Engineering Maintenance Solutions Feb 2012

February 2012

MAINTEC 2012 the premier event for plant & asset management Pages 29 - 37

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A culture of reliability Maintec Show Preview.

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How CMMS software can improve your chance of successful Implementation

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www.engineeringmaintenance.info

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Industry Latest News

13 - 15

Maintenance Best Practice

16 - 25

Product Spotlight – Including Dry Ice Cleaning

29 - 37

Maintec Show Preview

Contacts Publisher Michael Dominguez

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

Advertising Paul Clappison - Magazine Paul Miles - Online Advertising

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Humidity Calibrators

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Editors Choice

Email Info@engineeringmaintenance.info

Website www.engineeringmaintenance.info

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

48 - 50

Buyers Guide 2012

Latest News

NORBAR LAUNCHES TRUTORQUE™ SCREWDRIVERS An important development in torque tools has taken place with the launch of an innovative range of Norbar TruTorque™ torque screwdrivers. The selection includes adjustable tools providing exceptional flexibility of use and also fixed torque versions, ‘P’ Types, that have been designed for the production environment and pre-set for specific workplace demands.

These new Norbar products are safe, easy-to-use and extraordinarily accurate, to better than the International Standard. They offer high performance capabilities for dealing with a wide range of precision tasks requiring sensitive and safe screw connection.

These include: • Electronic assembly • Automotive applications such as assembling crash sensors, inertia reel fixtures, airbags and interior trim • Fitting cutting tool inserts All adjustable tools are supplied with traceable calibration certificates.

Further features and benefits: Easy torque adjustment without need of additional tools • All tools feature a lock to prevent the accidental adjustment of the set torque • Tools ‘slip action’ occurs when required torque level is reached, avoiding over-tightening • All screwdrivers supplied with ¼ inch hexagon bit holder using a 4mm hexagon stem • For maximum versatility and particularly for applications with limited access, the bit holder can be removed and replaced with widely available screwdriver blades.

•

Comfortable, durable handle, constructed from a strong base material covered with a soft overlay for comfort and slip resistance

Philip Brodey, Director of Norbar, comments: “The new screwdrivers are an invaluable addition to our TruTorque™ range. Accurate, robust and reliable, they expand the potential of applying torque measurement principles to the most precise and delicate applications.”

Norbar TruCheck™ Screwdriver Testers Norbar has introduced three new products specifically designed to calibrate torque screwdrivers, applicable to both its own products and those of other manufacturers. Accurate to +/- 1% of reading, Norbar TruCheck™ Screwdriver Testers allow operators to perform quick and simple calibration checks from easy-to-read LED displays without the need to call on third party calibration services, saving both time and expense.

For further information about Norbar products and services, contact: Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxfordshire, UK OX16 1XJ T+44 (0)1295 270333 enquiry@norbar.com

ifm electronic at Drives & Controls 2012 From 17th to 19th April this year ifm electronic will be joining almost 300 other world class companies at the NEC in supporting Drives & Controls, the UK’s leading event for Drives, Automation, Power Transmission & Motion Control. ifm electronic is well known as a market leader in sensing technologies, from inductive, magnetic and optical position sensors to flow, pressure and temperature process sensors, and ifm electronic has a growing reputation for up-to-the-minute condition-based maintenance systems, along with plant safety and efficiency.

On the control side, ifm electronic also offers much from dedicated controllers, including a major AS-interface offering, to identification systems covering RFID and barcode solutions.

At the Drives & Controls exhibition ifm electronic will be displaying the very latest from one of the most innovative companies in these fields of expertise, with experienced staff on hand to introduce, demonstrate and explain the latest products.

A show like this with free entry and leading manufacturers such as ifm electronic is an opportunity not to be missed.

ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.

For further information, contact Mel Lewis, ifm electronic Ltd., Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD. Telephone: 020 8213-0000. Fax: 020 8213-2228. E-mail – marketing_gb@ifm. com or visit our website www.ifm.com/uk

Sterling-SIHI Demonstrates Energy Saving Potential at Tate & Lyle Sugars Sterling-SIHI performed an energy audit at Tate & Lyle Sugars, London, which demonstrated the potential to save 90% of energy costs associated with the assessed pumping system.

Initially the auditing team visited the Silvertown refinery to assess the current system, gain an understanding of the layout, gather historical data, and most importantly – identify the system and process requirements. During the subsequent audit and thorough process research, Sterling-SIHI were in a position to take measurements and carry out run tests, enabling the auditors to determine a number of “what if” scenarios and establish an accurate process demand. Tate & Lyle Sugars received a detailed report and presentation, illustrating the energy-saving potential that could be achieved.

Impressively, Sterling-SIHI’s recommendations on one pump alone, would lead to an installation previously using 590MWh of electricity per year, to operate using only 40MWh. This would cut Tate & Lyle Sugars energy costs by £27,400 (the equivalent of 300 tons* of CO2 per year). Imagine the possibilities, should such advice be extended to the several hundred pumps currently operating at the plant. * based on 0.544kg of CO2 emitted / kWh as standard values, not necessarily actual sites values.

Sterling Fluid Systems (UK) Limited Atlantic Street, Altrincham, Cheshire, England, WA14 5DH Telephone: +44 (0) 161 928 6371 Fax: +44 (0) 161 925 2129 e-mail: uksales@sterlingfluid.com

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Latest News

Atlas Composites Ltd Achieves AS9100:2009 Rev C Accreditation The latest revision is now the established benchmark for any company in the composite engineering industry wishing to tender for new business in Aerospace and Defence. Compliance with it proves that a company’s Quality Management System relies on clearly defined business processes to measure its effectiveness in meeting customer requirements.

Atlas Composites are industry leaders in the design and manufacture of carbon, glass, kevlar and aramid composite components and tooling for the Aerospace, Defence and Satellite Communications industry. Customer approvals include Airbus, Agusta Westland, BAE Systems, Bombardier Aerospace, Cooper Antennas, GKN Aerospace, Lockheed Martin, MBDA, Meggitt, Nordham and Thales.

Work towards the revised standard began in 2010 using a gap analysis database designed by strategic partner TPT Consultancy, to verify the effectiveness of the management system and practices.

The gap analysis identified the need for Atlas Composites to make the transition from its procedural-based quality management system, which satisfied the requirements of AS9100 Rev B, to the required new process-led approach.

The first stage was to determine Key Performance Indicators for all the required processes. This was followed by integrating a review process where performance was measured against planned targets and improvements made where targets were not being met.

SGS conducted the successful audit in July 2011 and issued the AS9100:2009 accreditation with no non-conformities identified.

As a result, Atlas Composites business objectives are now clearly defined, deployed and integrated into the company, supported by clearly defined KPIs. The business process interactions are defined using the process approach and process owners identified. The process performance is measured through the effective deployment of KPIs to support continual improvement.

Delivery performance over the past 12

months stands at 100%, and Quality Performance 99.4%.

“Making the transition from Rev B to Rev C was a key objective,” says Shaun Moloney, Managing Director, Atlas

Composites Ltd. “Without this there was potential that business could be lost. Delivery and Quality was excellent, and the challenge was to measure how effective we were in achieving this.”

ENSURE COMPLIANCE WITH PPG26 POLLUTION PREVENTION GUIDELINES Fentex Ltd have consolidated their spill trays and absorption materials providing a range of products to achieve compliance with the national Pollution Prevention Guidelines (PPG26). Spill trays can be supplied for use with single or multiple primary containers of 1, 5, 20 and 25 litres capacity together with drums up to 205 litres. These provide the necessary secondary containment facilities during the storage or decanting of liquids, ensuring that drips, leaks and accidental spills can be successfully contained. They help maintain a clean, safe work area environment while preventing pollution or contamination of land, surface waters and groundwater from the run-off of inks, oils, solvents and a wide range of potentially harmful or noxious fluids. Applications for spill control equipment are truly universal, but typical industry sectors that would benefit from the use of Fentex products include motor trade and transport, printing, plastic production and the food industry, together with any areas where hydraulically powered machinery or plant are in use.

In general workshop conditions, spill trays can be used to provide a contained cleaning/dispensing area and can also deal with machinery leaks or the storage of oil contaminated components during breakdowns/servicing of machinery. They help to reduce floor contamination leading to better, safer working conditions, while leaked fluids that would have been lost can be recovered for

recycling or reuse.

