ems 2010 August edition

CHRISTER IDHAMMAR

SONATEST LAUNCH

" A NEW PHASED ARRAY

INSTRUMENT IS NOW LAUNCHED, THE VEO 16:64."

SKF

MAINTENANCE BECOMES LESS OF A GRIND AT FLOUR MANUFACTURER

ENVIRO

REDUCE EMISSIONS BY REVAMPING YOUR STEAM SYSTEM

ELECTRICITY! THE POWER OF OEE AND A FEW DISCRETE ENERGY METERS

Engineering Maintenance Solutions, August 2010

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Contents

Engineering Maintenance Solutions, June 2010 Engineering Maintenance Solutions, August 2010

Latest News & Products 7 - 19 Maintenance becomes less of a grind at flour manufacturer 20 - 21 Reduce Carbon Emissions 22 - 23 Insulation Testers 25 Condition Monitoring 26 OEE 28 - 29 MAINTAIN Preview 30-31 Power Plant Maintenance 32 - 33 Fastening Solutions Aid Compliance 35 - 37 August 2010 Publisher - Michael Dominguez Email: michael@engineeringmaintenance.info Editors/Contributers - Jon Barratt, Christer Idhammar, Alan France, Mick Saltzer, Mark Haarman

Improve Energy Conservation 39 Training - 41 + Buyers Guide, IR, Motors & Drives, Buyers Guide.........

Email: editorial@engineeringmaintenance.info Ad Manager - Paul Clappison Email: paulc@engineeringmaintenance.info Online Sales Director - Paul Miles Email: paul@engineeringmaintenance.info Website: www.engineeringmaintenance.info MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ Tel: +44(0)1634 731646 Fax: +44(0)1634 731644 www.engineeringmaintenance.info

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Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

Sustainable reliability and maintenance Christer Idhammar is a world renowned and awarded Reliability and Maintenance Consultant and Guru. He is the founder and executive vice president with IDCON, INC in Raleigh NC, USA; A reliability and maintenance training and consulting company to Industry worldwide since 1972. www.idcon.com outstanding financial results? Perhaps it is lack of patience and reinforcement?

I am no longer surprised to see reliability and maintenance improvement initiatives abandoned before the substantial results, which are possible to achieve, are delivered and sustained for years to come.

This phenomenon is recognized by many of my colleagues in the reliability and maintenance management profession.

I recently came across the findings illustrated in the graph below from the American Society for Training and Development. It illustrates what happen if training is not followed by practice and reinforcement. The findings show that 87% of what you learnt is lost within 30 days if training is not followed by practice and reinforcement.

Their findings illustrates very well why so many reliability and maintenance improvement initiatives delivers good results, but only about 50% of the improvement potential.

Reliability and maintenance improvements are one of the last major improvements opportunities the industries have left. Everyone with access to capital can buy the same equipment and technology, how productive your plant is will to a very large extent depend on the reliability of your process and your equipment. If your equipment runs, you make product, if it does not run your employees work harder, you pay more and you are not making product. So why does top management not reinforce that even the most basic maintenance practices are executed better and better over long period of time to achieve sustainable and

Another good comparison is safety. In 1994 the average overall incident rate in one process industry was 8.7. The latest statistics I just researched is 3.8 in 2008.

In 14 years this industry as an average reduced overall safety incident rates by about 64%. We all know that this is because of long term reinforcement and training.

Imagine if we used the same focus on training, implementation and reinforcement of basic maintenance practices; could you have reduced preventable maintenance work and down time by 60%? The majority of maintenance work is preventable and can also be executed in half of the time so I know it is possible, because I have seen it happen and the key to these successes has been top management long term support and reinforcement. And on top of better maintenance productivity and higher production throughput you would get an even better safety record.

The major reasons why reliability and maintenance improvement initiatives do not deliver more than about 50% of possible results is according to my experience: ·

·

Looking at reliability and main‐ tenance improvements as a program with a start and an end instead of a process with a starting point but with no end.

·

Confusion between concepts, whole systems and tools.

·

New names on good mainte‐ nance practices have confused and delayed implementation.

Why can we not call maintenance just maintenance?

·

More focus on systems and

tools instead of on people. ·

A lot of training and preaching not followed by immediate actions and implementation.

The new manager and new program phenomenon.

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Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

Custom eddy current and draw wire sensors for subsea oil & gas applications At this year’s Instrumentation Scotland & Offshore Systems 2010 exhibition (8-9 September 2010) precision sensor manufacturer Micro-Epsilon (UK) Ltd (stand 703) will be showcasing a range of displacement sensors and non-contact temperature measurement products for subsea, oil & gas applications, including draw wire sensors, eddy current displacement

M

icro-Epsilon’s wireSENSOR range

existing machine, components or

temperatures up to 350 deg C. Sensors

of draw-wire (string pot)

control and automation systems.”

have also been produced with extremely low thermal drift and with temperature

displacement sensors uses three main

errors of less than 20ppm/K.

measurement methods: a multi-turn potentiometer, an incremental encoder or an absolute encoder. One of these

Unique eddy current sensors Visitors to Micro-Epsilon’s stand will also be able to see the company’s brand new

Non-contact temperature

range of eddy current ECT (Embedded

measurement

Coil Technology) sensors. ECT is a

As well as displacement sensors, Micro-

technological breakthrough in eddy

Epsilon will also be showcasing a range

current sensor design and manufacture,

of non-contact temperature

which overcomes the previous

measurement products, including

limitations of using eddy current

thermal imaging cameras and inline

sensors.

process temperature sensors.

Due to its ultra-compact design and by

After recently setting up a partnership

using new inorganic materials in its

agreement with Flir Systems UK, a

As with traditional tape measures, the

construction, the new eddyNCDT ECT

leading supplier of infrared

wireSENSOR series is capable of measur-

sensors provide almost unlimited scope

thermography systems, Micro-Epsilon is

ing around corners and edges. Micro-Ep-

in terms of the external design and

now able to offer the thermoIMAGER i

silon supplies as accessories deflection

geometrical shape of the sensor. This

series of handheld thermal imaging

pulleys, which deflect the steel wire in

means that sensors can be adapted for

cameras, as well as its own inline

the desired direction. The sensors cover

almost any use, including subsea, oil

process temperature sensors.

a measuring range from 50mm right up to

and gas applications.

devices is mounted onto the drum axle, converting the rotary motion of the drum into a signal that can be evaluated. The measured displacement can be output as an analogue current, voltage or potentiometric signal. For a digital output, there is a choice of HTL or TTL, with interfaces for most of the common fieldbus systems, including CANopen, SSI and Profibus.

50m. Options are available for harsh environments (including subsea), with an

Micro-Epsilon’s eddyNCDT ECT sensors

For more information on Micro-

IP67 version available.

offer extreme mechanical robustness,

Epsilon’s range of sensors, or to see a

resulting in longer service intervals and

product demonstration, please visit

Chris Jones, Managing Director at Micro-

higher temperature stability. The

stand 703 or call the sales department

Epsilon (UK) Ltd comments: “Our draw-

complete circuit electronics are

on 0151 355 6070 or email:

wire sensors are being used in a wide

integrated into the sensor itself,

info@micro-epsilon.co.uk

range of applications, from general

providing a more compact solution for

industrial machinery and scissor lifts,

OEMs and machine builders. The sensors

through to more specific uses such as

are suitable for

pneumatic and hydraulic systems,

harsh

forklift trucks and subsea oil & gas

environments,

systems. Our wireSENSOR range is very

including high

popular with machine builders and

vibration, impact

OEMs, who require low cost, robust,

shocks, high

reliable sensing solutions that can be

pressure/vacuum,

easily integrated into their customer’s

and high operating

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Engineering Maintenance Solutions, August 2010

Oil Industry growth for AUMA India The Indian arm of the AUMA actuator group reports growth of the company’s modular actuation solutions in the oil sector. The latest contract for AUMA’s valve control technology has been placed by the Indian Oil Corporation Limited for a Naphtha Cracker and Polymer complex.

The Naphtha Cracker project is reported as the cornerstone for Indian Oil's entry into petrochemicals and represents a new market for business growth for the corporation.

Located in the Northern Indian state of Haryana, the installation is an excellent illustration of AUMA working in partnership with the customer to supply a comprehensive solution incorporating hard wiring and bus technology backed by master station support.

The installation, which confirms the company’s expertise in supplying the petrochemical industry, required 75 actuators at the Cracker complex - which has a capacity of 800,000 MT/year of ethylene production. All actuators have been supplied with control modules suitable for MODBUS RTU protocol.

Additionally, SIMA master stations and hot standby master station with loop technology have been provided. ESD functionality, achieved through hardwired operation, is provided, tailored to meet the customer’s requirements.

The master stations in redundant configuration communicate through MODBUS RTU protocol with Yokogawa DCS CS 3000. Additional features provided are PCs to monitor the actuators’ functions via the SIMA master stations.

AUMA Riester GmbH & Co. KG The global supplier of modular actuation solutions Headquarters address: Aumastr 1 79379 Muellheim, Germany Tel: + 49 7631 809-0 Web: www.auma.com

Condensate Recovery Condensate is a high purity, high heat content water that is a valuable resource and even the recovery of small quantities is often economically justifiable. Any condensate not returned needs to be replaced by cold make-up water, incurring further heating and water charges.• Returning more condensate to the feed tank reduces the need for blowdown, which in turn reduces the energy lost from the boiler. support

your

condensate

polishing and flexible design, it can be installed and

process.• Each MOFi unit is designed to brought online quickly and efficiently. treat water to 0.1µs/cm at flows ranging

ELGA Process Water Marlow International, Parkway, Marlow, Bucks SL7 1YL• UK parallel or series to suit your needs, and Tel + 44 (0) 1628 897000 resin regeneration takes place off-site Email: sales.uk@veoliawater.com

from 10-35m3/hr. Units can be set up in

eliminating the need for hazardous chemicals.• MOFi’s can be operated to 80 C and generate no wastewater, making ELGA Process Water’s Aquamove MOFi is a this the ideal solution for your condensate skid mounted ion exchange unit available on short to medium term rental, to

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polishing needs.• With its small footprint

Engineering Maintenance Solutions, August 2010

Perfect Online Condition Monitoring solution for beginners and specialists VIBNODE is a small Condition Monitoring system for production-critical standard machines, i.e. Motors, Fans, Pumps and even low-speed machinery.

