub-Metering Systems
Power Quality Analysers
Energy Data Loggers
Power Factor Correction
Flexible cost-effective metering for all utilities and every type of business. We have the hardware, software, networking and installation skills to supply the package you need, on time and on budget.
High performance instruments for the most demanding energy and power quality analysis applications designed and built to the highest quality standards. Supplied complete with the latest windows software.
Easy to use portable data loggers for electricity and general utility monitoring. Safe, non-invasive.
#OST EFFECTIVE AUTOMATIC 0&# UNITS FOR fast payback and real savings.
s !LL KITS SUPPLIED @READY TO GO
s !%' #APACITORS
s !UTOMATIC DATA COLLECTION AND alarm signalling
s !LL ELECTRICAL PARAMETERS
s &LEXIBLE NETWORKING OPTIONS
s /N BOARD POWER FOR mEX #4 S
s 7EB ENABLED HARDWARE
s 0LUG IN -EMORY
s 4ENANT "ILLING
s !VAILABLE TO HIRE
s 4($ (ARMONICS &LICKER ETC
s 4OUGH WATERPROOF CASES (3 phase analysers) s 3IMPLE 7INDOWS SOFTWARE s !VAILABLE TO HIRE
www.elcomponent.co.uk t 01279 503173 f 01279 654441 e sales@elcomponent.co.uk Unit 5, Southmill Trading Centre, Bishopâ&#x20AC;&#x2122;s Stortford, Hertfordshire CM23 3DY
For more information quote EMS Enquiry No. 126 on IBC
s &AST $ELIVERY
Structural Adhesives
Cyanoacrylates (instant adhesives)
UV Curing Adhesives for bonding acrylic, glass and metals
Electrically Conductive Adhesives
Thermally Conductive Adhesives
Conformal Coatings
Threadlocker
Ultra High Temperature Ceramic Adhesives
Glob Tops
High Performance Adhesive Technology www.eurobond-adhesives.co.uk sales@ eurobond-adhesives.co.uk T 01795 427888 F 01795 479685 Bonham Drive, Eurolink Industrial Estate, Sittingbourne, Kent ME10 3RY UK Distributors of Reinhardt-Technik Metering Mixing Dispensing Systems
For more information quote EMS Enquiry No. 124 on IBC
LEAN MAINTENANCE
Leicester based Cressall Resistors has put in place a lean programme, managed by manufacturing director Cy Wilkinson, that has helped increase turnover by 100 per cent in 18 months
LEAN PROGRAMME helps increase turnover The fundamental strategy was formed through the use of eight lean tools: value stream mapping, 5S, standard work, flow, pull, TPM (Total Productive Maintenance), mistake proofing and set-up reduction. After producing a strategic plan, Wilkinson began the implementation process by providing uniforms for the manufacturing team and implementing a set of external lean training courses. These courses resulted in improved manufacturing efficiency and provided staff with the chance to obtain an NVQ Level two qualification. During the sessions, teams of five or six delegates focused on a particular area and carried out a kaikiaku (blitz) to deliver focused improvement, usually resulting in implementation of the first three 'S's (sort, straighten and shine) of 5S and a new layout to improve flow. Cressall Resistors now has on ongoing training programme consisting of four day
seminars attended by a cross-functional teams consisting of shop floor operatives, sales engineers, designers, planners, engineers and directors. In order to improve sale to delivery times, Cressall tackled the 'order entry' to 'issue to manufacturing' part of its process. The company took a snapshot of the situation, using value streaming techniques, which highlighted areas of concern such as bottlenecks, delays and duplication of work and information, before developing ways to counteract these weaknesses. This has resulted in major improvements in contract review and file location, information consolidation, shop floor access to CAD files and purchasing. The company also applied its lean strategy to the manufacturing process, which reduced used-space by more than sixty per cent; reduced part associated employee movement and implemented single piece flow to reduce
WIP (Work In Progress). A Kanban was established to manage component inventory and the time needed to complete a physical stock-take was reduced by 50 per cent thanks to the 5S workplace organization. "When I joined Cressall in June 2006, there had already been several attempts to roll out 5S and to implement flow, all with varying degrees of success," explained Wilkinson. "Though there was impetus from senior management, these earlier lean attempts failed due to lack of follow-up and buy in from the work force." As well as tackling the present, Cressall has also made plans for the future. There are a minimum of six lean events happening at the company in 2008, and a minimum of 24 employees who will go through the Business Improvement Techniques NVQ formal qualification. www.cressall.com Reader Reply Number: 323