Individuals, private businesses and both large or small companies and commercial organisations are required to meet the pollution recommendations covered by the PPG26 guidelines as relevant to Scotland, Northern Ireland, England and Wales. Current legislation and recommended good practice requires that provision should be made for a spill tray capacity being provided to accommodate 25% of the total fluid volume of any stored primary container(s).

length can be supplied, suitable for small bottles and containers, or as convenient machine drip trays. Larger trays from 40 to 60cm in width and 56 to 120cm in length provide fluid spill retention capacities from 2 – 28 litres. These are complemented by larger capacity drip pans and extra deep trays with spill retention capacities up to 120 litres. Handy trays for general maintenance operations

The spill trays are manufactured from durable, lightweight rigid plastic, in a wide range of rectangular and square sizes and various depth configurations. They incorporate an all-around moulded lip, some featuring a pouring spout, which ensures extra rigidity and good lifting control for trays during moving when they are full with their spill contents.

Trays can also be supplied with moulded ridges on the base to allow for airflow under stored containers.

For more generous sizes, on trays providing the larger spill retention capacities, drop-in removable grids can be supplied providing a non-slip storage surface while allowing for easy access and cleaning of the spill tray itself.

or use as drip trays underneath mobile plant or other vehicles include a 41 x 31cm size tray together with an 85cm octagonal tray which covers a large floor area. Both general purpose and specialised oil and fuel absorbent material rolls can also be supplied for use with spill trays for easier handling of leaked fluids. Spill trays providing storage for multiple standard 20 litre containers can also be supplied. These cover combinations of 2, 6, 9 or 16 containers per tray, all supplied with removable internal grids to elevate the stored containers away from any spilt liquid and for easy cleaning.

Mini spill trays from 35 to 76cm in

Further information is available on request to: Fentex Ltd, Units E1 – E3, Brook Farm Business Park, Ellington, Huntingdon, PE28 0AE

Telephone: 01480 890104 Fax: 01480 890105 e-mail: sales@fentex.co.uk www.fentex.co.uk

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International Industry News

More public access to German dam data, academic demands A University of Salford academic is calling for more public access to the state of dams in Germany after his quick assessment toolkit uncovered several at a comparatively high risk of failure.

Professor Miklas Scholz has developed a quick assessment toolkit which has been used in Baden (Germany) as well as in Scotland and England. Using the toolkit he has assessed over 220 dams in the German region and found that although most are well maintained, there is very little publicly available information on their risk of failure and the impact this can have.

With his system, people living in areas near dams would have access to a simple traffic light scale of risk based on a scientific and rigorous series of tests, which can be applied in under three hours.

He’s now calling for Germany’s engineering associations to relax their strict rules on how assessments are carried out and how the results are communicated.

“I have sent my research paper to several engineering journals in Germany and met a very unnecessarily and unhelpful traditional attitude.” he said. “My novel and timely toolkit has been proven in the United Kingdom to be easy to use.

It can be carried out without costly detailed site visits to identify the most at-risk dams.

“It seems that German engineers who are responsible for these dams are unwilling to change their methods or open them up to proper public scrutiny.”

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Thorworld Backs Calls For Increased Market Surveillance Of Materials Handling Machinery Leading loading/unloading equipment specialist Thorworld Industries Ltd is supporting a European-wide initiative to raise awareness of the importance of market surveillance, to prevent non-compliant and potentially unsafe machinery entering the European market.

The new initiative (http://machinery-surveillance. eu) was launched at a conference in Brussels on 24th November 2011, hosted by the European Commission, at which Thorworld managing director John Meale chaired a discussion on Market Surveillance to Protect Innovation. The highly successful event was an unprecedented partnership between seven major European trade organisations, representing the construction, machine tools, weighing, agricultural machinery, plastics & rubber machinery industries, as well as Orgalime, the European Engineering Industries Association, and FEM the European Materials Handling Federation – www.fem-eur.com.

As John Meale explains, this is a vital issue designed to ensure a fair and level playing field for European manufacturers and peace of mind for customers.

“As consumers, we are all familiar with the concept of illegal goods that do not comply with regulations, and we are aware of the hard work done by the authorities to prevent such products from being sold.

“The aim of this conference was to address the question: why, if there is such robust market surveillance for consumer goods, is there not a corresponding level of protection for commercial equipment and machinery?

“Too often, market surveillance for materials handling equipment is reactive rather than preventative – which means that it is then too late for reputable suppliers who have been undercut by unscrupulous manufacturers, or for the workers who face injury or even death.

For more information about Thorworld’s market-leading equipment and to obtain a copy of their latest Product Range Catalogue contact Tel: 01246 260982, Fax 01246 260493, Email: info@thorworld.co.uk or visit Web: www.thorworld.co.uk

Senior appointment aligns strengths of Brammer and Buck & Hickman Ian Ritchie, managing director of Brammer, the UK’s leading distributor of maintenance, repair and overhaul (MRO) products and services, has an expanded remit to lead the recently acquired industrial tools, maintenance and health & safety product distributor Buck & Hickman, following its acquisition by Brammer plc.

The combination of Brammer UK and Buck & Hickman brings together extensive capabilities and resources to create a complete one-stop shop for industrial MRO supply, operating from some 120 locations across the UK. The appointment will see Ian build on the significant growth and development that he has overseen at Brammer since his appointment as UK managing director in December 2003.

local and close to our customers, with an expanded branch network enabling customers to benefit from our commitment to customer service right across the UK industrial landscape.”

Ian commented: “The acquisition of Buck & Hickman is an excellent strategic fit with Brammer’s ambitious development plans in Europe and the UK, with the tools, maintenance and health & safety market offering significant growth opportunities.

There are strong synergies across the two businesses and bringing their operations together will allow us to further enhance our customer offer.”

Brammer plc acquired the business and assets of Buck & Hickman, a market leader in tools, maintenance and health & safety products, many of which are supplied under the well respected ‘Roebuck’ brand, from Travis Perkins plc in September 2011 for £27.6 million.

“Combining the knowledge and expertise within both businesses will create a unique resource able to offer unrivalled product knowledge, advice and technical support, backed by a depth of product range and supply capability which is second to none. It also underpins our own belief in being

For further information on Brammer visit www.brammer.co.uk and for more details on Buck & Hickman visit www. buckandhickman.com.

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Latest Product News

MEMBRANE DRYERS SET HIGHEST STANDARDS FOR COMPRESSED AIR SYSTEMS The new range of Hi-DRI compressed air membrane dryers from Hi-line Industries have been re-engineered to be technologically superior products, achieving new standards for reliability, performance and energy efficiency.

They feature a patented arrangement of structurally packed, permeable hollow fibres spirally wound on a support core. This creates an optimised design combining efficient air flow with high contact areas to maximise the drying performance within a compact unit size.

These products are ideal for in-line installation to ensure the delivery of dry compressed air at the point of use. This ensures maximum effectiveness with virtually any dewpoint or degree of drying being achievable.

As the humid compressed air passes through the Hi-DRI unit, water vapour diffuses through the walls of the hollow membrane fibres without loss of compressed air. At the dryer outlet, a small volume of the now dry air is expanded and released into the annular space between the membrane fibres and the outer aluminium shell. This air purge then sweeps away entrained water vapour to atmosphere as a humid air stream.

The Hi-DRI air dryer makes it easier and less expensive to supply pneumatic equipment and instrumentation with clean, dry compressed air.

This simple, proven technology helps eliminate condensation, oxidation and microbial growth, resulting in reliable and predictable performance of downstream air operated equipment. It also reduces component failures, improves equipment performance and operator satisfaction while showing savings on both warranty and production costs.

These dryers are designed to provide the superior solution for existing compressed air systems, maintaining maximum process reliability while remaining virtually invisible to the process installation. They do not contain moving parts and there are no desiccants or refrigerant to replace. They are also compact and lightweight, do not incorporate valves, drains or electrical connectors and do not require adjustments.

Filtration combined with compressed air drying contributes most to the performance and reliability of airline powered operations.

Humidity in airline systems is a major factor of corrosion and tooling wear, which can lead to production breakdowns. However, humidity also creates conditions conducive to the growth of micro-organisms within an airline, which can result in contaminated condensate.

This is obviously highly detrimental in food or pharmaceutical production processes as well as in dental, medical or laboratory applications.

Almost any dewpoint can be achieved, even when accommodating high humidity ambient conditions as experienced outdoors, in open workshops or on seagoing vessels.

These Hi-DRI membrane air dryers are suitable for a wide range of industrial plant installations including specialised commercial operations.

The range of models available cover air flow rates from 17 to 1050 litres/min. Multiple dryer units can be used in parallel to achieve higher flows where required. Outlet dewpoints from +15° to -40°C can be achieved at 7 barg

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pressure (12.5 barg max) and with 35°C inlet air temperatures.