The system records the overall condition of a machine and in addition watches over individual components by monitoring the specific damage frequencies in a narrow frequency band. In variable speed machines it even uses tracked frequency bands. If a threshold value is exceeded, the operator is informed immediately and FFT spectra and time waveforms are recorded for purposes of damage diagnosis.

VIBNODE runs fully independently and can be operated without a PC. For analyses and storage, the collected data are transferred over the company network to the

OMNITREND PC software, a platform shared by all PRĂœFTECHNIK condition monitoring products. With its low up-front cost and modular structure that can be extended as required, VIBNODE is the ideal entry-level solution.

For more information please contact PRĂœFTECHNIK Condition Monitoring on +49 89 996160 or email info@pruftechnik.com.

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Spill Training Programme First Responders Clearspill Ltd have designed a spill training package with first responders in mind. In general, containment is the first immediate action required, subsequent action will involve the correct application of absorbents that are available to you. The course can be modified to suit supervisors or management. Safety is a requirement and training is essential.

(Your trainer is an approved ISO 14001 manager with 20 years hands-on experience with spills), having provided training for the National Grid, Shell, Power Utilities and project managed the Buncefield incident.

We can also arrange for a site inspection and risk assessment prior to the course in order to better tailor the course to your site specific needs.

The Training Package Covers: • Identifying potential pollution

incidents, as prevention is better than cure. The course will identify the best practices with a brief understanding of the legislative requirements.

• As a priority the use of spill kits, firstly with containment in mind. Then in the case of small spillages, cleanup techniques to include chemical neutralisation methods and health & safety.

• Practical use of spill kits, containment methods, blocking drains, seal damaged drums and deployment of Absorbents.

• Typical Course Content First Responder Level Building blocks to compliance • Your duty of care – order of importance, company policy to Health & Safety, legislation today ‘The polluter pays’. Understanding’ step by step the risks on your site environmental assessments.

• Clean-up strategy – first containment, including communication to management as to flow path, volumetric assessment,

EXTENDING THE OPERATIONAL LIFE OF LIFTING EQUIPMENT As lifting equipment and associated

PUWER 1998. At a time when health and

components age, efficiency and

safety is high on the public agenda, in an

reliability are inevitably compromised,

increasingly litigious society, accidents

often resulting in higher operating costs

or injuries arising from poorly

and potential safety implications. To

maintained plant and equipment, may

address these issues, Demag Cranes &

lead to the investigation and prosecution

Components Ltd recommends that its

of employers under these statutes. In

lifting equipment should be subject to a

extreme cases, where a fatality occurs,

general overhaul at least every ten years

prosecution and expensive compensation

of its operational life.

claims may be brought under the Corporate Manslaughter & Homicide Act

Demag general overhaul programmes

2007.

have been designed to restore equipment to optimum performance and

Demag technicians are fully qualified to

safety levels, providing a cost effective

repair, maintain and overhaul

alternative to investment in new

proprietary products and those of other

materials handling technologies. Such

original equipment manufacturers.

regimes, backed by ongoing certification,

Overhaul programmes include an

also help operators meet obligations

assessment of materials handling systems

under workplace health and safety

and the replacement of worn or damaged

legislation, including the Health & Safety

components. Subject to assessment,

at Work Act 1974, LOLER 1998 and

Demag also undertakes the replacement

relative impact. Tailored to the guidelines set by the IP Environment Agency in there 2004 Inland response.

• Spill management each person will be given a task that will need managing as a spill develops, team role play provides understanding for management and operation tasks.

• Understanding the colour coding of absorbents, white/blue hydrocarbons, grey maintenance / general purpose, yellow chemical. How to stop product entering drain systems, handling runway run-off lagoons, understanding interceptors, and recovery techniques.

• Modules available First Responder, spill supervisor, spill management, preventative planning. Preparation for ISO 1400`1 “Get your site right” includes site environmental audit oil/chemical.

Certificates for spill response and containment will be issued to all successful delegates after completion of the training. www.clearspill.com Clear Spill Ltd, 55 Spencer Street, Oadby, Leicester, LE2 4DQ Tel. 0116 271 9436 (4 lines) | Fax. 0116 271 2143 | Email:•sales@clearspill.com or adjustment of mechanical, electrical and optical controls, as well as switchgear, brakes, chains, friction clutches and rope staysWhere appropriate Demag provides for the upgrade and modernisation of lifting equipment, which may include the addition of features such as overload protection, inverter controlled drive systems, anti collision systems, remote controls, capacity/load increase and safety interlock systems.

Demag Cranes & Components Ltd, Telephone enquiries to: 01295 676157 · Email:service@demagcranes.com Website: www.demagcranes.com

Engineering Maintenance Solutions, August 2010

ABB Instrumentation Partner network gets new look web site ABB’s Instrumentation Alliance partner network now has a new look web site at www.abbiap.com, making it easy to find the products and services you need and your nearest partner that can provide them.

Each ABB Instrumentation Alliance partner has been carefully selected to ensure that customers in every part of the UK will enjoy the same high levels of service and support. The ABB Instrumentation Alliance consists of JWF Process Solutions in Scotland, JWF Instrumentation in Teesside, WH Good in Lancashire, AM Sensors in Somerset and KC Controls in West Sussex and Sheffield.

“We are now able to provide everyone, wherever they are in the UK, with equal access to any of our instrumentation products, backed by easy ordering, rapid delivery, training programmes, on-site support and ready availability of spares and repairs,” says John Thomson, ABB Instrumentation Alliance manager. “All of our partners have been trained to ensure that customers receive the same levels of support as they would if they were dealing with ABB directly.”

The ABB Instrumentation Alliance offers:

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Fast, efficient delivery to anywhere in the UK – Many products stocked by the ABB Instrumentation Alliance are available with 24 hour delivery (for orders placed in mainland UK before 12 midday). Any items of equipment that are not stocked by one partner can be readily sourced from throughout the network.

Installation & Commissioning expertise Each ABB Instrumentation Alliance partner is able to provide help and guidance with installing and commissioning instrumentation equipment.

Equipment health checks and lifecycle management – ABB Instrumentation Alliance partners are able to assist with health checks on installed instrumentation equipment, the results of which can be used to draw up preventive maintenance plans and identify and rectify potential problems.

Training – An extensive range of courses are available through each ABB Instrumentation Alliance partner, covering topics such as product familiarisation and usage, installation and commissioning, fault finding and how to meet the latest relevant legislation and standards.

The web site also provides information about products and services available from ABB Instrumentation Alliance partners, together with details on how to contact them. The site can also be used to download application guides, brochures and other technical documentation and has many useful links to other ABB and external sites.

“The ABB Instrumentation Alliance extends our sales and support network and provides our customers with greater access to ABB, its products and services,” says John Thomson..

Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

ABB and partner to highlight safety and flow expertise at Instrumentation Scotland ABB Limited (stand 308) and its Instrumentation Alliance partner, JWF Process Solutions Ltd (stand 118), will be hosting two workshops at the Instrumentation Scotland & Offshore Systems exhibition, as well as showcasing the latest temperature, pressure, data recording and flowmetering technologies.

The first workshop, Wireless – providing the key to unlocking stranded information in your field instruments, will commence at 12.30 pm on Wednesday 8th September. Presented by ABB’s process communications expert, Gareth Johnston, the workshop will show how WirelessHART technology can be added to existing field instruments to enable operators to access a raft of new process and maintenance information.

Although wireless technology is unlikely to replace analogue 4-20mA or fieldbus communications, it offers an attractive alternative in locations where conventional communications would be difficult or expensive to install.

The second workshop, presented by ABB’s DP flow expert, Ian Robertson, is titled A solution to measure the flow rate of Wet Gas. In wellhead applications, the mixture of fluids and

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gases has traditionally been separated into its various phases to enable accurate measurement of each of the component phases, a critical requirement in determining production capabilities.

The event will also provide an opportunity for visitors to see ABB’s latest product offering for oil, gas and petrochemical applications.

New features include the use of ABB’s common HMI platform, which now features across its instrumentation product range. Enabling operators to easily scroll through and select options, the HMI simplifies operation, maintenance and training, reducing cost of ownership and providing a consistent user experience.

The 2600T series also has the optional extra of ABB’s Plugged Impulse Line

Detection system (PILD). Incorporated within the transmitter itself, the system compares the application background noise against a pre-programmed baseline to detect blocked impulse lines, with any blockages being relayed as an alarm via HART, Profibus or Foundation Fieldbus.

These products will be accompanied by ABB’s surface mount temperature assemblies for demanding applications, plus the SM500F field mountable data recorder, an electronic data recorder that can be installed anywhere with a choice of pipe, panel and wall mounting options.

For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref.

‘Instrumentation Scotland’.

Engineering Maintenance Solutions, August 2010

Spirax Sarco heat exchanger helps Harrogate cure high hydrotherapy heating bills A compact Spirax Sarco EasiHeat™ steam-tohot water system is proving to be a vital component in an innovative refurbishment project to help Harrogate Hospital save energy and improve patient comfort in its hydrotherapy unit.

The EasiHeat system was supplied as a compact, skid-mounted assembly, complete with all the necessary ancillary equipment. At its heart is a plate heat exchanger, which is more responsive and easier to control than bulkier shell-and-tube versions.

By delivering improved heat recovery, temperature and humidity control, the scheme is expected to save over £2,000 per year in heating bills. The new measures are also expected to save almost 300 tonnes of CO2 emissions over the 15-year life of the plant.

The Spirax Sarco unit was chosen because it can use plant steam to provide a reliable supply of on-demand hot water at a precise temperature. “We need rapid availability and close control of low-temperature hot water at a constant 82oC,” says Bob Howie, Capital Design and Project Manager. “The plate heat exchanger provides very good close control and hot water on-demand. It also has a much smaller footprint than other heat exchangers, freeing up space in the plant room.”

The EasiHeat system provides hot water to an integrated Calorex Delta 10 unit, which controls both the temperature of the pool and the temperature and relative humidity of the air in the hydrotherapy and swimming pool.