33 EMS September/October 2008 www.engineeringmaintenance.info
For more information quote EMS Enquiry No. 127 on IBC
MECHANICAL ENGINEERING
War Pilots reunite with English Electric Lightning plane for honour award
BEST OF BRITISH is simply supersonic A British Cold War plane which soared through the skies with supersonic speeds of more than 1,500 mph is to receive its own ‘medal of honour’ in Warton, Lancashire. Former pilots and staff who worked on the English Electric Lightning will be reunited with the plane (an FMk.6 registered XS928) at its current ‘home’ at BAE Systems to see the Institution of Mechanical Engineers’ (IMechE) honour it with an Engineering Heritage Award. Only 45 such awards have been made in the scheme’s 21 year history which recognises innovation and excellence in mechanical engineering. In total 339 of the aircraft type were built – today just four remain that are able to fly. Back in the Fifties and Sixties, BAE Systems’ facilities at Preston, Warton and Samlesbury were hives of activity as thousands of Lancashire aerospace workers cut new ground by delivering one of the fastest fighters the world has seen. Chartered Engineer, Professor Isobel Pollock, Chair of IMechE Heritage Committee said: “This is not just one of the world’s most proud engineering creations – it is an example of British excellence that made the rest of world sit up and notice. This year marks 50 years since it first reached Mach 2 – twice the speed of sound, so bestowing a heritage award on something that is still making history today is amazing.” A stalwart of the RAF for a record 28 years, it was also used by the Saudi Royal Air Force. It was specifically designed as a point defence interceptor, essentially a guided missile¬armed, air superiority fighter with an aim to defend mainland Britain against bomber attacks. One of the criteria that made the Lightning a cut above its piston¬powered predecessors was its ability to ‘dash’ to heights of
18.3 km (60,000 feet). It even had a nickname of ‘Frightening’ in some cases, not just because of its challenging crosswind landing but its thunderous roar. Only experienced pilots were assigned to fly it. British engineer W.E. ‘Teddy’ Petter designed the Lightning, having previously designed Britain’s first jet bomber ¬the Canberra ¬an aircraft so fast the Ministry of Supply realised that virtually no fighter could catch it – and if the Soviets could produce something similar then Britain would need a supersonic fighter to deal with any counter threat. Simon Howison, Engineering Director, for BAE Systems Military Air Solutions business, said: “It is the spirit that gave birth to the Lightning that drives much of what we still do today at here at Warton. We are still pushing boundaries, still
striving to astound through innovation and delivery and we are still getting the results. Indeed the F¬35 Lightning ll – the namesake of the original Lightning that we are now engaged in at Samlesbury is testament to that.” He added: “It is a fantastic honour for us to receive this Award, and it is a tribute to all those who worked on such an incredibly ambitious and ground¬breaking programme. Few aircraft carry a reputation like that of the Lightning – still fewer have achieved similar levels of capability. Days like today remind us all that the UK can and should be proud of what it does in the fields of engineering and technology.” www.imeche.org Reader Reply Number: 324
35 EMS September/October 2008 www.engineeringmaintenance.info
ADVERTISEMENT FEATURE
Identifying particulate contamination is key to predictive maintenance. Particle contamination in hydraulic oils and lubricants can have a significant impact on system efficiency, safety and operating costs. This is especially true in modern high performance systems, where tolerances are becoming ever tighter, and where equipment is used in critical industrial, mobile and process applications.
Together, we can ensure that fluid contamination doesn’t compromise your maintenance programme.
Parker’s IcountPD represents the most up-to-date technology in solid particle detection; delivering countless advantages to maintenance engineers worldwide. The design dynamics, attention to detail, and small size of the permanently mounted, on-line particle detector combine to deliver a truly innovative product. The laser based, leading-edge technology means the IcountPD is a cost-effective market solution to fluid management and contamination control.