With in-line connection ports at each end, the dryers can be easily integrated into an existing airline. They are compact, lightweight and cost effective, while the polymeric hollow fibre membrane is maintenance-free and does not need replacing where adequate pre-filtration has been provided. A 0.01 micron coalescing filter element is recommended to prevent damaging particulates, oil aerosols and liquid water entering the Hi-DRI filter. The use of a Hi-line HF series filter with regular replacement of the cleaning element will ensure long-term continuous, trouble-free dryer operation.

Where cost effective centralised refrigeration drying is required, a Hi-line CDA dryer connected directly to a compressor can

The latest HI-DRI compressed air dryers from Hi-line Industries Ltd, offering dewpoints from +15°C to 40°C. be combined with individual Hi-DRI units of varying outputs fitted at points of use.

Further information is available from: Hi-line Industries Ltd, 5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PG Telephone: 01283 533377 Fax: 01283 533367 enquiries@hilineindustries.com www.hilineindustries.com

SOLVING SEALING PROBLEMS FOR FLOW CONTROL PRODUCTS Ball valves, utilising a drilled-through ball rotating in a retaining socket, are widely used for process line control operations within industry. Typical areas of application for these valves include oil and gas, chemical processing, power generation together with pulp and paper industries among many others.

Ball valves offer both flow throttling and full shut-off conditions, while applications can involve an extensive range of pressures, temperatures and even the use of chemically aggressive fluids. The importance of specifying the right sealing products for use within these valves becomes paramount, particularly where breakdowns or plant shutdowns caused through valve failure can be catastrophic.

The specialist sealing company, Dichtomatik Ltd, are able to provide the Kalrez® range of perfluoroelastomer ‘O’ rings from the Dupont™ Performance Polymers range, which have been formulated to provide superior sealing qualities for even the most difficult applications.

A recent problem application featured a trunnian mounted ball valve used in the gas cleaning/sweetening processes. This involved the removal of carbon dioxide and acidic gasses such as hydrogen sulphide from gas streams, including synthesis gas produced by the gasification of coal, coke and heavy hydrocarbon oils. Gas sweetening is commonly undertaken in refineries, petrochem plants and NG processing etc, where the process often utilises a glycol-based solvent for the acid gas removal.

The solvent chemistry, together with RGD (Rapid Gas Decompression), can attack the valve seals and ‘O’ rings typically located in the valve seat. This can lead to seal life reduction, premature valve leaks and higher costs for both plant operation and maintenance.

A successful solution was achieved by the fitting of DuPont™ Kalrez® Spectrum 7090 seals. These perfluoroelastomer products offer an excellent combination of chemical compatibility, with both RGD and high temperature resistance for ‘O’ ring applications, particularly where handling glycol-based solvents. Valve leakages can be dramatically reduced, with a reduction in maintenance procedures resulting from the extension of MTBR (Mean Time Between Repairs).

Further information is available from: Dichtomatik Ltd, Donington House Riverside Road, Pride Park, Derby DE24 8HX Tel: 01332 524401 Fax: 01332 524425 kalrez@dichtomatik.co.uk www.dichtomatik-kalrez.co.uk

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Maintenance Best Practise

A Culture Of Reliability Christer Idhammar is a world

I see the equipment reliability component of manufacturing

renowned and award winning

organization does and the process reliability component as

Reliability and Maintenance Consultant and Guru. He is the Founder and CEO of IDCON, INC in Raleigh NC, USA; A reliability and maintenance training and consulting company to the Pulp and Paper Industry worldwide since 1972. www.idcon.com Reliability is a term that has become more commonly used in the industry. Many organizations are using reliability to describe their predictive maintenance department. To me reliability has

reliability as the revenue side of what the maintenance the results of what the operations organization does. The maintenance organization is supported by efficient and cost effective stores and engineering is responsible for cost effective design including maintainability and reliability considerations.

The roles of these departments must be clearly defined and their joint goal should be manufacturing reliability. They are in a relationship of equal partners and never in an internal customer relationship between each other. (See article in October 2011 PPI issue).

Organizational silos.

One of the biggest obstacles to overcome is that organizations are set up in silos with different goals.

For the engineering organization it is not necessarily so that lowest Life Cycle Cost (LCC) over more than fifteen years of ownership is most important. Costs as a result of poor maintainability and reliability design might consequently be much higher than necessary over the years equipment is owned and operated. In most organizations the project manager is

always encompassed the measurement of manufacturing efficiency and includes Operations, Maintenance, Engineering and Spare Part Stores as the major players. Together these departments shall deliver Manufacturing Reliability and we know that better reliability results in: •

Improved safety.

•

Faster manufacturing throughput.

•

Lower manufacturing cost.

•

Lower energy consumption.

There are many ways to measure manufacturing reliability. The least complicated is to divide Quality Tons Manufactured by Capacity Quality Tons. However it is beneficial to break up this equation in three elements: % Quality Tons x % Time Efficiency x % Speed performance. If each of these is 95% the total manufacturing reliability is 85.7%. By measuring these three elements it will be easier to pinpoint where the biggest losses are. It is not uncommon for mills to only measure the time element of this formula often expressed as % availability or “% time we have sheet on reel” for a paper machine. To me this is wrong because you might have a high availability but you might have to scrap all products made or you are not running at full speed. engineeringmaintenance.info Jan/Feb 2012

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Maintenance Best Practise

“To me reliability has always encompassed the measurement of manufacturing efficiency and includes Operations, Maintenance, Engineering and Spare Part Stores as the major players.” driven and awarded if projects come in on time and under

•

Cut the cost.

budget not by lower LCC. Key operations and maintenance

•

Prevent Maintenance.

people are often not included in the early specification phase of

•

Execute remaining maintenance more efficiently.

a project and many good ideas are lost. It is not uncommon that basic documentation such as detailed bills of materials is left

Cut the cost

out. This will lead to difficulty to optimize stores and much extra work to document these bills of materials later.

To just cut the cost instead of improving what drives cost is the wrong thing to do.

The operations organization is rewarded by tons manufactured.

The maintenance organization is measured primarily by cost as

If maintenance costs are cut by layoffs of people and no

set in the maintenance budget and stores are often challenged

improvements in systems, processes and practices are done it

to reduce inventory value. It is not necessarily so that these

will within one to two years lead to more overtime, more use of

measurements are wrong but if applied in organizational silos

contractors more total maintenance hours, lower reliability and

they lead to sub optimization and total results will suffer.

higher costs. Some valid maintenance work can be deferred with the risk associated with that but sooner or later the work

To improve this situation mills need to rethink their departments

must be done.

roles and goals and bring them together in a partnership work system with one goal expressed as manufacturing

To just cut the cost is a short term action with expensive long

competitiveness e.g. Quality Tons/Cost (instead of Cost/Ton) to

term results. My observations are that this is not as common as

articulate the focus on manufacturing reliability. All other goals

it used to be but it is still far from uncommon.

and performance indicators shall drive actions to support this goal.

Increased reliability will drive down costs.

Over the years this will repeatedly happen in mills where a well defined, documented, communicated and executed reliability and maintenance strategy is absent. 60% of mills have had more than three mill managers, production managers and maintenance managers in the last ten years per response to a

Cost to achieve improved reliability is important. Most of the

survey on www.idcon.com .

cost consists of implementation of better maintenance and operations practices and training of your employees to do better

If you do not have a reliability and maintenance strategy to

with what they already have. After a short period of increased

execute there is a risk that each new manager will implement a

costs reliability will improve and manufacturing costs including

new program. This will very often confuse the organization and

maintenance costs will continuously go down over many years.

ongoing improvements will discontinue.

An established fact is that improved reliability is a major driver to

Prevent Maintenance.

improve safety and costs.

To prevent maintenance work from occurring is the right thing to do.

To simplify there are three ways to reduce maintenance costs:

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Maintenance Best Practise Whatever name you give your maintenance program it will always be important to execute the fundamental elements of maintenance better and better. To prevent maintenance or maintenance prevention includes the following must do essential elements.

•

Right equipment. Procurement of new equipment should be based on lowest Life Cycle Cost and include reliability and maintainability design.

•

Lubrication. It is still one of the most important things to do well by trained people.

•

Alignment must be done to a precision level with considerations to operating temperature, pipe strain, number of shims etc.

•

Filtration of hydraulic fluids, lubrication oils, seal water for mechanical seals must be done to specified levels.

•

Balancing must be done to precision level.

•

Operating Practices are essential to prevent maintenance.