The Calorex system incorporates heat exchangers, an air handling unit and a heat pump. The heat pump recovers energy from excess moisture in the air above the pool to provide up to 25% of the heating energy needed in the pool room. The rest is provided by hot water from the EasiHeat system. The system maintains the pool temperature at between 34 and 36oC and conditions the air to a comfortable 30oC and 60% Relative Humidity.

Another reason to opt for a heating system based on steam was the ready supply of plant steam, which was previously used in the shell-and-tube calorifier that heated the pool before the refurbishment.

As well as the new pool room systems, the refurbishment also includes a second air handling unit bringing fresh air into the adjacent rest area, while an integrated building control system monitors and optimises the energy performance of the entire hydrotherapy unit.

All the new systems are designed to comply with the latest recommendations for hydrotherapy units laid out in NHS Health Technical Memorandum Health Building Note 8 for Facilities for Rehabilitation Services.

“These regulations weren’t around when the hospital was built in the mid-1970s, because no one worried then about climate change,” says Mr. Howie.

Sharon Graves, Marketing Communications Manager Tel: +44(0)1242 521361; Fax: 01242 573342 Email: SharonGraves@SpiraxSarco.com Web: www.SpiraxSarco.com/uk

Middle East expansion for SIPOS SIPOS Aktorik, supplier of specialist variable speed and standard actuator solutions, reports the success of its Middle East agent. Torento Energy Systems, a member of the Al Dhafra group, was appointed as the exclusive representative for SIPOS for the region in 2008.

The technology specialist incorporates SIPOS’ actuation products into its turnkey solutions across a range of sectors including major utilities, district cooling and construction in the UAE. Commenting on the synergies of SIPOS’ actuation technology with Torento’s product portfolio, Mr Ahmed Sobhi, a director of Torento Energy Systems, said: “SIPOS, with its focus on high level service and bespoke solutions, is a perfect match for our business and our customers’ requirements.

Chilled water delivered via an underground pipeline is recognised as more cost-effective and environmentally friendly than distributed, building specific cooling technology. SIPOS’ actuation technology plays a key role controlling valves that manage the cooling water flow and protect hydraulics from water hammer.

Regions supported by Torento Energy Systems include Oman, Qatar, Saudi Arabia, Yemen, Bahrain, Kuwait and Pakistan.

SIPOS Aktorik GmbH

“The extreme heat of the UAE makes the centralised production of cooling energy a highly attractive solution and this has made district cooling, a technology that is supported by SIPOS’ actuators, a particularly strong growth market.”

Im Erlet 2, D-90518 Altdorf, Germany Tel: +49 (0) 9187 / 9227- 0 Fax: +49 (0) 9187 / 9227-5111 Web: www.sipos.de

Photocaption: SIPOS Aktorik actuator technology installed in UAE installation at Mohamad Bin Zayed

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Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

JUNG jacks and skates make light work of moving lathe A package of JUNG hydraulic jacks, castors and steerable trolley supplied by Movetech UK is helping Hawke International UK to move and install heavy machinery quickly and safely at their plant in Ashton under Lyne, Greater Manchester.

The company, a world supplier of cable glands, EXE GRP Enclosures, EXE stainless steel enclosures, EX connectors and transformer breathers, needs to move machine tools and other heavy plant round the workshop.

cases an alternative method would be to use winches (tirfors) and low tech skates, which require the shop floor to be drilled in numerous locations for anchorage. This is both time-consuming and labour intensive.

As Production Engineer, Carl Heitmar, explains:

“Over the years I have been responsible for moving a number of heavy machine tools, and I have found that the best solution is to use heavy duty skates such as those supplied by Movetech UK. Heavy machinery can be moved very quickly and at little extra cost once the equipment has been bought.

“The latest machine we have had to move is a large 1" x 6 spindle Wickman automatic lathe, which weighs in at 5335 kg.

“In the past the most common method would be to pay contractors to use their heavy moving equipment to take care of the job. However, access for the required fork lift trucks of 10 tonnes plus capacity is often restricted, and heavy moving plant cannot be used. In these

“The JUNG jacks, skates and trolley were more than up to the latest job and will, in fact, take weights up to 13,000 kg.”

More information is available from Movetech UK on tel: +44 (0)1204 537681, email: industrial@movetechuk.com or from the website at www.movetechuk.com/industrial.

Effective climate control in indoor pools reduces risk of structural damage Michell’s WM33 and WM261 relative humidity sensors are used to keep thousands of swimming pools around Europe dry.

While the hot weather in the summer sends many of us want to cool off in the water at the local pool, the high levels of humidity caused by the water vapour and heat in indoor swimming pools create a nightmare for the facilities managers. Without effective dehumidification and ventilation systems to keep the air dry, indoor pools face attack from a host of humidity-related problems such as mould and corrosion – not to mention complaints from visitors that it is uncomfortable.

Failure to keep control over levels of humidity of may eventually cause structural damage as the warm air carries the moisture into the walls and ceiling. When combined with chlorine from the pool chemicals, the humid air becomes highly corrosive, attacking both metal and concrete.

Controlling the humidity levels of the air in a pool room is easier said than done, when the surface of the pool itself acts as a giant humidifier each time the dew point of the air falls below the temperature of the water. Without effective dehumidification systems, the air ‘sucks’ vapour from the surface of the pool to create just the humid atmosphere you want to avoid.

easy to re-calibrate and maintain for long-term accuracy and reliability.

The WM33 and WM261 from Michell Instruments work as an integral part of a dehumidification system to help ensure that the surface temperature of the water remains lower than the air temperature, and the relative humidity is kept at a constant 50 to 60%. Both instruments are work effectively with long-term exposure to the aggressive atmosphere created by the pool chemicals. They are also cost-effective,

CB6 3NW

Sarah Lawrence Michell Instruments Lancaster Way Business Park Ely, Cambridgeshire

UK Tel - +44(0)1353 658 000 Fax - +44(0)1353 658 199 e-mail – sarah.lawrence@michell.com

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Engineering Maintenance Solutions, August 2010

SMARTER ELECTRICAL TESTING AT AMEC AMEC's Power and Process Europe business is using advanced test instrumentation from Seaward to improve the compliance testing of its own electrical installations.

AMEC’s Power and Process Europe provides a range of project management support to customers in the power and renewable energy sectors.

As part of its facilities management arrangements at two of its largest sites at Birchwood Park, Warrington and Booths Park, Knutsford, the company is using a PowerPlus 1557 combined electrical testing and certification system to ensure that new electrical installations comply with the 17th Edition wiring regulations.

The PowerPlus 1557 is a new concept in electrical test instrumentation and combines the functions of a conventional multifunction electrical installation tester with a data logger to enable test

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certificates to be created as testing is undertaken.

system has improved our testing and record keeping systems considerably.

It does this by storing an electronic version of the test certificate within the tester, eliminating the need for ‘dummy’ certificates and manual or PDA recording of test results.

“The test process itself is much more streamlined and we now have both paper and electronic records of all installation and periodic testing undertaken on both sites along with the necessary test certification.

At AMEC the testing is carried out on site by specialist electrical contractors and when complete the data is output onto NICEIC test certificates as proof of compliance with the 17th Edition wiring regulations.

Peter Smith, Facilities Officer, Electrical and Mechanical, at AMEC’s Power and Process Europe’s business, said: “The new electrical test and certification

“This has made it much easier to demonstrate our compliance with the necessary wiring regulations and prove to electrical inspectors and external auditors that everything is as it should be.”

Full details of the PowerPlus 1557 are available at www.seaward.co.uk/products/PowerPlu s_1557_Installation_Tester.asp

Engineering Maintenance Solutions, August 2010

Sonatest launch the veo Phased Array flaw detector.

As a result of Sonatest’s drive to bring desirable and innovative products to the NDT market, a new Phased Array instrument is now launched, the veo 16:64.

The veo is a fully capable Phased Array instrument with multi-technique functionality, including TOFD; fast data recording, a simple to use interface and rugged housing design renders the veo a performance leader from the beginning.

Combine this with Sonatest’s outstanding commitment to customer support and product service; the user experience is a winning one. Typical applications include Pipeline Weld Inspection, Corrosion Mapping, Aerospace and Composite Testing.

Key design elements considered in the development of the veo series are user and performance focussed which include simple controls and a workflow driven Menu structure. The 3D Scanplan feature displays a full 3D view of the user’s test set up including probes, wedges, the weld and geometry, with phased array beams. There are also on-board probe and wedge databases for fast setups.

Power & Performance perfectly packaged.

This 16:64 Phased Array instrument has TCG and ACG, a superior encoding speed with fast A-scan recording and excellent reporting functionality. There are two separate conventional channels providing simultaneous Phased Array and TOFD scanning to speed inspection and ensure correct data referencing for improved defect characterisation. Real Time Focal Law calculations allow the user to change scanning parameters instantly,

reducing the time spent on setup and defect investigation.

The veo enclosure has been designed to withstand the tough environments in which NDT inspections are carried out, achieving IP67 standard for water and dust ingress and employing internal shock mounts to withstand impacts. The market sectors largest sunlight readable screen, enables the technician to see and interpret results with ease and efficiency, especially when complex inspections need multiple probe configurations. The veo batteries give up to 6 hours use, and are hot swappable for continuous use.

Wayne Woodhead, Managing Director of Sonatest Ltd “Phased Array is an exciting technology that is becoming regarded as the future of Non Destructive Testing for critical inspections and productivity improvement. The new veo brings Sonatest’s design values of Simplicity, Capability and Reliability into this rapidly expanding market, giving users an

effective, efficient tool to meet their demanding needs. The veo builds on Sonatest’s success in the ultrasonic flaw detector market, with a global sales network supporting our customers throughout the world. Launched at the European Conference for NDT (ECNDT) in Moscow June 2010, initial reaction has been very positive and we are looking forward to a very successful future.”

Sonatest will be at various exhibitions over the next months with the veo, including the UK NDT 2010 show between September 14-16th and the ASNT Fall Conference in the USA, Houston, between November 15-19th.

For further and dedicated information on the new Sonatest veo please visit www.sonatestveo.com Email: corinna@sonatest.com

19

Engineering Maintenance Solutions, August 2010

Maintenance becomes less of a grind at flour manufacturer Allied Mills, part of Associated British Foods, has been able to turn its perception of maintenance on its head thanks to in depth analyses undertaken by SKF, the world’s leading knowledge engineering company.