Recognising this fact, Parker Hannifin has developed innovative contamination monitoring technology that measures both the size and concentration of particles in oils and lubricants. The latest IcountPD particle detector is based on the company’s 20 years experience of particle analysis, and of working with customers in building predictive maintenance programmes. IcountPD is designed as a simple to fit and operate instrument, that provides plant and maintenance
engineers with an extremely accurate, reliable and cost effective method of particle detection. IcountPD can be permanently fitted on-line to any hydraulics or lubrication system and features proven laser detection technology for precise and repeatable particle detection. The instrument provides a continuous indication of the quality of oils or lubricants, with an easy to read digital status display, backed by appropriate alarms, to confirm that operating conditions are within safe parameters or are changing due to fluctuations in contamination levels. With the ability to be used at flow rates from 6 to 380 l/min and at line pressures from 2 to 420bar, a choice of output signals, including 4-20mA, 0-5V, CANBUS, J1939 and RS232, plus an optional moisture sensor, IcountPD is ideal for a wide range of industrial, process and mobile applications.
Xdcbdc^c[d@eVg`Zg#Xdb lll#eVg`Zg#Xdb$][YZ
To learn more about IcountPD and other Parker fluid contamination monitoring products email conmoninfo@parker.com.
For more information quote EMS Enquiry No. 128 on IBC
PLANT EFFICIENCY
Monitoring critical components inside a hydraulic pump, fan, blower or compressor, can improve plant efficiency, eliminate production downtime and increase the operating life of plant equipment, says Ian Taylor of Corus Northern Engineering Services (CNES)
Improving life expectancy Although the cost of a component inside a hydraulic pump, such as a rolling element bearing, rotor or fastener, is often small compared to the total cost of the pump, the cost of production downtime and losses caused by component failure, are often significant. For a processing plant, the typical cost of production downtime can equate to hundreds of thousands of pounds per day, however there are numerous technology safeguards out there that, when compared to the cost of lost production, are relatively inexpensive. They use the latest condition monitoring and predictive maintenance technology, including acoustic emissions monitoring, vibration monitoring and thermography, to protect plant and machines. Business development engineer plant condition monitoring at CNES, Ian Taylor, said: “At Corus, we monitor all pumps, some every week, but each pump at least once per month. Where the pump is critical to our production process, such as the hood cooling pumps on our basic oxygen steelmaking plant, we have installed fixed CM systems to monitor the plant 24/7.”
Condition monitoring prevents maintenance teams replacing components unnecessarily and introducing possible new and unrelated problems. A number of techniques are available and these can be used individually, or in combination to protect the company’s valuable assets. Good vibrations Taylor explained: “As most pumps run at a steady load and speed, patrol monitoring with vibration analysis equipment is usually the most effective condition monitoring technique however, it depends on the pump design. Acoustic emissions monitoring may be more effective if the pump speed is less than 80rpm or if the maintenance technician wants to monitor the condition of plain bearings inside the pump or motor.” Vibration monitoring can identify a number of potential pump problems, including misalignment or coupling issues; mechanical looseness inside the pump, through to the condition monitoring of rolling element bearings; cavitation issues; or rotor erosion. Wear of gear teeth on gear pumps can also be monitored using vibration analysis.