Operators must understand how to operate equipment and the impact wrong operating practices have. E.g. how to start a pump, what happens to an electric motor if it is dirty or is frequently started. Redundant equipment should be shifted to operate same amount of hours etc.

•

Fixed Time Maintenance is very seldom justified and often leads to over maintaining. Only if it is justified based on failure developing times and distribution of failures in time it

maintenance is 90% about people and 10% about technology

can be cost effective to do.

and as engineers we often like to deal with technology more than with motivating people. Most maintenance people like

Execute remaining maintenance more efficiently.

Maintenance Prevention will increase reliability and reduce

gadgets while they might not like to change to working in a disciplined system. A reactive system rewards action and extra income through overtime.

maintenance work. All work cannot be prevented so remaining work should be done more efficiently by skilled people in the

The big challenge is to change the way maintenance work is

following process:

viewed by top management. Maintenance is often controlled way too much based on cost instead of the results delivered

1. Identify work early through good inspections of

through efficient maintenance work. As mentioned above,

equipment and disciplined priorities.

the results of maintenance work include equipment reliability

2. Plan work.

followed by better safety and lower costs. Maintenance

3. Schedule work.

managers are often not aggressive enough. As a maintenance

4. Execute work according to schedule.

manager you need to know how good your organization is

5. Record work done.

compared to how good it can become. Then you need - a well

6. Use recorded information to trigger a Root Cause

documented plan showing how you are going to close that gap,

Problem elimination action.

what benefits you will deliver and how much it will cost. Then you need to sell that plan to top management and then to the

What is the secret?

people in your organization that will help you deliver the plan

The secret is that there is no secret. The above concepts are

over the next three to five years.

very well known and documented in hundred of books the last



fifty years. So why is it so difficult to do something so simple

Remember that almost all improvement initiatives have to

well? One of the reasons for this is that companies often make

be executed by your front line organization; if they are not

it much more complicated than it is. New names on well known

supported to execute nothing will be delivered. As the picture

concepts confuse people. They think it is another new program

above describes the front line organization in a bigger mill

that will only last until we get the next manager so why make

includes planners, supervisors, coordinators, operators and

too much effort to buy in? We need to realize that to improve

maintenance crafts people.

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Condition Monitoring

Condition Monitoring The TD Pocket-Scan coupled with Technology Design’s Corrosion Mapping Kit is the ideal solution for recording material loss data without the need for bulky and costly mechanical scanners.

The TD Pocket-Scan coupled with Technology Design’s Corrosion Mapping Kit is the ideal solution for recording material loss data without the need for bulky and costly mechanical scanners. Data is collected manually with a standard normal ultrasonic probe and positional information is recorded by the

video tracking system.

The TD-scan Ultrasonic Software provides integrated tools for both setup and analysis of data. The data is viewed as a true depth C-scan with associated side views that can be interrogated using a range of powerful software tools including an easy to use report generator. The TD Corrosion Mapping Kit is easy to use and is the answer to your ongoing condition monitoring challenges.

For more information on all our products, please contact Jackie Berry: E: utsales@agr.com W: www.agr.com/fo

Non Destructive Testing

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New Tinytag Thermocouple Data Logger Gemini Data Loggers’ Tinytag Ultra 2 Thermocouple data logger provides fast response, versatile and cost-effective temperature monitoring. It supports the most popular thermocouples types – K, J, T and N – providing monitoring from -270°C to 1370°C, depending on the type being used.

The compact, battery-powered logger features burn-out response, and has a built-in temperature channel allowing the particular process and the ambient air temperature to be monitored simultaneously. It incorporates a connection that supports both standard and miniature thermocouple plugs. Data is downloaded to a PC via a USB connection and viewed with easy to use Tinytag Explorer software.

From £99 + VAT. Gemini Data Loggers (UK) Ltd Scientific House Terminus Road Chichester PO19 8UJ +44 (0)1243 813000 info@tinytag.info www.geminidataloggers.com

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Non Slip Flooring

PROVIDING SOLUTIONS FOR THE LEADING CAUSE OF ALL ACCIDENTS AND INJURIES – SLIPS, TRIPS & FALLS. At AMS we believe that one slip or fall injury is one too many, so whatever the application or environment, our every expanding line of solutions called the Advanced Mat System ensures that you have the right mat for the right application.

With our first of a kind heated version called the Arctic Pad, this innovative all season solution gives year round protection for colder climate operations.

Safety, Warmth & Comfort it all starts with the feet!

Take the next step towards improving safety.

www.advancedmatsystems.com

Cranes

Efficient Lifting and Handling from 125 Kilos to 200 Tonnes Street Crane Company overhead travelling cranes for industry are available in configurations for safe lifting and handling up to 200 tonnes. In the mainstream one to 50 tonne category they offer the advanced ZX modular hoist.

For lighter lifts, LX chain hoists meet handling meet needs from 125 Kilos up to five tonnes safe working load. These may be used for static lifting or attached to crane beams for easy product transfers.

Light crane systems are designed for local handling and productivity, freeing the main factory overhead crane for heavier lifts and down shop transfers.

More information Andrew Pimblett, Tel. 01298 812456 Fax. 01298 814 945 Street Crane Company, Chapel-en-le-Frith, High Peak, SK23 0PH, UK E-Mail: admin@streetcrane.co.uk Web: www.streetcrane.co.uk

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engineeringmaintenance.info Jan/Feb 2012

Dry Ice Cleaning

Olivo contain dry ice Olivo portable insulated containers have been manufactured for over fifty years.

Used by many leading names in the dry ice sector- Air Liquide, Messer, Linde, BOC, Praxair, Coljet, Yara, etc -the combination of high quality insulation and robust plastic construction with steel fittings ensures that the containers have a very long life.

The ease of movement on casters or feet makes the containers very easy to handle so that the dry ice pellets for blast cleaning can be taken direct to the point of use and still at exactly the right temperature.

Contact: www.olivo.fr engineeringmaintenance.info Jan/Feb 2012

19 19

Dry Ice Cleaning

Safe, mess-free cleaning with Kärcher Ice Blasters As one of the world’s largest manufacturers of cleaning equipment, Kärcher has the products and knowledge to provide the best cleaning solutions for a wide variety of industrial environments.

As well offering ranges of

chemicals.

traditional industrial cleaning

The process is

machines such as parts washers,

particularly suited

vacuum cleaners and stationary

to environments

high-pressure cleaners, Kärcher

where machine

has developed highly innovative

cleaning and

blast cleaning products to improve

maintenance is

safety, reduce costs, and offer

essential, and

new levels of blast cleaning

can significantly

standards.

reduce downtimes and costs.

Kärcher ‘s range of Ice Blasters

The system uses

offer a portable, non-aggressive,

dry ice pellets kept at -79ºC,

but thorough method of cleaning

injected into a jet of compressed

surfaces, tools, moulds and

air, accelerated to speeds in

machines without causing

excess of 150 m/s and then fired

damage to the substrate or the

at the surface to be cleaned. The

environment. The machines

abrupt cooling of the surface

can be used in indoor and

causes a thermal shock and

outdoor areas and do not require

produces fine cracks in the top layer. The dry ice pellets penetrate these cracks and sublimate instantly (turn into a gas without becoming a liquid) lifting

where cleaning with water is prohibited or inconvenient. Unlike sand blasting, ice blasting keeps surface abrasion to a minimum, and there is only the contaminant to collect after cleaning has been completed.

This superb technology is available from Kärcher’s officially appointed Ice Blaster specialists, all of whom can offer expert advice on your ice blasting requirements.

the contaminant from the surface, and return to the atmosphere as CO2 gas leaving only the contaminant behind. As cleaning with dry ice is performed without chemicals or detergents, and leaves no

engineeringmaintenance.info Jan/Feb 2012

blasting can make a difference to

wastewater, it is

your business, and to find your

environmentally

nearest specialist, call 01295 752

friendly and can

142, email iceblaster@karcher.co.uk

be used in areas

20

To find out more about how ice

or visit www.karcher.co.uk

Dry Ice Cleaning

Dry Ice Cleaning

engineeringmaintenance.info Jan/Feb 2012

21

Flow Meters

Flow Meters

Alicat Mass Flow Meters Tucson, Arizona – For industrial analytical lab use, Alicat Scientific, Inc. offers the ATEX-rated M series Mass Flow Meter. The M series mass flow meter is a good choice for analytical applications including process measurement, calibration of HPLC and analyzers, and in pilot reactors.