Indeed, as opposed to being seen as a necessary evil, maintenance is now viewed by Allied Mills as a fully integrated element of the company’s business effectiveness model. Perhaps most importantly, the implementation of SKF’s maintenance programme has meant that the ratio of unplanned vs. planned maintenance at the company has been completely reversed, with planned work now accounting for 90% of the total, while significant reductions have also been made in Allied Mills’ stores value and stock holding costs.

Duncan Lawson, Group Engineering Manager at Allied Mills, explained, “With so many rotating elements within our processing facilities, we needed a company with a vast level of global knowledge and experience in the field.

As a result, we invited SKF in to see what they could offer and whether they could assist us in the design of an accurate and effective maintenance strategy.

“Our existing processes and procedures had delivered significant benefits, but

20

in an increasingly challenging manufacturing environment, our focus was shifting towards providing longterm sustainability and a value added service from our manufacturing teams.”

The first step in the preventative maintenance programme was to perform detailed Client Needs Analyses (CNA) at each of the three Allied Mills’ plants in Belfast, Manchester and Tilbury.

The CNA analyses were conducted during discussions between key managers and engineers at Allied Mills and a team of SKF professionals to gain a snapshot of the current maintenance strategy and its efficiency.

The CNA process uses a sequence of assessment questions from each of the four main facets of SKF’s Asset Efficiency Optimisation (AEO) process, which focuses on improving processes, culture and technology: maintenance strategy, work identification, work control and work execution.

Using the data gathered from the initial assessments, SKF engineers were able to analyse the results and create an action plan and route map for Allied Mills to adopt.

Described as, “A real eye-opening learning process”, by Lawson, it asked what challenges existed towards maintaining current performance, what Allied Mills was doing well and, just as importantly, what the company could do better.

In many instances, the CNA process highlighted preventative activities that Allied Mills was able to undertake using its own in-house expertise; but it also highlighted the need for a significant maintenance strategy review, something that both Lawson and his Managing Director already suspected.

With the help of SKF Asset Management Services, a thorough review of all maintenance tasks was justified technically to promote the efficient use of labour. One advantage was that Allied

Engineering Maintenance Solutions, August 2010 Mills used similar equipment at all three of its plants so company-wide processes and procedures could be standardised.

“The team at SKF examined the majority of the plant,” Lawson explains, “using Failure Mode and Effect Analysis (FMEA) to determine the best maintenance approach for all of our assets. They then studied each piece of equipment and machinery, breaking it down into its component parts, in order to envisage the impact that a failure might have.

They then looked at the spares stock, the existing maintenance schedule and whether it was reactive or predictive.

We also looked at the general performance of the maintenance discipline. From these results we were able to make the first major changes in our maintenance ethos.”

Lawson explains, “We quickly realised that we were weak at interfacing between production operations and maintenance. They were very much perceived as two separate entities and, at times, operated as such – with the metaphorical brick wall, as so often seen in many other companies, between them.”

The first step, therefore, was to integrate them into one department, having them both report to a new internally appointed manufacturing manager. The benefits were immediately apparent, almost instantly both had visibility of each other in terms of agenda and operations and, perhaps most critically, team working was enhanced.

“In addition, the integration of the new concepts introduced by SKF, saw our Computerised Maintenance Management System (CMMS) transform into a manufacturing tool, greatly enhancing its benefits and effectiveness to the enterprise as a whole,” Lawson added.

“We also realised that there were areas to which we had given too much prominence in our maintenance strategy. It quickly became clear that SKF was helping us to work smarter rather than harder. In some instances, we learnt that it was okay simply to let something come to the end of its lifecycle and then replace it; it was not deemed a critical component and did not warrant the level of support we were giving to it. In other cases the reverse was true.”

For further information, please contact: Phil Burge, Communication Manager, SKF (U.K.) Limited T: +44 (0)1582 496433 M: +44 (0)7770 647591 phil.burge@skf.com

21

Engineering Maintenance Solutions, August 2010

Reduce carbon emissions by revamping your steam system With the introduction of the carbon trading initiative, the CRC Energy Efficiency Scheme, steam users are under increasing pressure from the government to reduce their carbon footprint. One of the best strategies for reducing carbon emissions is to cut energy consumption. Steve McKie, Manager for Carbon & Environment at Spirax Sarco, explains how even minor changes to a steam system can save thousands of pounds in energy costs and promote a socially responsible image.

The CRC Energy Efficiency Scheme is

year by 2020, which is the equivalent of

cient are rewarded and the most waste-

designed to drive energy efficiency and

taking 4 million cars off the road.

ful are penalised. It doesn’t take a busi-

carbon saving by combining the financial

ness genius to see which side of the

incentive of emissions trading with Cor-

For those in the CRC energy efficiency

porate Social Responsibility incentives by

scheme, failure to meet the carbon

publishing a league table showing how

targets set will mean buying carbon

Steam is used to distribute energy widely

the participants perform. A recent report

credits at ÂŁ12 per tonne and then trying

across industrial sites and other big

from the Environment Agency suggests

to claw the money back by improving

installations, such as hospitals and offic-

that it could reduce CO2 emissions in the

performance. The payouts from one

es. It should therefore be a prime candi-

UK to around 11.6 million tonnes per

company effectively become revenues

date for anyone looking to save energy.

for another, so that the most energy effi-

In fact, some steam users have already

22

equation it’s better to be on.

Engineering Maintenance Solutions, August 2010 carried out projects that will give them

tems designed to provide heating and hot

a head start when carbon trading begins

water. For instance, chocolate manufac-

in earnest.

turer Bendicks (Mayfair) now has an un-

FREME is proven to achieve energy savings of up to 26%

limited supply of hot water for washing Boiler gas use cut by 25%

down its equipment, thanks to the installation of a Spirax Sarco EasiHeat™ Engi-

For instance, in 2008, Abbey Corrugated

neered System. EasiHeat systems rely on

became one of just 12 organisations

a compact plate heat exchanger that

across England and Scotland to be

uses plant steam to produce hot water

awarded the “Carbon Trust Standard”,

on demand. Not only does this ensure a

thanks in part to the installation of an

constant supply at peak times, it also

energy recovery system from Spirax

eliminates the need for hot water stor-

Sarco. Organisations holding the Carbon

age and increases energy efficiency, typ-

Trust Standard certificate for the CRC

ically saving at least 6%.

period will gain an initial advantage with an improved league ranking and there-

Smaller investments produce

fore an increased share of the recycled

big savings

allowances.

Installing major new items of plant may Abbey’s success centres on a type of

not be an option for everyone –

engineered system from Spirax Sarco

especially while cash flow remains an

the scheme are just one element, with

known as FREME (Flash Recovery Energy

issue for many organisations. However,

energy savings and CO2 reductions having

Management Equipment). By recycling

there are probably still significant

even more potential to boost the bottom

the energy from liquid condensate and

savings to be made if you know where to

line.

flash steam, Abbey estimates that the

look, so calling in steam specialists such

FREME system has cut the amount of gas

as Spirax Sarco will almost always be

it uses in its steam boiler by 25%. A

beneficial.

great advantage of the FREME system is that it can be supplied as a pre-engi-

Spirax Sarco steam experts can show you

neered, skid-mounted system, taking the

how to optimise your system to lower

stress out of designing, specifying, build-

your energy consumption. Starting with

ing and installing it. This approach

a tailored steam system audit, Spirax

makes it an “easy win” to deliver big

Sarco engineers can suggest a variety of

savings for users.

energy saving measures to improve the efficiency of your steam system. This

Visibly more environmentally friendly

was evident with Dairy Crest, which re-

Find out how Spirax Sarco can help to improve your process and reduce carbon emissions by contacting: Steve.McKie@uk.SpriaxSarco.com

duced gas consumption at its Kirkby fac-

alternatively visit

In another example, an engineered flash

tory by 18%. Steam system optimisation

www.SpiraxSarco.com/uk or

steam recovery system is delivering di-

played a major role in achieving the

rect energy savings of 10% plus a further

overall savings, leading to an extremely

10% in indirect savings at De Mulder &

rapid payback of just a few months for

Sons in Nuneaton. The system from

Spirax Sarco’s audit.

phone 01242 521361.

Spirax Sarco has also dramatically cut visible plumes of flash steam from the

These examples show how organisations

site, which is one of the UK’s largest

can act now to get ahead in the race for

processors of meat and poultry residues.

a good place in the CRC Energy Efficien-

Steve Mckie , Manager for carbon and environment Spirax Sarco

cy Scheme league table. For those that The pre-assembled approach to steam

succeed the end result will be a cost sav-

improvements also works well for sys-

ing, not an expense. The payouts from

23

Engineering Maintenance Solutions, August 2010

24

Engineering Maintenance Solutions, August 2010

Fluke introduces Insulation Testers for up to 10kV Fluke, the global leader in handheld electronic test and measurement equipment, has introduced two insulation resistance testers offering digital insulation testing up to 10kV for testing a wide range of high voltage equipment including switchgear, motors, generators, transformers and cables.

The new Fluke 1555 and redesigned Fluke

enables easy downloading to a PC run-

without additional setup. They also offer

1550C Insulation Resistance Testers ena-

ning the FlukeView速 Forms software

capacitance and leakage current meas-

ble users to conduct tests over a wide

that is provided with the insulation test-

urement, as well as resistance readings up

range of voltages with a best-in-class 3-

er. FlukeView Forms allows the user to

to 2T Ohms. A guard system eliminates

year warranty and CAT IV 600V safety

document, store and analyse the read-

the effect of surface leakage current on

rating. With their measurement storage

ings, and present them in professional-

high resistance measurements.

and PC interface capabilities, they are the

looking documents.

ideal tools for engineers, maintenance managers, industrial electricians, sub-station specialists and linemen using predictive

and

preventive

maintenance

programmes designed to identify poten-

Kit versions are also available which offer

The Fluke 1555 and Fluke 1550C feature

an IP67 hard case, heavy duty alligator

a large digital/analogue LCD display for

clips and a calibration certificate. For

easy viewing. They provide automatic

more information about all Fluke products,

calculation of Dielectric Absorption Ra-

visit www.fluke.co.uk

tio (DAR) and Polarisation Index (PI)

tial equipment failures before they occur.