Standby pumps are another application where vibration monitoring techniques can be useful. Companies often operate two identical pumps on a common bedplate, one as duty and the other as standby. Unfortunately, constant vibration from the duty pump can cause bearing problems on the standby pump, referred to as false brinelling. Once the standby is switched on, it very quickly fails, resulting in two pumps out of service. Perfect acoustics For hydraulic systems that rotate at less than 80rpm and operate under fluctuating load conditions, or only move through a part revolution, it is more difficult to collect meaningful data using vibration monitoring. For this reason, CNES has developed its own, patented acoustic online condition monitoring system, Aquilla AE Pro. Acoustic emission monitoring equipment has a high sensitivity to machine faults but is also immune to audible noise and low frequency background vibration. It works by detecting the high frequency stress waves generated within a material during crack growth, plastic deformation or phase transformation. Surface-mounted transducers detect these stress waves, which lie within the 25kHz to 1MHz frequency range. “The problem,” warns Taylor, “is that many companies do not possess the skills in-house to interpret data from acoustics emissions monitoring effectively.” Correct selection of lubricant or hydraulic fluid can also significantly reduce component wear and associated energy costs. Analysing the level of degradation and debris present helps asses lubricant efficiency and facilitates correct lubricant selection and oil change periods. CNES can also monitor the condition of hydraulic fluid, ensuring a longer life of system components at minimum cost. www.corusnes.com Reader Reply Number: 325
37 EMS September/October 2008 www.engineeringmaintenance.info
w w w. m s l re c r u i t m e n t . c o m JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY:
MECHANICAL DESIGN ENGINEER OIL & GAS 5419 MILTON KEYNES £Neg (per year) RISER ANALYSTS OIL & GAS INDUSTRY 6285 WOKING SURREY ANALYSIS ENGINEERS OIL & GAS INDUSTRY 6286 WOKING SURREY NUMERATE GRADUATES OFFSHORE OIL & GAS 6287 WOKING SURREY CORROSION ENGINEERS 6442 LOUGHBOROUGH £Neg (per year) BUSINESS COMPLIANCE MANAGER 7229 DORKING OR BRISTOL £Neg (per year) PRODUCTION/OPERATIONS DIRECTOR 7553 JAMAICA £Neg (per year) + US $ salary & attractive bonus CHIEF COST ENGINEER 6229 GREENFORD, MIDDLESEX £Neg (per year) ENVIRONMENTAL ENGINEERING MANAGER 7094 GREENFORD, MIDDLESEX £Neg (per year) ELECTRONIC PRODUCTION LAB MANAGER 7356 NEAR CARDIFF £Neg (per year) LEAD/PRINCIPAL INSTRUMENT ENGINEER 5332 QATAR £Neg (per year) COST ENGINEERS EPC PROJECTS 5566 MIDDLESEX £Neg (per year) SENIOR PROJECT PLANNING MANAGER 7519 SOUTH WALES £ 55 to £ 65 K (per year) + Package to £65k SENIOR PROCESS CONTROL ENGINEER 5072 MIDDLESEX £Neg (per year)
j o b s @ m s l re c r u i t m e n t . c o m JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY:
38 EMS September/October 2008 www.engineeringmaintenance.info
MECHANICAL DESIGN ENGINEERS 6301 NORTH WEST / CUMBRIA £Neg (per year) VENTILATION BUILDING SERVICES ENGINEERS 5666 READING £Neg (per year) DEVELOPMENT ENGINEER 5934 SHOREHAM, EAST SUSSEX £Neg (per year) MECHANICAL ENGINEERS NUCLEAR FUSION 5939 OXFORDSHIRE £Neg (per year) MECHANICAL BUILDING SERVICES ENGINEERS 5665 READING £Neg (per year) DESIGN ENGINEER POWERTRAIN SYSTEMS 5418 PETERBOROUGH £Neg (per day) MECHANICAL DESIGN ENGINEER OIL & GAS 5419 MILTON KEYNES £Neg (per year) NUMERATE GRADUATES OFFSHORE OIL & GAS 6287 WOKING SURREY MECHANICAL ENGINEERS 6300 CUMBRIA/CHESHIRE £Neg (per year) DESIGN & SAFETY ENGINEERS MARINE DEFENCE 4103 SOUTH WEST £Neg (per year) DESIGN SUBSTANTIATION & SAFETY ENGINEERS 4391 PLYMOUTH AND BRISTOL £Neg (per year) PRODUCT DEVELOPMENT ENGINEER AUTO EMISSIONS 4431 WARTON LANCASHIRE CONTROL AND INSTRUMENTATION ENGINEERS 7615 WESTERN AUSTRALIA £Neg (per year) ELECTRICAL/INSTRUMENTATION TECHNICIANS 5638 READING to £ 30 K (per year)