The M series mass flow meters quickly and accurately measure pressure, temperature and volumetric flow in addition to mass flow. Alicat’s patented laminar flow differential pressure technology delivers highly accurate results with a much faster response time than that of competing technologies. Devices come pre-calibrated (NIST traceable) for Acetylene, Hydrogen, Ethylene, and Propane, as well as 16 other gasses and 10 gas mixes. For use in a wide range of applications, an ATEX approved -X option is available.

Operating simply as a stand-alone device, the integrated digital display of the M series Mass Flow Meter enables users to change the configuration of the meter without the need for computers, complicated software or scripts. For more complex operation, the M series also interfaces with most process control software without requiring any additional equipment or controllers, a simple to install and cost effective solution.

To learn more about the M series Mass Flow Meter, and all of Alicat’s flow control products, visit: www.alicatscientific.com, or call +1 520 290-6060.

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engineeringmaintenance.info Jan/Feb 2012

Corrosion Monitoring

Leak Protection

Belzona Repairs Leaking Caustic Tank In September 2011, Belzona refurbished a leaking caustic tank for a global soft drink manufacturer at their bottling plant in London.

The engineers at the plant were looking for a long term repair solution for a caustic tank suffering leaks on the welded seams where the caustic acid was leaking from the painted mild steel tank. The tank was situated within a stainless steel secondary containment area and was made up of four half round sections which were welded together. The tank contained around 8000 liters of 28% caustic soda.

The tank was fully drained prior to the application and the front of the secondary containment area was removed to aid access. A scaffold was erected to gain access to the higher parts of the tank.

Application service provider Belzona Technosol won the contract to refurbish the tank. The entire area was pressure washed to ensure full adhesion of the Belzona products. An 80mm wide repair area was then masked off along the length of the welded seam and prepared

using a Monti速 MBX Bristle Blaster, a hand-held surface preparation tool suitable for use on a variety of substrates including metals, rubbers and plastics.

The product selected for the repair of the leaking areas was Belzona 1111 (Supermetal) a multi-purpose, machinable, repair and rebuild system.

The two-component paste grade product is based on a ceramic steel reinforced polymer system which when cured is durable and chemical resistant. The product is ideally suited to applications on tanks, pipes, casings, keyways, bearing housings, shafts, hydraulic rams, engine blocks and flange faces.

The first layer of Belzona 1111 (Supermetal) was applied incorporating Belzona 9341 (Reinforcing Tape) to the repair area. Once cured, a second coat of the reinforced product was applied. After removing the masking tape the product

was left to cure. This application will provide a long term, corrosion protection solution for this caustic tank.

Belzona Polymerics Limited Claro Road, Harrogate, HG1 4DS England Telephone: +44 1423 567641 Facsimile: +44 1423 505967 belzona@belzona.co.uk http://www.belzona.com

engineeringmaintenance.info Jan/Feb 2012

23

Online Condition Monitoring

Brüel & Kjær Vibro has delivered plant-wide condition monitoring systems to the O&G and petrochemical industry for over 20 years The oil & gas and petrochemical industries face

An integrated plant-wide machine condition and performance monitoring

the most demanding challenges in fulfilling today’s

strategy is essential to achieving this.

machine management and reliability requirements.

Vibro’s Compass platform has been the

Since its inception in 1991, Brüel & Kjær industry leading integrated monitoring solution. Successfully utilized in refineries, offshore and onshore oil & gas production facilities, LNG, olefin, polyolefin and chemical plants, the system has delivered considerable uptime, efficiency and cost benefits to customers the world over.

Combined with our global sales and technical support network, Compass can deliver uptime to your plant!

Brüel & Kjær Vibro is part of Spectris plc, the leading supplier of productivity enhancing instrumentation and controls.

Contact: Brüel & Kjær Vibro, e-mail: info@bkvibro.com, www.bkvibro.com

Online Condition Monitoring

Brüel & Kjær Vibro provides a comprehensive integrated monitoring solution to the hydro industry Hydroelectric power plays an increasingly important role in the worldwide energy market.

monitoring systems are tailored to the varying demands of the hydro industry and include unique specialized functions including the multiple machine state

As the Operation & Maintenance

Over the past 20 years, Brüel & Kjær

monitoring function - ideal for pumped

requirements become more demanding,

Vibro has built a global customer base by

storage applications. In addition to

the importance of effectively monitoring

monitoring all types of turbines ranging

comprehensive vibration monitoring, Brüel

these machines becomes imperative.

from 1MW to 1GW. Our dedicated hydro

& Kjær Vibro also provides integrated air gap, magnetic flux, process, performance and cavitation monitoring. Combined with our global sales and technical support network, we can provide a solution to your Hydro application!

Brüel & Kjær Vibro is part of Spectris plc, the leading supplier of productivity enhancing instrumentation and controls.

Contact: Brüel & Kjær Vibro, e-mail: info@bkvibro.com, www.bkvibro.com

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engineeringmaintenance.info Jan/Feb 2012

Online Condition Monitoring

Brüel & Kjær Vibro provides a unique dedicated monitoring system and service concept for the wind turbine industry Condition monitoring requirements in the wind industry are like no other, thereby requiring an entirely different monitoring approach to traditional rotating machines.

Wind turbines are subject to widely variable operating conditions, which together with the compact construction, non-rigid foundations, complex gearbox

and slow rotating speed complicate the analysis and diagnostic process. To deal with these challenges, Brüel & Kjær Vibro has developed a unique monitoring

concept that combines its dedicated wind turbine condition monitoring system with a unique service program; the surveillance centre. The GL certified surveillance centre uses ISO18436 certified specialists and the unique alarm management concept integral to the monitoring system to evaluate all alarms and provide actionable information to the client’s service organisation. This versatile combination reduces unplanned maintenance, enables just-in-time service, maximises uptime and reduces maintenance costs. Your wind turbines/ turbine park can benefit from this dedicated monitoring concept.

Brüel & Kjær Vibro is part of Spectris plc, the leading supplier of productivity enhancing instrumentation and controls.

Contact: Brüel & Kjær Vibro, e-mail: info@bkvibro.com, www.bkvibro.com

Online Condition Monitoring

EtaPROTM Detects Machinery Problems Sooner Rather Than Later Productivity increases because plant staff can be proactive with maintenance that is focused on avoiding future failures rather than reacting to them.

GP Strategies’ EtaPRO technology suite is the power generation industry’s leading real-time Performance and Condition Monitoring System. Our first principlesbased thermodynamic modeling software, VirtualPlant™, calculates “targeted” performance, validates data, and simulates “What-If” scenarios for combined cycle, Rankine cycle, and nuclear power plants.

To provide early warning and reduce unplanned maintenance, GP Strategies integrated advanced pattern recognition (APR) technology into Version 10 of EtaPRO. EtaPRO APR models are used to detect anomalies in plant or equipment conditions by continuously comparing current values to detailed empirical models of “normal” data.

To learn more about EtaPRO please contact: GP Strategies Corporation Energy Services Group Tel: +1 (716) 799.1065 Fax: +1 (716) 799.1081 Email: tsass@gpstrategies.com Web: www.etapro.com

engineeringmaintenance.info Jan/Feb 2012

25

Compressed Air

Distributors Lead The Way To Energy Efficient Compressed Air Systems Most compressed air users would agree that to get the best return from their capital investment, the monitoring, measuring and management of compressor installations is essential if optimum control, improved productivity and energy efficiency is to be achieved.

That is why Atlas Copco and its distributors conduct energy audits as the definitive approach to identifying trends, establishing how well operators’ systems are performing, and recommending energy-efficient solutions where needed.

Applying simple non-intrusive air audit data logging techniques over a fixed period of time will establish a true indication of a system’s air usage and cost and, ultimately, will help to identify any wastage factors such as leakage and pressure drops.

Whether the purpose of an air audit is part of an on-going service contract, a means to monitor the progress of an established

installation or to determine the level of efficiency of an existing system for its potential replacement, the fundamental question that the Atlas Copco distributor asks of the customer is ‘Do you know how much compressed air you use and how much it costs to produce?” For the answer, the starting point is to measure the power requirement for the compressor installation, a simple initial procedure that may be followed by a full system audit where deemed necessary.

Atlas Copco authorised distributors have successfully applied these monitoring techniques to a considerable number of diverse applications throughout industry,

and as a result of implementing these energy-efficient measures, it is not uncommon for operating cost savings of as much as 40% to be realised. For example, the Walesbased distributor Control Gear helped a bridgeworks and water engineering products manufacturer in South Wales to make savings of £8,000 per annum following an energy audit.