The Fluke 1550C Insulation Resistance Tester enables testing up to 5kV, while the Fluke 1555 tests up to 10kV. Test voltages are selectable in 50V steps from 250V to 1000V, then 100V steps thereafter. A ramp function enables breakdown testing, and timer settings of up to 99 minutes allow timed tests. A warning voltage function alerts the user that line voltage is present and gives the voltage reading up to 600V AC or DC for increased user safety.

Measurements can be stored in up to 99 memory locations. Each location is assigned a unique, user-defined label for easy recall. An optical interface cable

25

Engineering Maintenance Solutions, August 2010

New powertrain simulation tool will improve wind turbine performance and reliability A collaboration project between four companies has led to the development of new simulation software that is able to calculate the dynamic operating loads acting on wind turbine powertrains. dynamic

In order to gain a better understanding

operating loads is a

of the dynamic loads acting on the

critical factor in the

mechanical powertrain components in a

design of wind turbines.

wind turbine, the four project partners

Despite

wind

have brought together their respective

turbine designs, which

mechanical engineering and software

have stemmed from

expertise to develop a complex MBS

new alternative main

model.

Simulating

new

bearings and gearbox

multi-body simulation (MBS) model enables designers to optimise the design of individual powertrain components and establish how these interact with other systems across the entire powertrain.

The simulation tool, which can be used at the initial wind turbine design stage, will help to make wind turbine designs more reliable and cost effective under a wide variety of load conditions.

26

concepts,

as

BEARINX® enables users to make bearing

well

as

greater

calculations, including shaft deflections

demands in terms of

and stress calculations of complex

performance

and

bearing and gearbox arrangements. The

reliability of turbines,

software allows users to optimise their

up

load

designs by seeing the effect of any

simulations have been

changes rapidly. Various bearing designs

conducted

using

and shaft deflections can be considered,

relatively simple design

and then allow the results to be

calculation models.

compared with FEA calculations.

to

now

These simplified models

BEARINX®

consider

consideration,

only

the

takes

everything

including

into

non-linear

effects of load over

elastic deflection behavior of bearings;

time

specific

the elasticity of shafts and axles; the

stress

influence of fit, temperature and speed

variables, independently rather than for

on bearing operating clearance, preload

all powertrain components and how they

and contact angle. The software also

interact. This means that complex units,

takes into account load-related contact

such as gearboxes, which have multiple

angle shifts. Even for complex gears, the

dynamic components, are treated as a

contact pressure on each rolling element

‘black box’. The design of the gearbox

is

and how it affects other parts of the

Lubrication conditions, contamination

powertrain is not taken into account by

and actual contact pressure on fatigue

this over-simplified model, which could

life are also taken into account.

internal

Used in combination with Finite Element Analysis (FEA) tools, the new complex,

design

for

considered

in

the

result in an unreliable wind turbine design.

info.uk@schaeffler.com

calculation.

Engineering Maintenance Solutions, August 2010

service@axflow.co.uk infoscot@axflow.co.uk

info@axflow.co.uk

27

Engineering Maintenance Solutions, August 2010

The power of OEE and a few discrete energy meters The energy companies are giving away small meters to accurately measure domestic electricity consumption; I guess you will have seen the advertisements. It’s a simple process you place a small clamp around a cable near the electricity meter which is then cabled to a transmitter.

That transmitter links via wireless to a small screen which is probably placed in the lounge. The screen then displays kilowatt hour (kWh), cost or CO2 usage, and you can set targets to help persuade the kids to put on an extra jumper, rather than firing up the heating system.

The meters seem to work very well and give you an insight into what appliances zap the most energy. As I have replaced most of my traditional bulbs with LED lamps, my base house load is quite low at a few hundred watts, but start up the big screen TV and surround sound system and you can see just where the money goes. When my kids bring round with a couple of Pizzas for Saturday lunch it costs a surprising 9 pence to heat them in the electric oven. (I now collect the money at the door.)

All of these programmes are necessary to reduce energy consumption but they are not sufficient on their own to provide step-changes in energy efficiency. We need to address a bigger issue – equipment effectiveness in relation to products made.

A meter in each area will show how much electricity the entire area uses, and give a good indication of energy costs per product, but what is the true cost and level of usage if for instance we suffer a breakdown and the kit is left running at the end of production? In essence, how does our energy consumption compare to the products made?

The graph below illustrates the point.

Production starts at 6am and our kilowatts increase in line with a healthy product count, we experience short periods of slow running but then a major failure occurs at 10am. The product count stops immediately but our kilowatts continue because we don’t turn everything off. In any event the glue heaters will need to stay on to ensure production when we manage to fix the breakdown. By 11am we manage to begin production again until the end of shift at 2pm. It then appears that we forgot to turn off the glue heaters and the rest of the plant, as kilowatt values continue, albeit, at a slightly lower level. We can see from the zero product count that no products are being made – and the energy used is pure waste.

Taking this concept to the factory floor presents some interesting opportunities.

It is pretty easy to measure overall factory kWh and providing there are enough meters it is possible to measure each zone or area. But until recently, unless you spent big money, it wasn’t so easy to measure the energy consumed by individual bits of equipment.

So, now it’s fairly easy and has a sensible cost, is it a good ideas?

Let’s think through the normal energy reduction process. Most manufacturers have already implemented a wide-range of energy related programmes with varying degrees of success, including switch-off campaigns or installing sensors to turn lights off automatically. In fact, I remember training at IBM in the early 80s, and after 5pm I had to use a phone in order to turn on the lights for my desk while the rest of the office remained in total darkness. Other energy-reduction measures have included intelligent production scheduling at a lower timetariff, the installation of new energyefficient equipment, and improving maintenance procedures to reduce leaks.

28

The blue line shows products being made, the red depicts electricity usage.

We start glue heaters at 4am so that they are available for production at 6am; our base load at that time includes lighting and other ancillaries.

There is clearly a perfect link between OEE performance measurement and energy usage and, as such, there are a number of analysis points for this example factory’s continuous improvement team, including: 1.

Between 4am and 6am, is it possible for the electricity

Engineering Maintenance Solutions, August 2010

2.

3.

4.

5.

supply to be limited to only the glue heaters?

Is it possible and more efficient to turn the heaters on later?

Is it possible to speed up the plant to make more products for the same amount of energy?

Is it possible to turn off any of the assets during a major breakdown?

Is it possible to automate plant shut-off at the end of production?

And the obvious question: Can we use OEE & loss analysis to reduce slow running, and prevent breakdowns?

There is significant logic in linking simple current transformer (CT) type meters to an OEE application. OEE software already includes the asset structure, running hours and a product count. If we then include the output from a number of meters, at least at line level, we can ‘read’ the electricity consumption at defined intervals and compare the value to products produced. We can then consolidate the values at higher levels for effective site reporting.

If we go further and link meters at asset level we provide even more

opportunities for analysis. We can then see which machines consume the most energy and which should be switched off during a breakdown. Also think about fixing plates to each machine to show operators the energy consumed by each piece of equipment.

Contact him by e-mail, alan.france@idhammarsystems.com, or visit www.idhammarsystems.com for more on CMMS and OEE software.

And let’s not forget the impact of slow running; a filling machine running at 150 bottles per minutes instead of the 300bpm it’s designed to run at uses virtually the same amount of electricity.

But for that same energy cost you only have 9,000 bottles to sell at the end of an hour instead of 18,000. Quite some loss if the product is Vodka.

These types of meters are becoming very economical and they can be easily accessed via an Ethernet IP Address.

Surprising what you could learn, and improve, from a few discrete meters and a product count!

Alan France, Operations Director of Idhammar Systems, has extensive experience in lean manufacturing with a background that includes several years as Engineering Systems Manager for the largest food company in Europe. A systems specialist, he now consults on the importance of underpinning lean initiatives with realistic targets and sound metrics.

MANUFACTURING PERFORMANCE MASTERCLASS 2010 The annual Manufacturing Performance

'achieving competitive advantage

effectiveness and includes syndicate

Masterclass is proving an ideal forum for

through sustainable improvement' and

exercise to highlight key learning points,

sharing best practices across industries,

will be focusing on how manufacturers

question & answer sessions, and several

as well as providing an excellent

can compete post-recession as they are

case study examples.

networking opportunity. This year's

required to do more and more, with less

Agenda has been shaped by an Advisory

budget, time, and resources.

Group - comprising members from Premier Foods, Constellation Wines, Saint-Gobain, and Willmott Solutions - to ensure that the seminar addresses the most topical issues that UK manufacturers are facing...

Wednesday 13th October 2010 Heritage Motor Centre, J12 M40 Warwickshire

NEW for 2010, an exclusive half-day TPM & OEE Workshop (12th October, Heritage

The theme for MPM’10, held on

October at the Heritage Motor Centre, is

Workshop2010 are available online

Motor Centre) precedes the Masterclass

- www.MPM2010.co.uk – and

and will be jointly facilitated by Peter

delegates booking before 31st July

Willmott, a recognised leading authority

will benefit from an earlybird

on the application of Total Productive

discount. Please direct telephone

Maintenance (TPM), and Alan France of Idhammar Systems, a specialist in OEE and OEE Systems. Following feedback from last year’s Masterclass, the

13th

Full details for both MPM’10 and

and e-mail enquiries to +44 (0) 1179 209405 / MPM2010@idhammarsystems.com.

Workshop has been designed to take an in depth look at measuring equipment

29

Engineering Maintenance Solutions, August 2010

MAINTAIN 2010

Europe’s most important event for the industrial maintenance sector Tuesday 12 – Thursday 14 October – Munich MOC (Munich Order Centre), Germany About MAINTAIN Held in Munich, Germany, MAINTAIN is the industry's most important gathering.

As such, it brings together all decisionmakers in the manufacturing and processing industry, who use it as a forum to reach their common goal: to promote technical innovation, efficient management and service solutions.

MAINTAIN is the marketplace for impetus, strategies, concepts and sectorspecific solutions in industrial maintenance.

Since German industry remains strong and its engineering capacity is still the envy of the Western world, visitors should expect an extremely high standard of presentation. Visiting MAINTAIN will give you the opportunity to study at close range the extensive range of products and services that OEMs and service-providers have available in specific categories.

30

MAINTAIN emphasises solutions that translate into concrete competitive advantages and factors for success.