RECRUITMENT continued JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY:
HYBRID VEHICLE ENGINEERS 6380 WEST MIDLANDS £Neg (per year) BATTERY ENGINEERS 6381 WEST MIDLANDS £Neg (per year) ELECTRIC DRIVES ENGINEERS 6382 WEST MIDLANDS £Neg (per year) LEAD INSTRUMENTATION ENGINEER 7587 PERTH, AUSTRALIA £ 150 to £ 180 K (per year) COMMISSIONING ENGINEERS/PROFESSIONALS 6488 READING, BERKSHIRE £Neg (per year) CONTROL INSTRUMENTATION ENGINEERS 4089 MARINE DEFENCE SOUTH WEST CONTROL & INSTRUMENTATION ENGINEERS 6774 READING, BERKSHIRE £Neg (per year) SYSTEMS ENGINEERS 7069 SOMERSET £Neg (per year) ELECTRICAL, CONTROL & INSTRUMENT ENGINEERS
7096 VARIOUS £Neg (per year)
w w w. m s l re c r u i t m e n t . c o m
JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY:
NUCLEAR DESIGN AND SAFETY ENGINEERS 5639 BASED SOUTH WEST £Neg (per year) COMMISSIONING ENGINEER 5641 NR READING, BERKSHIRE £Neg (per year) HUMAN FACTORS SPECIALIST 4090 SOUTH WEST £Neg (per year) DESIGN & SAFETY ENGINEERS MARINE DEFENCE 4103 SOUTH WEST £Neg (per year) NUCLEAR DECOMISSIONING SPECIALISTS 5640 BASED SOUTH WEST £Neg (per year) MECHANICAL BUILDING SERVICES ENGINEERS 5665 READING £Neg (per year) PRODUCT SUPPORT ENGINEER 6232 DERBY £Neg (per year) SAFETY ENGINEERS 5669 READING & WARRINGTON £Neg (per year) DECOMMISSIONING PROJECT ENGINEER 5670 READING, BERKSHIRE £Neg (per year)
j o b s @ m s l re c r u i t m e n t . c o m
TO ADVERTISE YOUR LISTING PLEASE PHONE 0207 9933355 Company WebsiteIN OUR BUYER’S GUIDE Email Contact Telephone Number ACCESS EQUIPMENT Planet Platforms
www.planetplatforms.co.uk
info@planetplatforms.co.uk
0800 0854161
www.rockwellautomation.co.uk
ukmarketing@ra.rockwell.com
0870 2425004
ASSET MANAGEMENT Rockwell Automation BOILERS Byworth Boilers
www.byworth.co.uk
sales@byworth.co.uk
01535 665225
Certuss Steam Generators
www.certuss.co.uk
sales@certuss.co.uk
0121 3275362
Wellman Robey
www.wellman-thermal.com
info@wellman-thermal.com
0121 543 0000
www.wellman-thermal.com
info@wellman-thermal.com
0121 543 0000
www.nord-lock.co.uk
enquiries@nord-lock.co.uk
44 (0)1980 847129
Cayman Venture
www.cayman.co.uk
info@cayman.co.uk
0191 2963816
Idhammar Systems Ltd
www.idhammarsystems.com
info@idhammarsystems.com
0117 9309300
PMI Software
www.pmisoftware.co.uk
Louis.Tuttle@pmisoftware.com
353 (0)1404 0000
BOILER HIRE Wellman Robey BOLT SECURING SYSTEMS Nordlock Ltd CMMS
FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info 39 EMS September/October 2008 www.engineeringmaintenance.info
ANNUAL BUYERS GUIDE continued TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355 Company
Website
Email Contact
Telephone Number
Productivity Europe
www.productivityeurope.org
m.jones@productivityeurope.org
01234 215867
Shire Systems
www.shiresystems.co.uk
info@shiresystems.co.uk
44(0) 23 80224111
CMMS continued Softsols Group Ltd
www.getagility.com
info@softsolsgroup.com
44(0)1924 200344
SRO Solutions
www.srosolutions.net
info@srosolutions.net
44 (0)845 408 4250
Airchannel Ltd
www.airchannel.co.uk
info@airchannel.co.uk
0800 526581
Atlas Copco Compressors
www.atlascopco.co.uk
gba.info@uk.atltascopco.com
0800 181085
Gardner Denver
www.gardnerdenver.com
info.uk@gardnerdenver.com
01452 338116
www.speedyhire.co.uk/compressors
enquiries@speedycompressors.co.uk
0845 307 0777