With the aid of iiTraks and supporting software a potential saving of £12,000 was also realised by another of the distributor’s customers who manufacture vibration dampening products in Wiltshire. In the North West, Precision Pneumatics helped a theme park to cut its annual power consumption by 50% and also achieved a 35% annual energy savings for a newspaper publisher in the area. In South Yorkshire, the Compressed Air Division of the Search Group of Companies was also able to achieve £35,000 in energy savings for a large engineering plant and a further £15,000 per annum for a health care products manufacturer.

That is why it is standard practice within the distributor network to conduct these investigations as part of its professional energy management expertise. Every distributor in the nationwide network has the technical capacity and dedication to help compressed air users maximise energy savings and to improve the reliability and productivity of their compressed air systems.

Using the latest iiTrak data loggers, which basically supersede the

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engineeringmaintenance.info Jan/Feb 2012

Compressed Air

conventional measurement box monitoring procedure, Atlas Copcotrained engineers can help operators to establish a true indication of a system’s air usage and cost without any interruption of the air supply or production process. The end result is an accurate indication of a plant’s compressed air demand and, most importantly, of any potential wastage.

The compact, unobtrusive, batterypowered iiTrak loggers incorporate the latest data capture technology to log compressor load status via current sensing. They are designed as stand alone units, with one logger allocated to each machine in a multiple installation, or one unit dedicated to each compressor characteristic to be measured. Easily installed at the point of use, they are connected by a single cable for one leg of incoming power. All data is captured by the unit’s flash card memory for subsequent computer download and scrutiny.

The true amount of energy drawn by each compressor (both on load and off load) is measured. The mains voltage and power factor correction

is also recorded which gives the true kilowattage consumed by each compressor. The candidate compressors are logged for a minimum period of one week after which the data is downloaded to a computer. In some instances, the user’s production process programme and relevant air demand variations may require an extended measurement period to be necessary but the battery power for the iiTrak units is adequate for approximately three weeks of operation before replacement is necessary. The unique Atlas Copco software programme for the iiTrak enables simulated compressor comparisons to be made against the actual system.

It is usual for Atlas Copco’s iiTrak energy monitoring to take place prior to a full, in-depth investigation to obtain a comprehensive understanding of the air usage by scrutinising every stage from compressed air production to its point of use.

The audit procedure employs sophisticated equipment items such as a mass flow measurement meter,

relative pressure sensor/transmitters, ultrasonic leak detection apparatus and power meter monitoring.

These instruments pinpoint inefficiencies such as inadequacies in the production and utilisation of the compressed air supply, poor pipework design and pressure drop sites. It will also reveal where systems are operating at too high a pressure and where energy is being wasted because of piping network leaks.

With this data available, the next stage in the distributor’s investigation is to look at the operator’s present and future requirements in depth, to submit a full report of the application findings, and to make recommendations on actions and equipment solutions based on precise audit data and close knowledge of how the application operates. As a result, customers can be provided with the most energyefficient systems tailored to suit their precise needs. The recommendations may well include energy-efficient VSD compressors that match compressor output to process demand thereby generating energy savings of up to 35%. engineeringmaintenance.info Jan/Feb 2012

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engineeringmaintenance.info Jan/Feb 2012

Maintec Preview

MAINTEC 2012 TO SHOWCASE THE VERY LATEST IN MAINTENANCE TECHNOLOGY Now in its 37th year, easyFairs MAINTEC – the only UK show dedicated to the industrial maintenance and asset management sectors – returns to Birmingham’s NEC next February (28 February – 1 March 2012) to showcase the very latest technologies in the sector.

More than 1,700 chief maintenance officers, engineering and plant managers – many from UK blue chips like Astra Zeneca, BAE Systems, NHS Trust, Royal Mail and Walkers Crisps – attended the 2011 show to get their hands on the latest kit and talk to the developers making

learnShops™ that focus on practical knowledge sharing

advances in condition monitoring, asset management

and cover the latest trends, issues and technology

and hazard detection.

developments.

The 2012 show will once again play host to all the

Exciting additions have also been added to easyFairs

major players within the sector such as Fluke (UK) Ltd,

MAINTEC 2012. In particular, a new hazardous goods

Idhammer Systems Ltd, and Panasonic UK Ltd, as well

event called ‘HAZEX’ will be taking place, to reflect the

smaller growing companies such as 2011 debutants

growing responsibilities of maintenance professionals,

Business Development Strategic Maintenance Ltd.

and the growing concerns and tighter legislation over plants’ health and safety.

Colin Wilson, Consultant Director at the company, commented: “At MAINTEC 2011 we had 59

The show also has the support of key sector

conversations of note over the three days with several

organisations, including the British Compressed Air

potential companies interested in using or reselling this

Society, the British Institute of Non-Destructive Testing,

product. This was our first MAINTEC exhibition, having

the Institution of Diagnostic Engineers, Institute of Asset

last year come as visitors to assess its suitability as an

Management, the Facilities Management Association,

exhibition for a small, growing company like ours. We’re

United Kingdom Thermography Association and The

certainly glad we came as exhibitors.”

Institute of Engineering and Technology.

easyFairs UK, Managing Director Matt Benyon, added: “Maintec is the perfect platform for both large and small

To find out more information about the

companies to showcase their latest maintenance and

show visit:

engineering offerings to key decision makers within the

www.easyFairs.com/MAINTECUK

industry, as well as visitors wanting to witness first hand

and for stand bookings and exhibiting

the very best in maintenance technology.”

Exhibitors and visitors will get all the benefits of the easyFairs approach to trade shows, including convenient

enquiries contact Jerry Dawson on: +44 (0)20 8843 8823 or e-mail: jerry.dawson@easyFairs.com.

and cost-effective all-inclusive stand packages and free engineeringmaintenance.info Jan/Feb 2012

29 29

Maintec Preview

Maintec Preview

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engineeringmaintenance.info Jan/Feb 2012

Maintec Preview

Maintenance Key To Improving Plant Productivity Maintenance budgets are set to remain buoyant and focus on improving plant productivity, even in these times of austerity, research from MAINTEC 2012 show organiser easyFairs has revealed.

to source the predictive maintenance technologies to help them tackle the tough economic climate.

Matt added: “There’s a lot going on at this year’s show. We’ve launched a new hazard prevention area called HAZEX, plus have put a real emphasise on predictive maintenance technologies, which will come as pleasing news to those who took part in the survey.”

Indeed, and in addition to utilising predictive maintenance systems, the research showed that training (45 per cent), energy management (42 per cent), and inventory/spare parts management (39 per cent) were other popular ways respondents planned to boost profits.

Additionally, more companies are responding to the recession by focusing on contracting and outsourcing: of those surveyed over half (55 per cent) do not outsource maintenance and asset management at the moment, but contracting and outsourcing was ranked top priority for them over the coming months.

Nearly eight in 10 maintenance and engineering managers interviewed by easyFairs ahead of the 28 February – 1 March NEC exhibition say they expect their budget to remain the same or increase over the coming year.

Additionally, over a third (36 per cent) said that improving plant productivity is the main driver behind their maintenance spend.

show at MAINTEC 2012 that can deliver significant efficiency savings and help protect machinery and equipment.”

Now in its 37th year, easyFairs MAINTEC 2012 is the UK’s leading exhibition dedicated to showcasing the latest asset management solutions, and offers maintenance managers an opportunity

Other key findings included that 70 per cent said the board uses productivity to measure plant performance, followed by downtime (61 per cent) and running costs (42 per cent). And encouragingly, 41 per cent said that the current climate had not forced them to postpone planned investment in major new equipment.

MAINTEC 2012 takes place from Tuesday 28 February to Thursday 1 March 2012 at the NEC, Birmingham.

This is welcome news given that 55 per cent of respondents are planning to tackle the economic slump through added investment in predictive maintenance technologies that will extend plant longevity, improve efficiency and avoid catastrophic, costly plant failures.

However, easyFairs found opinion divided when it came to views on the board’s attitude to maintenance; 8 per cent said they saw it as expensive, while 8 per cent believed their bosses considered it as good value for money. Nearly two fifths said their respective boards saw maintenance as an invaluable part of the business, but one fifth said directors saw it merely as a “necessary evil”. easyFairs UK & Ireland Managing Director Matt Benyon said: “Businesses are still finding it tough, but many realise that cutting back on maintenance budgets is false economy. There’s a wealth of advanced, affordable technology on

For more information or to register for the show please visit www.easyFairs. com/MAINTECUK, and for stand bookings and exhibiting enquiries contact Jerry Dawson on +44 (0)20 8843 8823 or email Jerry.Dawson@easyFairs.com.

engineeringmaintenance.info Jan/Feb 2012

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Maintec Preview

Thermal Energy International Raises The Bar On Thermal Efficiency On Stand C8 At Maintec 2012 Thermal Energy International Inc. (TEI) will be exhibiting its range of awarding winning energy efficiency products on stand C8 at the NEC Birmingham from 28th February to the 1st March. TEI’s products include its GEM venturi orifice steam traps and its flue gas condensing heat recovery economisers .