Maintenance management and related services are becoming increasingly important in the maintenance industry, so in addition to high-quality components and special solutions, more and more companies rely on complete and system solutions.

Ensure you visit MAINTAIN this year, since after 2010 it will be switching to a two-year cycle. The decision was taken in a move to meet the industry’s requirements after consultations with exhibitors, leading associations, and partners. The next MAINTAIN will therefore be held in October 2012.

In 2009 3,500 visitors attended from 36 countries – 94% of whom had an impact on the decision making process - and there were 230 exhibitors from 9 countries. A total of 160 companies from Austria, Belgium, China, Croatia, France, Germany, Great Britain, Korea, the Netherlands and Switzerland have already registered for this year’s fair.

Once again, exhibitors will occupy all three exhibition halls and some 10,000 square metres of exhibition space.

Register here now as a visitor for MAINTAIN, and receive all these benefits:

You can find a full database of exhibitors, and online visitor registration is now open.

How to buy your entrance ticket

• reduced admission to the fair - you will save more than 30%!

• save time when you are at the fair – no more time lost to queuing •

the now famous free Bavarian snack!

• free further training - free entrance to the exhibitor forum • free branch-specific information – the opportunity to participate in Guided Tours

Engineering Maintenance Solutions, August 2010 • free copy of the exhibition catalogue How to get there The MOC exhibition centre is situated in the north of Munich and is easily reached by underground train or taxi. Take the U6 underground line to Kieferngarten and follow the signs to the MOC – about a seven minute walk. Hotel accommodation is plentiful in the beautiful Bavarian city of Munich, and flights operate from all UK airports frequently. Contact Pressplan Travel on 01727 833291 for a quote. Alternatively, if you are in Munich just for the day, take a taxi to the MOC from the airport, since it lies directly between the airport and the centre of town. The taxi fare takes around twenty minutes and will cost about 50 Euro.

Come and network!

MAINTAIN gives maintenance professionals a comprehensive view of the industry and its trends. However, exhibitors and visitors also appreciate MAINTAIN’s strong networking character.

Gerhard Gerritzen, deputy managing director at Messe München GmbH explains: “MAINTAIN has a strong network character, which is why we also place special emphasis on the exchange of ideas and information within the

industry. We have instituted a number of changes for this year’s fair. For example, for the first time ever this year’s fair will feature specially developed seminars and contact points in the halls for groups of international guests. The “Makers&Markets” programme of related events feature technically founded presentations that will educate participants and spark lively discussions. A long-standing tradition is the free Bavarian midday snack, which has been inviting visitors to get to know one another and exchange ideas in an informal setting since the first MAINTAIN in 2005.”

The new “Makers&Markets” programme The fact that all presentations are being held at a central location in Hall 3 is not the only thing about the Makers&Markets that is new. Dividing the lectures up into various theme blocks such as Methods and Tools for Maintenance Management; Maintenance, Retrofitting and Modernising or Personnel Leadership, Personnel Management and Talent Management give visitors access to a range of presentations that meet their needs and are easy to integrate into their visit to the fair. The compact range of events allows trade visitors to choose between direct examples of specific applications in the products

sector and process-oriented topics that apply to all companies.

Guided Tours at MAINTAIN 2010 Guided Tours round out the programme of events at MAINTAIN 2010. Specialists from FIR (Research Institute for Operations Management at RWTH Aachen) will take users and other interested parties on a tour to the stands of exhibitors that sell CMMS solutions. During the tours, software manufacturers will examine concrete problems and answer questions. The tours will be held on all three days of the fair, are free of charge for visitors, and will be available in English and German.

Further information For all further information, please contact Pattern (Trade Fairs) Ltd, agents in the UK and Ireland for Messe München International, tel +44 (0) 20 8940 4625; info@pattern.co.uk

31

Engineering Maintenance Solutions, August 2010

Tools for Power Plant Maintenance First time exhibitors at the Energy Event this year ,Thermoteknix Systems Ltd will be showing their impressive range of thermographic tools for Predictive Maintenance for all areas of the power plant.

New VisIR thermal Imaging Camera for Predictive Maintenance VisIR thermal imaging cameras are designed for today’s industrial Predictive Maintenance programmes – with crystal clear images from a highly sensitive uncooled infrared detector, real time visual images and precise temperature measurement with the most powerful range of easy to use camera tools and unique Condition RED® database and software for routine Predictive Maintenance inspections.

VisIR Condition RED In-Camera Screen VisIR 640’s unique Condition RED asset based thermography system guides the camera operator through surveys to ensure consistent, repeated inspections.

Reference images of each asset are displayed alongside the live image at every inspection point to ensure the correct equipment is being surveyed.

Condition RED then compares the asset’s current condition against its historical data to assess whether any action needs to be taken.

generate trending and prediction for early fault identification and planned service. A wide range of customisable reports are generated automatically with repair recommendations including reinspection intervals and critical equipment work lists.

Thermal Image of motor displayed on crisp DayBrightTM Touch Screen Interface With a unique rugged industrial housing, an articulated central optics pod for ergonomic and safe operation and high contrast DayBright™ touch screen, VisIR provides high definition thermal and visual image clarity in any lighting conditions.

Stunning clarity with VisIR 640 – High Voltage Power Lines High Voltage Transformer viewed using VisIR’s powerful Image Fusion Mode Boilers and Hot Vessels

ThermaScope High Temperature Camera Thermoteknix will also be showcasing their range of ThermaScope® high temperature cameras which help improve efficiency, increase combustion control and reduce pollution.

ThermaScope SLK is a high performance radiometric temperature imaging system. It displays bright clear video images within high temperature

Ÿ Heat Loss from Insulation Ÿ Steam Trap

Thermoteknix Condition RED software combines PC based database storage and

Ÿ Pipes and Valves ŸElectrical Switchgear ŸPumps, Bearings, Motors

procedure handling with automated route based image inspections to

32

VisIR’s high resolution detector and digital colour camera make surveys more efficient and cost-effective with integral LED illuminator/flash, laser pointer and voice recording.

For carrying out Predictive Maintenance on the pre-heater, motors, drives, switch gear, and much more equipment, VisIR is the ideal thermal imager. Both 320x240 and 640x480 models are available.

processes and measures the temperatures at every point in the ThermaScope field of view.

The ThermaScope processor software gives the process engineer or operator advanced analysis tools with control interface signals for advanced closed loop control.

Engineering Maintenance Solutions, August 2010

ThermaScope SLK view in a 16-burner heavy fuel fired power station boiler High temperature boiler, kiln, furnace or oven operating conditions are continuously monitored by the ThermaScope SLK. Abnormal conditions such as over or under temperature, poor temperature distribution or irregular flame shape is instantly shown.

These can be alarmed and interpreted by the Operator or Process Engineer with user-friendly analysis tools and temperature displays.

ThermaScope HTV is an alternative low cost non-radiometric high temperature video camera which will also be on display on the Thermoteknix stand 301.

The Energy Show takes place 8th-9th September in Birmingham (UK).

33

Engineering Maintenance Solutions, August 2010

34

Engineering Maintenance Solutions, August 2010

Southco fastening solutions aid compliance with new EU Machinery Directive For machine builders worldwide, operator safety is of paramount concern. Now, with the advent of the new Machinery Directive 2006/42/EC which became effective on December 29, 2009, safety attitudes are further emphasised.

The latest legislation, which is concerned with the mechanical and electrical safety of machines, represents a consistent message of safety for machine builders across Europe - they must design safeguards to protect equipment operators, while providing service that minimises downtime! In this context, machinery is described as “an assembly of linked parts or components, at least one of which moves, with the appropriate actuators, control and power circuits etc joined together for a specific application, in particular for the processing, treatment, moving or packaging of a material�.

The rationale behind the framework of the strict measures laid out within this latest legal requirement for equipment manufacturers globally selling within the EU, is to ensure the safety of individual workers whoever or wherever they may be. The fastening of machine guarding and the ergonomics of operator equipment are both high on the list of safety requirements imposed by the new directive.

Specifically, the directive states that to obtain CE accreditation, machinery and equipment must be restricted by attaching protective devices such as fixed, adjustable and movable guards.

Such protection devices should be of

robust construction, not be easy to bypass and must be used to protect risks such as moving parts. Fixed guards need to be held in place by fixings which can only be opened or removed with tools, movable guards should be interlocked, and adjustable guards should be readily adjustable without the use of tools.

Compliance – the right choice This new legislation has created a dilemma for machine builders, operators and purchasers across the industrial equipment market place as they struggle to decide on the most effective choice from a plethora of different options, in terms of meeting the new safety

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Engineering Maintenance Solutions, August 2010 • where possible, guards must be incapable of remaining in place without their fixings

Southco’s access hardware solutions aid machine builders

Engineered fixing systems using Southco’s established and proven range of captive screws minimise problems commonly experienced with loose screws, nuts, or bolts dropping into operating equipment. And from a productive perspective, engineered fixing systems that utilise captive, selfaligning designs, improve assembly speed and convenience. The company’s extensive range includes screws with a smooth knob action, screws that are flush fitting for safety, and smooth head screws for use in a limited space. For added safety, differently coloured headstyles are available.

adhere to the new EU regulations for machine guarding

requirements in the most cost effective way. As the global leader in the provision of access hardware solutions, Southco believes it is ideally positioned to help machine builders adhere to these new regulations.

equipment manufacturers and operators to stay on the right side of the law.

Sturman: “We believe those who adopt these short-term approaches will create a lot of problems for themselves longer term. However, those willing to invest in our reliable and easy to use captive and quick access hardware solution, rather than plump for cheaper options, will not only comply with the directive but also enjoy additional benefits as a result of the company’s industry-leading technical values. These include a longer life cycle, enhanced product performance and longterm cost savings.”

Fixed guards

Ulrike Sturman, Industry Marketing Manager for Diversified Technologies at Southco, takes up the story: “The industrial machinery and equipment market is a very fragmented industry and covers a vast and diversified range of sectors. At Southco, we can offer designers, suppliers and purchasers of industrial equipment the complete solution, in terms of fastening devices, technical expertise and a wide and localised distribution network to support the requirements of a segmented industry to comply with the EU directive.

As well as having the industry’s widest range of captive and quick access fasteners available globally for machine guarding, as the market leader in positioning technology we can also provide a host of hinges and positioning control devices for positioning adjustable guards, and for allowing monitor screens and control panels to be moved smoothly and effortlessly with zero backlash through controlled torque mechanisms.”