Alpine Components
www.alpine-components.co.uk
mike@alpine-components .co.uk
01424 437000
Artesis
www.artesis.com
info@artesis.com
0845 634 3854
Elcomponent Ltd
www.elcomponent.co.uk
sales@elcomponent.co.uk
01279 503173
Holroyd Instruments
www.holroyd-instruments.com
sales@holroyd-instruments.com
01629 822060
Proviso Systems
www.proviso-systems.co.uk
sales@proviso-systems.co.uk
01777 817536
Monitran
www.monitran.co.uk
info@monitran.co.uk
01494 816569
Schaeffler
www.schaeffler.co.uk
info.uk@schaeffler.com
0121 351 3833
SPM Instrument UK ltd
www.spminstrument.co.uk
info@spminstrument.co.uk
01706 835331
www.rockwellautomation.co.uk
ukmarketing@ra.rockwell.com
0870 2425004
www.metrum.co.uk
enquiries@metrum.co.uk
0118 973 3000
www.icm-uk.com
info@icm-uk.com
01779 474748
www.rockwellautomation.co.uk
ukmarketing@ra.rockwell.com
0870 2425004
www.dixoneurope.co.uk
enquiries@dixoneurope.co.uk
44 (0) 1772 323529
www.totalprocesscooling.co.uk
sales@totalprocesscooling.co.uk
44(0)121 711 4014
www.bidgroup.co.uk
sales@bidgroup.co.uk
0870 607 5050
CG Flooring Systems Ltd
www.cg-flooring.com
info@cg-flooring.com
01484 600085
Dura Composites
www.duracomposites.com
info@duracomposites.com
44 (0)1255 423601
www.ats-electro-lube.co.uk
info@ats-electro-lube.co.uk
0191 491 4212
www.tcardsdirect.com
sales@tcardsdirect.com
01732 871417
COMPRESSED AIR
COMPRESSED HIRE Speedy Compressors CONDITION MONITORING
CONDITION MONITORING EQUIPMENT/SERVICES Rockwell Automation DATA ACQUISITION Metrum HEALTH & SAFETY Integrity&Compliance Management HEALTH & SAFETY PRODUCTS Rockwell Automation HOSE AND COUPLINGS Dixon Europe INDUSTRIAL COOLING TPC(Total Process CoolingLtd) INDUSTRIAL DOOR SERVICES BID Group INDUSTRIAL FLOORING
LUBRICATION ATS Electro-lube (UK) ltd PLANNED MAINTENANCE T Cards Direct THERMOGRAPHY Express Instrument Hire
www.expresshire.net
sales@expresshire.net
01772 815600
Flir
www.flir.com
sales@flir.com
01732 221245
Fluke
www.fluke.co.uk
industrial@uk.fluke.nl
020 7942 0700
Hawk-IR
www.hawk-ir.com
sales@hawk-ir.com
01642 497000
Testo Ltd
www.testo.co.uk/testo880
–
01420 544 433
www.infraredinstitute.co.uk
info@infraredinstitute.co.uk
44 (0)151 424 4060
www.nfpc.co.uk
enquiries@nfpc.co.uk
01909 504700
www.hansfordsensors.com
sales@hansfordsensors.com
0845 6801957
THERMOGRAPHY TRAINING The Institute of Infrared Thermography
TRAINING National Fluid Power Centre VIBRATION ANALYSIS Hansford Sensors
FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info 40 EMS September/October 2008 www.engineeringmaintenance.info
REGISTER NOW to continue to receive your FREE copy of EMS JUST FAX THIS COMPLETED FORM BACK ON Please fill in your details if you (a) wish
(Delete as appropriate)
Job Title
or, (b) wish to be included in the
Company
Surname
First Name
(Mr, Mrs, Miss, Ms)
to continue to receive a free copy of EMS
0208 7113153
magazine’s circulation list for the first
Post Code
time. (Please use capitals and please
Fax
Tel
sign and date as indicated). Fax Back on:
0208 7113153
Signed
Date
/
/
Please send me FREE information on: PLANT MANAGEMENT Artificial Intelligence/Expert Sys
❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏
Asset Management Bearings Calibration Coding Systems Computerised Maintenance Management Condition Monitoring Consult Condition Monitoring Consultancy – unspecified Contract Maintenance Corrosion Prevention Couplings Data Analysers/Loggers Degreasers Descaling Drives Electric Motors Electrical Maintenance Equipment Rental Filters Flexible Hose Flexible Ducting Flow Meters Food Safety Lubricants Gaskets General Engineering Services
❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏
❏ ❏
Handling Equipment Hose & Cable Reels Hydraulics/Pneumatics
Visual Planning Welding and Joining
TRAINING Institutes and Professional Bodies
❏ ❏ ❏
Internet Services to Maintenance Labelling and/or Barcoding Laser Alignment
Recruitment Training Aids and Services
BUILDING MAINTENANCE Access Equipment
Leak Detection Equipment
❏ ❏ ❏ ❏ ❏ ❏
Lubrication/Oil Analysis Maintenance Consultancy Maintenance Materials Measurement Instrumentation NDT Equipment or Services Pipe Freezing Pumps, Valves and Process Equipment
❏ ❏ ❏ ❏ ❏ ❏
RCM Consultancy Remote Monitoring Seals Sensors or Probes Specialist Maintenance Services/Products
❏ ❏ ❏ ❏
Surface Treatment and Coating Temperature Measurement Thermographic Services/Equipment
Building Maintenance Consultancy Chemicals/Paints/Finishes Cleaning Components Cleaning Machines/Equipment Computer Aided Facilities Management (CAFM) Cranes/Hoists Doors/Curtains Flooring Lifts/Escalators Lighting Property Maintenance and Management Roofing Security and Fire Prevention Storage Systems Tank Linings & Bundings
ENVIRONMENTAL Dust/Fume Extraction
Tools & Workshop Equipment
❏ ❏
TPM Consultancy Vibration
Environmental Health/Testing/Equipment
❏ ❏ ❏
Noise Control Pollution Control Equipment Water Treatment
HEALTH & SAFETY Communication
❏ ❏ ❏ ❏ ❏ ❏
Health & Safety Products Legislation & Compliance Machine Guards Safety Showers & Eye Baths Workwear
ENERGY MANAGEMENT Boilers
❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏ ❏
Burners Climate Change Levy Combined Heat & Power Compressed Air Equipment and Ancillaries Energy Energy Control Systems Energy Metering/Monitoring Systems Generators Heating, Ventilating and Air Conditioning Industrial Controls Power Quality Steam Traps
September/October 2008
ENQUIRY?
F R E E
P R O D U C T
I N F O R M AT I O N
S E R V I C E
COMPLETE AND FAX THIS PAGE BACK TO 0208 7113153 enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
enquiry no.
Artesis MCM – Advanced Technology for Simple, Effective Condition Monitoring
Every now and then, a new solution comes along and changes your thinking. Artesis MCM is a new approach to condition monitoring, providing all the benefits without the complication and costs of traditional systems. Artesis MCM monitors the condition of equipment driven by electric motors, using the motor itself as a sophisticated transducer. It requires only connection into the motor’s electrical supply, avoiding the need to attach specialised sensors to the plant. Because Artesis MCM is permanently installed, it provides continuous fault monitoring and doesn’t require the manual data collection that represents a major cost of using walkaround systems. So Artesis MCM is especially applicable to situations where the plant is not easily accessible, either because it is remote or because the local environment is hazardous.
DEVELO
P
NA
ED TECHNO
L
O
Artesis MCM uses advanced technology developed for NASA to bring you a selflearning capability in a compact, panel-mounted instrument. Over the initial period of operation, it teaches itself about the normal operation environment of your equipment so that it can accurately identify and diagnose faults when they start to occur. Artesis MCM doesn’t demand specialist setup or operating expertise, it just tells you what you need to know, when you need to know it. If you want all A S the benefits of condition monitoring but think it’s too difficult or expensive for you, Artesis MCM will make you think again.
GY
simple, effective
condition monitoring “...it simply works” tel 0845 634 3854 info@artesis.com
www.artesis.com For more information quote EMS Enquiry No. 129 on IBC