TEI’s flue gas condensing heat recovery economisers can reduce the energy consumption of an industrial boiler by up to 18% by capturing the waste heat in the flue stream and converting it to hot water.

Thermal Energy International Inc. is an innovative technology company providing custom energy and emission reduction

Instead of utilising a valve mechanism

traps also improve product processing

solutions. The company’s award winning

to close off steam, the highly efficient

by enhancing the quality of steam and

energy recovery, conservation and

GEM steam traps use the patented

reducing equipment repairs, downtime

bio-energy solutions provide significant

venturi orifice design to effectively drain

and replacement costs. Available in a

financial and environmental benefits to

condensate from the steam system and

wide range of sizes for a cross section

customers.

maximise energy and water conservation.

of applications, and with optional filter

As the GEM steam traps have no moving

where applicable, the GEM steam traps

parts to wedge open or fail they provide a

provide companies with a fast payback in

permanent solution to steam trapping and

increased equipment reliability, water and

condensate return problems. GEM steam

energy savings of up to 30%.

About Thermal Energy International Inc. Thermal Energy International Inc. is an innovative clean technology company providing a variety of award winning energy efficiency, emission reduction, water efficiency and bio-energy products and solutions to the industrial, commercial and institutional markets worldwide. Thermal Energy’s products include; GEM® - Steam traps and condensate return systems, FLU-ACE® - Direct contact condensing heat recovery, and Dry RexTM - Low temperature biomass drying systems.

Thermal Energy International Inc. is also a fully accredited professional engineering firm, and offers advanced process and applications engineering services.

FLU-ACE®, GEM®, DRY-REX®, THERMALONOX®, and THERMAL AUD® are trademarks of Thermal Energy International Inc.

For more information, visit: www.thermalenergy.com & Thermal Energy International produces a range of GEM venturi orifice steam traps to suit a range of applications.

32

engineeringmaintenance.info Jan/Feb 2012

www.gemtrap.com.

Maintec Preview

Maintec 2012 Floor Plan Exhibitor list on pages 34 & 35

F25

E25

E24

F22

E23

D23

E21

D22

D20

D21

C23

D19

B26

C20

B25

C21

19 C

A26

B22

25 A

D17 D18

C17

C17a

B21

C18

A21

E19

D14

E15

F20

D12

D13

C16

D11

C14

F21

C15

B18

B16

B17

A22

B19

B19a

B15

A18

B14

B14a

C13

A19

17 A

8 F1 F15

E13

B13

E11

B11

A14

B12

A15

F16 A12

B10

F14

A11

F11

F12

E8

E9

D8

D7

C10

C9

B8

A6

E7

D6

D5

C8

C7

B6

B5

B9

A7

A5 F9

F10

A4

B7

F8

A3

F6

F5

F4

E3

D3

F7

C5

B3

B4

C3

B1

B2

A2a

A2

A1 F2

F1

E1

D1

C2

A1a

A1b

engineeringmaintenance.info Jan/Feb 2012

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Maintec Preview

Exhibitor List | Maintec 2012 Adash 3TP Ltd AESPUMP Ltd Alpine Components Ambersil (CRC UK Ltd) Antech Hydraulics (NTZ Filtration) AV Technology Ltd BCAS Bel-Ray Company Inc. BELGRAVIUM BINDT - The British Institute of NDT C-Cubed Ltd/Jenton Group Castle Group Ltd Censol Ltd CEPSTRA (UK) LTD Clean Air Group Cobalt Conveyors Control Freq GSM CorDEX Instruments Crimson Industrial Vision Ltd Des-Case Corporation DP Doors & Shutters Ltd Dust Control Systems Ltd Dustcontrol UK Ltd

A25 B14a B10 B4 A12 C20 F4 E8 A1b F12 B5 D22 A4 A15 D13 E25 C19 F5 A2 D12 C16 F9 E15

EA Technology Easylaser / Damalini AB ERIKS STOREROOM SERVICES ERIKS UK Ltd Facilities Management Association Flexilube Ltd FLIR Systems Flowcrete UK Ltd Fluke (UK) Ltd Flux Pumps International (UK) Gardner Denver Ltd Gemini Data Loggers (UK) Ltd Hansford Sensors Ltd High Voltage Partial Discharge Hire Torque Ltd Holroyd Instruments Ltd Icetech UK

engineeringmaintenance.info Jan/Feb 2012

E23 B6 E3 A14 F7 B18 F1 B16 C7 C21 C3 F22 B1

Idhammar Systems Ltd C15 IFM Electronic Limited B2 IGS UK LTD A1 Infor C10 Inpro-Seal C17 Institute of Infrared Thermography A2a IPEC Ltd B13 IPS International Ltd B11 Jacob UK Ltd D7 Jena Rotary Technology F16 John L Lord & Son Ltd (Specialist Flooring) D6 Jungheinrich (UK) C5 Jungheinrich (UK) C23 KRR Prostream C13 Kuwait Petroleum International B7 Lighthouse (UK) Ltd A17 Llumarlite Ltd B3 LOBO Systems Ltd F25 Losomat UK B12 MACS EU Ltd E9 Maintenance Connection UK LTD E13 Mattei Compressors F6 MEPCA B17 Metrum Information Storage Ltd Michell Instruments Ltd Micropoly Europe Ltd MIDLAND GROUP TRAINING SERVICE MONITION LTD - Fixturlaser UK

34

E21 A19 B9 A6

A7 D21 B25 E19 A3

Maintec Preview

Maintec Preview

MSL Group OCIP Energy Ltd OPTRIS GmbH Pickerings Lifts Plate & Locate PMI Software Ltd Prevost UK Ltd Probe Technical Recruitment Process Industry Informer PRUFTECHNIK Ltd Quartzelec Ltd R. STAHL Radir Ltd RMS Ltd Ro-Dor Ltd RRC Training S.E.M.CO SAFELIFT ONSHORE SCHAD AUTOMATION Schaeffler UK Ltd Shire Systems Ltd Sira Test & Certification

A26 D23 E1 F15 F18 E11 F2 F21 B26 D1 D17 D18 C2 F20 D5 A18 D19 A1a E7 D3 D11 D20

Siveco UK Ltd SMARTAG LTD

C9 C14

Softsols Group SPM Instrument UK Ltd

D8 A21 B19a C18 A11 B15

SRO Solutions Ltd Technical Training Solutions Tempus MTAS Ltd SRI Teseo UK Testo Limited THE INSTITUTE of ASSET Management Thermal Energy International TotalMobile TR Floor Systems Valveforce Walrus Pumps UK Ltd WD40 Company Western Business Publishing Wymark Ltd XETEC

F14 B8 F8 C8 A22 B21 B14 B22 B19 C17a F11 A5

More Maintec Preview On Page 36... engineeringmaintenance.info Jan/Feb 2012

35

Maintec Preview

New Video Endoscope for Maintec 2012 Inspection camera Specialist Crimson Industrial Vision will be bringing its range of Thermal Imaging cameras and Remote Visual Inspection products to MAINTEC 2012.

New to the show this year will be the VISIO PRIME Inspector – a 6mm dia. Video Endoscope with 4-way articulation specifically designed for industrial inspections or machinery, pipes

Vision is able demonstrate systems to

and tubes, and other hard to access

suit every application, from a simple video

equipment. The VISIO PRIME Inspector

inspection camera to the premium fully

will deliver high quality images, allowing

articulating, long range endoscope for

minimal dismantling to inspect the area

detailed inspection. Also on show will be

of interest. Weighing in at less than 1kg,

a range of FLIR Systems Thermal Imaging

this highly portable, battery powered unit

cameras, including the latest i7 and

has the ability to go anywhere and makes

E-Series. As a special offer at Maintec,

an ideal inspection tool when you need to

if you buy a FLIR E or T series camera

get to those hard to access areas.

after visiting us on Stand A2 at the show,

With a complete range of Video

we will include an Extech BR250 Video

Endoscopes, the Crimson Industrial

Borescope free of charge.