Southco fully recognises that compliance means extra costs to a business and is therefore a price sensitive issue. This fact is reflected by the ‘quick fix’ and DIY solutions being adopted by many small to medium-size industrial

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For fixed guards, the directive has three key stipulations: • fixed guards must be fixed by systems that can be opened or removed only with tools • their fixing systems must remain attached to the guards or to the machinery when the guards are removed

Also, for quick and easy access - which is particularly advantageous for repeataccess applications – and high strength and economical performance, the Dzus quarter-turn and fast-lead captive fasteners ranges provide different options for tool-restricted access, and flush or low-profile installations. Also available are self-ejecting options that provide a visual indicator for unfastened guards, while the spring-ejection feature helps clear fasteners out of the way in multiple fastener applications.

Adjustable and movable guards For adjustable guards restricting access to those areas of the moving parts strictly necessary for the work, the directive states that they must be readily adjustable without the use of tools.

For these applications, Southco has a range of controlled-torque positioning devices providing the ability to raise, lower, tilt, swivel, and position adjustable guards for better safety protection during equipment operation and for easy access when necessary.

Southco offers the industry’s widest range of access hardware solutions and most innovative positioning technology products

Engineering Maintenance Solutions, August 2010 as for activating electronic lockout sensors on movable guards.

Additional devices such as captive spring-loaded plungers also allow for quick positioning and fixing of sliding guards.

Sturman: “Initially, our main focus is on machine guarding applications across five key segments - namely printing and labelling, textile, processing and packaging, materials handling and compressors.

Southco Europe Ltd;Touch Point, Wainwright Road, Warndon, Worcester, WR4 9FA, UK • Tel: +44 (0)1905 346500 • Fax: +44 (0)1905 346501

These specific sectors have been identified as those that we believe would best benefit from Southco’s access hardware solutions.”

These devices, which include the recently launched AV-D30 mounting arm, can also hold guards in a partially or fully open position without secondary hardware, to provide unrestricted maintenance access.

According to the directive, "interlocking movable guards must, as far as possible, remain attached to the machinery when open, be designed and constructed in such a way that they can be adjusted only by means of an intentional action, and be designed in such a way that the absence or failure of one of their components prevents starting, or stops the hazardous machinery functions”.

AV-D30 Mounting Arm

For such applications, Southco can offer tethered quick-access pins with simple push-button actuation for locking movable safety guards into place, as well

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Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

CORUS INSTALLS GEM STEAM TRAPS TO IMPROVE ENERGY CONSERVATION AND REDUCE CO2 Corus’s Trostre Steel Works in South Wales has installed Thermal Energy International’s GEM Venturi orifice steam traps as part of the plant’s continuous improvement programme into energy conservation and CO2 reduction. A leading supplier of high quality light gauge steels, the site produces over 400,000 tonnes annually of packaging steels for the UK market.

As part of the steel making process, Trostre Works operates a continuous annealing (CAPL) process line to give the steel its required hardness. The CAPL process line uses around 600 tonnes a week of saturated steam supplied at 8 BarG. As the name suggests, the operation is continuous process achieved through the use of two entry and exit reels. At any one time there will be over 1,000 metres of strip running through the line. The furnace section of the line heats the strip to a selected temperature within a 650°C to 690°C range. This temperature is maintained through the mid section and the strip is gradually cooled in the final furnace. By passing the strip through cooling chambers and a quench tank further cooling is achieved.

Finally the strip is recoiled for further downstream processing.

The site had previously installed a GEM Venturi steam trap following a bucket test on a line drainage trap, which had provided 60% savings. Following the appointment of Dr Darryl Lewis as Energy Operations Manager, TEI was asked to survey the CAPL process line and V Stand Mill. This found that of the 12 steam traps surveyed 25% had failed closed and 17% had failed open.This was increasing energy and having an environmental impact by creating additional amounts of CO2 emissions each year. Now a total of 18 GEM Venturi orifice steam traps have replaced the existing mechanical steam traps.

“I have been extremely pleased both with the operation of the traps and, equally importantly, the after sales service provided

by TEI’s engineers”, said Dr Lewis. “The site was the first steel works and heavy industry in the UK to win a Carbon Trust Standard Accreditation in January 2010 in recognition of our commitment to reducing energy and CO2 emissions. The trap improvement programme was an important element in achieving this”.

Based on nominal consumption rates of 600 tonnes of steam a week, the GEM traps are providing around 5% energy savings which equates to £0.5K a week based on a gas tariff of £4.4/GJ and condensate waste treatment costs. These savings will provide a payback on the GEM steam traps in around 30 weeks.

Available in a wide range of sizes for a full cross section of applications, the hardwearing GEM steam traps are manufactured from corrosion resistant stainless steel and are guaranteed for 10 years.

Thermal Energy International Inc., 1 John Street, Bristol, BS1 2HS Tel: 0117 917 7010 Fax: 0117 917 7011 www.gemtrap.com

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Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

Ametek Solidstate "AMETEK Solidstate Controls is not only known for its rugged and reliable products but also its world renowned client support.

At Ametek Solidstate Controls we take client service to a level far beyond that of a traditional field service department by offering a variety of customized maintenance and technical training programs worldwide to cater to our customers’ specific needs.

Maintenance Our preventive maintenance programs are designed to keep your UPS systems and other critical power equipment in optimal condition and minimize downtime. We also provide equipment rental services in emergency situations. All of our services are provided by factory trained personnel to ensure the highest level of service.

Our UPS & Battery Technical Training Seminars present excellent learning opportunities for our clients. Seminars can be presented at our training facility or at the clients’ site. Our facility features a variety of equipment that allows trainees to gain practical hands on experience in a learning environment. All seminars are designed for the equipment the client has at their facility.

More information is available at http://www.solidstatecontrolsinc.com/s upport/training.html Our factory trained experts are ready to provide highly customized training solutions upon your requested time and location.

Contact Information Training: 800-635-7300/ 614-846-7500 or Email: Tech.Training@ametek.com Service & Maintenance: 800-222-9079 For more information, please visit us at: http://www.solidstatecontrolsinc.com

Training

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Engineering Maintenance Solutions, August 2010

THERMAL IMAGING MAKES KAWASAKI PROACTIVE Around the world, in virtually every area of construction, marine and manufacturing industry, Kawasaki Precision Machinery (KPM) provides quality power and control solutions.

KPM UK, the UK arm of KPM’s Heavy Industries Group, focuses on the supply of hydraulic motors and pumps worldwide.

It also provides a maintenance service.

And it is in this field that KPM’s investment in a FLIR T425 thermal imaging camera is really helping the company to predict mechanical faults before they become costly failures.

“We are actively developing new programmes to improve our overall equipment efficiency (OEE) by reducing unplanned downtime,” explained Ray Wilson, Assistant Manager – Maintenance with KPM. “To that end we are moving from a reactive- to a pro-active approach.

So we have appointed a PPM engineer and it’s his job to encourage machine operators and production managers to use predictive maintenance tools. Thermal imaging is now one of the tools at his disposal.”

An important ingredient in this initiative is the introduction of a ‘birth certificate’ for each of the KPM machines. This record is retained on KPM’s own IT system and a hard copy displayed on the installed machine. Once this project is completed it will form an essential part of the PPM programme and provide a benchmark against which regular checks will be made.

Indeed it was in the creation of one ‘birth certificate’ at a customer’s site that a problem with a breaker to a machine tool became evident. “The FLIR T425 camera detected the fault in time for us to get a replacement from Japan,” Ray Wilson explained.

“This part had to be made to order, so if the camera had not flagged up the problem and the breaker had failed, we could have had a machine down for weeks.

Worse still, if the faulty breaker had

caused an outbreak of fire, the electrical system

would have been damaged and the safety compromised.”

of

the

workforce

The FLIR T425 was introduced for the express purpose of reducing energy consumption and minimising downtime through highly efficient electrical and mechanical fault-finding. Features such as auto-focus and digital zoom lens enhance its flexibility. Ergonomic design combined with low weight, picture-inpicture fusion, touch screen, tiltable lens unit, laser pointer and interchangeable optics made it the best choice for KPM. “We tried a selection of different brands,” Ray Wilson added. “The FLIR camera and the training support provided

by FLIR best suited our needs” One of the greatest advantages of thermal imaging is the wide range of applications to which it can be applied.

The website and magazine dedicated to engineers working in hazardous environments:

www.hazeng.com

And this is a benefit which KPM is now experiencing. The company is now also starting to use its FLIR T425 in the commissioning new equipment and also for evaluating health and safety issues such as fire risk.

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Engineering Maintenance Solutions, August 2010

New bent-axis hydraulic piston units Parker Hannifin's new bent-axis hydraulic piston units are ideal for open- and closedloop circuits in demanding industrial and offshore applications, including winches, pile drivers and cranes.

Now available in 150 and 250cc models, Parker's F12 series motors feature an enhanced design to ensure lower loads of internal friction, reduce operating temperature and noise levels, and improve reliability and productivity.

The F12 series of high-performance motors delivers high shaft speeds and can operate at pressures of up to 480bar Featuring a spherical piston design, the motors offer high shaft speeds with the capability of operating at pressures of up to 480 bar, while producing high torque at start-up and low speeds.

Featuring piston-lock technology and a minimal number of moving parts, the F12 Series piston motors are said to be very robust, providing long service life with high reliability.

Parker's timing-gear design synchronises the shaft and cylinder barrel, meaning that the motors can tolerate high Gforces and torsional vibrations, while the heavy-duty roller bearings ensure high

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external-axial and radial-shaft-load capacity.

The 40deg angle between the shaft and cylinder barrel allows for a particularly compact design.

The F12 Series motors also feature highprecision valve plates for increased selfpriming speed and low-noise operation, with options for left- and right-hand rotation.

The use of laminated piston rings ensures low internal leakage, thermal-shock resistance and a operating life.

With the addition of these models, the F12 Series bentpiston units are now available 30, 40, 60, 80, 90, 110, 125, and 250cc sizes.

high long latest axis in 23, 150

Standard options for the motors include a choice of CETOP, ISO and SAE mounting flanges, and shaft-end configurations, with a compact cartridge version also available.

Engineering Maintenance Solutions, August 2010

Anti-vibration mounts for industrial motors A range of rubber anti-vibration dampers for small flange-mounted industrial motors, such as steppers and servos, has been introduced by motion control specialists Astrosyn International Technology A range of rubber anti vibration dampers for small flange-mounted industrial motors, such as steppers and servos, has been introduced by motion control specialists Astrosyn International Technology.

systems in analytical instruments or in marking and engraving machines.

lightweight, the dampers can be mounted directly onto the motor flange.

Available in NEMA motor frame sizes 16, 17, 22 and 23, they can be easily retrofitted to existing motors.

The mounts are ideal for applications where motor noise and vibration need to be minimised, such as in security camera controls, sample movement

Their thin profiles (6 mm for the smaller sizes and 10 mm for the larger ones) allow them to be used with standard shaft length motors. Robust but

Threaded mounting holes are provided on the damper metal mounting face. The central access hole is large enough to accommodate a spigot and gear or pulley. The hole diameter is 22 mm on the smaller sizes and 40 mm on the larger models.

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Engineering Maintenance Solutions, August 2010

Halifax ATEX blowers kill all known germs With MRSA and C. Difficile seemingly endemic in our hospitals, this might well be called the age of the superbug. For that reason sterilisation of everything used in a hospital is absolutely critical and most of us visualise sterilisation as a high temperature process. However, not everything medical can withstand the high temperatures necessary to bring about absolute sterility.

Items such a soft rubber goods, surgical implants, intravenous kits and the like would all be damaged by high temperatures.

One option is gaseous sterilisation.

Ethylene Oxide (EO) gas kills all known bacteria and their endospores, mould and fungi and is highly effective in sterilising materials that would be damaged by, for example, pasteurisation or Gamma radiation. Unfortunately, EO is carcinogenic, toxic, highly flammable, potentially explosive and gasifies at 10oC. It therefore requires great care in its utilisation and the design of EO sterilisation plant is a highly specialised one whereby all electrical and mechanical equipment must be fully compliant with hazardous area standards.

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Getinge UK of Sutton-in-Ashfield are a centre of excellence in the design and construction of EO sterilisation systems and install bespoke sterilisation plants worldwide for manufacturers of medical devices, sterilisation contractors and other healthcare product manufacturers.

In a typical system, pallets of the products to be sterilised are placed in a conditioning area where the temperature is raised to around 55oC and the humidity to around 70% RH. This ‘activates’ any microbes and renders them more susceptible to the EO gas.

The pallets are then loaded into the hermetically sealed sterilisation chamber and the integrity of the chamber is

confirmed with a vacuum test. The chamber is then flooded with EO gas at below atmospheric pressure and the temperature maintained at the conditioning level by circulating heated water round a water jacket surrounding the chamber. During the typically 12 hour period the goods are exposed, it is critical that the EO gas is maintained as a homogenous environment throughout the chamber. To achieve this a specially designed explosion-proof Halifax Fan blower is used to continuously circulate the gas through manifolds on the sides and top of the chamber, changing the entire volume of the chamber typically 8 to 10 times per hour, eliminating gas

Engineering Maintenance Solutions, August 2010 stratification and ensuring that the gas penetrates every nook and cranny.

Once sterilisation is complete, the chamber must be progressively flushed with nitrogen while the EO gas mixture is bled off through a catalytic converter that converts the EO to CO2 and water.

The Halifax blower continues to circulate the gas mixture in the chamber as the gases are of different densities and would stratify if not actively circulated.

Once the concentration of EO is reduced to the point where it is safe to introduce air to the chamber, the pallets are moved to the post-condition area where the temperature is elevated to aid the degasification process.

The potentially explosive nature of Ethylene Oxide means that the circulating blower has to be designed to meet the exact needs of every installation, and to full explosion-proof standards. Halifax’s design is based upon many years experience building fans and blowers to handle explosive gases and features spark-proof features such as brass rubbing strips and a coupling guard.

The stainless steel 316 shaft is fitted with a dual cartridge mechanical shaft seal purged and cooled with water.

The fan is rated to work down to very low sub atmospheric pressures but the

high integrity, gas tight, stainless-steel casing is designed to +10Bar and tested to +11Bar. ATEX certified stainlesssteel inlet and outlet flame arrestors protect against potential flame propagation beyond the fan in the event of internal combustion. ATEX certified accelerometers and vibration monitors are included for early detection of any imbalance in the fan impeller that might lead to contact with the casing, potentially causing a spark.

the most demanding specifications of all our applications. We’re happy with Halifax Fan’s self certification for Zone 1 as this satisfies the environmental and gas groups with which we must comply but we also draw confidence from the increased safety margin of the Cat 1, Zone 0 rating to which Halifax builds the fans.

Ian Crum According to Shaun Riley, EO Product Specialist at Getinge, ‘Although some of our competitors build their own blowers, we attach so much importance to this item that we wanted it designed, built and certified by specialists and supplied as a reliable fit-and-forget fully certified component. The hazardous nature of Ethylene Oxide meant that we wanted to deal with a manufacturer with a proven expertise in ATEX and hazardous gas applications. Halifax worked closely with us to develop a range of bespoke blower sizes that we can use for quotation purposes and then, once we have a contract settled, the blower design is fine tuned to the exact specification of that application.

Although the blower comes to us fully certified to ATEX 94/9/EC for Category 2G, Zone 1, it is actually fully rated for duty at Category 1G, Zone 0, meeting

Halifax Fan Ltd Mistral Works Brookfoot Business Park Elland Road Brighouse, W Yorks HD6 2SD Tel 01484 475123 Fax 01484 475122 e-mail:- Ian@halifax-fan.co.uk web:-www.halifax-fan.co.uk

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Buyers Guide 2010

EngineeringMaintenance MaintenanceSolutions, Solutions,August June 2010 Engineering 2010

Asset Mngmt/CMMS Cayman Venture is a British based engineering software company who have been developing and supporting maintenance and engineering systems since 1991.

Telephone: 0191 296 3816 Fax: 0191 296 3856 e-mail: info@cayman.co.uk website: www.cayman.co.uk

Logimatic Logimatic is an international engineering and IT company with more than 20 years of experience of sales, implementation and support of in-house developed software solutions. In addition to that we focus strongly on system integration and consulting services.

Logimatic Aalborg (coporate office)

Tel.: +45 9634 7000 Fax: +45 96 34 7001 E-mail: lmc@logimatic.dk www.logimatik.dk

PMI Software has been established since 1987 providing Engineering & Safety Software Solutions to businesses Worldwide. Best known for its CMMS product PEMAC, we also supply Permit to Work, Risk Assessment & Accident Report Systems.

We also provide innovative Custom Software solutions through our Custom Division, servicing those customers with specific software requirements that are not being met by the marketplace. www.pmisoftware.co.uk 353(0)1404 0000 For more information please contact:

Approved Doors

By Email: sales@simplisys.co.uk

Siveco Group have been developing and producing CMMS (Computerised Maintenance Management Systems) solutions since 1986 for companies within the Industrial and Tertiary sectors.

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Call our 24 Hour Call Centre: 01536 482187 T. 0161 495 4600

Tel: (44) 1 25 684 38 33,

F. 0161 495 4690

Fax: (44) 1 21 684 37 67,E-mail : byainne@siveco.com

E. info@solutionspt.com

info@stanair.co.uk www.stanair.co.uk

Buyers Guide 2010

Engineering Maintenance Solutions, August 2010

Boilers

Condition Monitoring

Steam has been generated by CERTUSS steam generators for over 50 years, technically perfect, economical and utilised in a controlled manner.

Telephone Number +44 (0)1494 816569 +44 (0)1494 812256 sales@monitran.com

Sales@certuss.co.uk +44(0)121 3275362 www.certuss.co.uk 49

Buyers Guide 2010

Engineering Maintenance Solutions, August 2010

Hydraulics WFE Hydraulic Services Ltd are designers and builders of bespoke hydraulic cylinders, rotary couplings and power pack systems. Our 35,000 sq ft manufacturing base is situated in North Sheffield adjacent to the M1 J34.

Reliability Software

Formed in 1986, Isograph is a world leader in the development of Safety, Reliability, Maintainability and Availability software.

Isograph software is in use in a wide variety of industries at around 10000 sites worldwide.

Garry Marsh for repairs on:

Isograph products are used extensively in industries such as rail, nuclear power, automotive, defense and aerospace to improve safety and reliability. They are also used to optimize the maintenance and to improve asset performance in industries such as utilities, petrochemical, mining & mineral processing.

Sales: +44 1925 43 7001

Tel: +44 (01142) 430 936

Support: +44 1925 43 7002

Fax: +44 (01142) 425 516

Fax: +44 1925 437010

Tel: +44 (01142) 430 931

E-mail: wfe.hydraulics@btinternet.com

Training

Lubrication

SPM Instrument has 40 years of experience with machine condition monitoring and close cooperation with our customers in all fields of industry.

SPM Instrument UK Ltd. Tel +44 1706 835 331 | Fax +44 1706 260 640

Reliability Consultants

info@spminstrument.co.uk Mutual Consultants Limited specialise in assisting clients to apply ReliabilityCentred Maintenance (RCM) in the United Kingdom and the Republic of Ireland through world class RCM training, RCM consulting, RCM facilitation and the supply of dedicated RCM software.

Increase efficiency – reduce costs These targets are set daily for industrial managers. We have found solutions which have quick pay-backs and which will give you decided competitive advantages. Rely on our experience and competence – which we have gained over 25 years. www.chambers-company.com

As a member of the Aladon Network of companies we can draw on experience from (and provide contact with) Reliability-Centred Maintenance (RCM) users world-wide. Our approach is to impart knowledge of Reliability-Centred Maintenance (RCM) to clients via Training Courses and Technical Support.

Our support may include project management and contract facilitation.

Tel:

+44 (0)1788 555000

Fax:

+44 (0)1788 555010

Thermography

Tel.: +44 1420 5444-33 Fax: +44 1420 5444-34 E-Mail: webenquire@testo.co.uk

Hire - Sales - Calibration - Thermal Imaging Tel: +44(0)1772 815 600

Email: info@mutualconsultants.co.uk

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testo Ltd.

sales@expresshire.net.

Web: www.testo.co.uk

Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, August 2010

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