Maintec Preview

EXPERTS TO REVEAL WINNING MAINTENANCE TECHNIQUES AT MAINTEC 2012 easyFairs has attracted a wealth of maintenance specialists, all willing to share their winning techniques and vast experience with visitors of the MAINTEC 2012 show, taking place from Tuesday 28 February to Thursday 1 March 2012 at the NEC, Birmingham.

There will be 30 learnShops

engineers to keep their machinery

(seminars) running over the three

running efficiently,” says Ian Pledger,

days, with speakers from major

Field Service Engineer for Schaeffler

brands such as Britvic, Siemens, and

UK, and who will be the first speaker

Schaeffler, all revealing their secrets

to start the learnShops programme.

to help those visiting succeed in 2012.

36

Ian continues: “We talk to many

actual case study examples, we can

industry professionals who are

demonstrate that it is possible to

“In today’s challenging economic

considering CM for their facility but

start off slowly with a few techniques

climate, it is even more important

who are not sure at first how best

and then develop them over time to

to introduce an effective condition

to go about it, or feel that CM may

suit their plant equipment and their

monitoring (CM) regime that enables

be too complicated or costly. With

maintenance budgets.”

engineeringmaintenance.info Jan/Feb 2012

Maintec Preview

Maintec Preview

engineeringmaintenance.info Jan/Feb 2012

37

Health & Safety

Draeger Safety Centres – Now Across The UK One of Draeger’s greatest successes is being able to offer its’ customers “a total solution” rather than just “a product”.

formerly a technical advisor to Firebuy and Assistant Divisional Officer with the London Fire Brigade (LFB), manages the new Southern Safety Centre at Gatwick.

Now operational, Gatwick ,in addition to the range of services offered by Aberdeen , also offers test facilities for chemical protection suits as well as calibration and repair of thermal imaging cameras, and test and certification of compressed air cylinders.

Peter will also be responsible for the running of another new Safety Centre in Plymouth, looking after the needs of Cornwall, Devon, Somerset and the south west. Modelled on Aberdeen and covering all areas of industry, the Plymouth Centre offers the full range of services and, like each of the other facilities, can accommodate Draeger’s mobile confined space trailer and mobile display vehicle.

This has never been clearer as more and more innovative Draeger ideas are becoming viable commercial offerings and state-of-the-art equipment for the very best in personal protection. As part of this total solution offering, Draeger has opened a number of dedicated Safety Centres across the UK. Located in Aberdeen, Blyth, Gatwick and Plymouth, additional Centres are also currently being discussed In charge of this initiative is Brian Hesler, ex Fire Chief at Northumberland Fire and Rescue Service, who brings first hand experience of the need for effective training and first class equipment.

Developed to meet business demands and serve its customers better, these Centres are intended to bring Draeger closer to its customers. Combining sales and service from experienced personnel, they also offer a wide range of training courses and access to the complete range of Draeger gas detection and respiratory protection products on a short or long term rental basis.

Draeger’s Aberdeen Safety Centre, for example, has been proven to offer a very successful formula. Opened 18 months ago, it has just been granted approval to double the size of its facility to offer more training and other services alongside additional storage. As well as assisting and supporting fire and rescue services, this facility also supports general industry and, of course, Aberdeen’s core oil and gas industry which operates in both upstream and downstream market areas.

Offshore safety inductions, for instance,

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engineeringmaintenance.info Jan/Feb 2012

have been carried out for up to 35 people a day prior to rig shutdowns.

Located just 20 minutes from the harbour, the Centre is run by Kenny Durward who has extensive experience in rental, service and maintenance as well as the marine, oil and gas industries. In addition to service, maintenance, face fit testing and a range of training courses, including OPITO approved H2S awareness training, this Bridge of Don site is also finding that the rental side of the business is extremely buoyant. Whether planned or in an emergency, plant and rig shutdowns require the use of different personal protective equipment over differing time frames. Offering fully maintained and certificated equipment for rental over short, medium and long term periods, Draeger ensures that essential equipment is available immediately. On-site training can also be provided at the time of rental if required.

In the north of England, the Blyth Safety Centre combines a centralised administrative base with repair workshops, services, lecture areas and confined space training facilities.

Welcoming customers from all over the UK, it echoes Aberdeen’s commitment to meeting customer needs with more choice and more experience in training, service and the sale or rental of equipment.

Other specialist personnel, each bringing their own particular knowledge and experience to dedicated areas of the business, as well as these new facilities, have joined Brian’s team. Peter Silk,

Representing a significant capital investment and employing around 50 people so far, these Safety Centres are at the forefront of a new era in Draeger customer service. Additional Centres are currently being discussed, as is the potential to work with partners in joint facilities. Also under development is an innovative E-learning platform which is set to take online training to a completely new level.

Brian concludes “We are still growing, still recruiting and still looking at ways to become even closer to our customers.

The development of these Safety Centres was the result of in-depth customer discussions and listening to industry feedback. We are fully committed to meeting our customers’ needs and, in so doing, believe that we can help to ensure the utmost safety for those customers.

A total solution offering is the key to our success and, we believe, the key to a safer future.”

For further information contact Customer Service, Draeger Safety UK Limited, Ullswater Close, Blyth Riverside Business Park, Blyth, Northumberland, NE24 4RG. Tel: 01670 561200, fax: 01670 356266, www.draeger.com.

Humidity Calibrators

The M2000SP-XR Humidity Generator One System‌Three Functions High Accuracy Calibration of Instruments Over Full Operational Range The field proven M2000SP-XR with new solid state electronics for high accuracy and performance over the full operating range of humidity and temperature.

chamber. Three (3) top ports are for instruments with long probes (250mm) or reference standards to verify internal readings. Clear chamber door for visual observation of instruments with digital displays.

Calibration of Chart Recorders with Embedded Sensors Using

The temperature compensated

and 18mm. NVLAP Accredited

Programmed Procedures

control probe provides higher

calibration of control probe. System

For fast, accurate calibration of

accuracy over the range of

tested for performance at ICH

battery operated chart recorders

measurement. Newly designed

guideline parameters to meet

having the RH/T sensors embedded

electronics is incorporated within

accuracy and long term stability

within the recorder housing. The

the heat/cool circuitry and a more

requirements. Typical response time

internal blower of the M2000SP has

efficient peltier mechanism, has been

is 3 minutes for 70%RH step change.

been modified for a more efficient air

incorporated for faster response and

Production and Volume Calibrations

flow, both within the internal chamber

temperature stability. The number of

at Ambient Temperature

and the external chambers. The

ports in the chamber door has been

The chamber size of the M2000SP

large external chamber has internal

increased to accept 5 probes with

standard system is 2 liters. For

dimensions of 300mm x 250mm x

diameters of 10mm, 12mm, 15mm

calibrations of multiple data loggers

150mm (h x w x d). Accurate RH

or sensors the chamber

calibrations over the range of 10-

capacity must be

90%RH, at ambient temperature,

increased. The

can be done more quickly than when

M2000SP-XR, using

using larger chambers. A typical 3

the 12 port external

point RH calibration can be done in

chamber, provides the

less than 1 hour after temperature

increased calibration

has stabilization. The internal

capabilities through the use

chamber conditions are verified using

of a chamber with

a reference instrument calibrated

internal dimensions

by an NVLAP Accredited laboratory

of 250mm x 200mm

according to ISO/IEC guidelines and

x 100mm (h x w x

17025 procedures. Through the

d). Nine (9) horizontal

use of pre-programmed calibration

ports have sufficient

procedures , the required calibration

separation

cycle can be done automatically.

to prevent interference and

Kaymont Consolidated Industries

to maximize

Tel: (631) 951-9100

number of transmitters for insertion within the

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engineeringmaintenance.info Jan/Feb 2012

Fax: (631) 951-9109 180 Oser Avenue, Suite 200, Hauppauge, NY 11788 rmcouch@gmail.com

Hardness Test Solution

Level Measurement

SiloPatrol® level sensor can improve silo inventory control and plant safety Monitor Technologies’ SiloPatrol® smart weight and cable-based level sensors are effectively utilized to improve inventory control of powders and bulk solids stored in vessels.

The sensors measure the material inventory level automatically and on-demand without the need for plant personnel to climb silos, which helps to increase plant safety. SiloPatrol can also be interfaced with optional operator interfaces.

The SiloPatrol® uses time-proven weight and cable techniques and includes Hall Effect sensor technology, state-of-the-art sealed bi-directional optical sensing, a split-compartment enclosure design, isolated outputs and

For more information:

other valuable features to produce a rugged, reliable and

Please visit www.monitortech.com, e-mail monitor@

accurate measuring system designed for the harshest and most dynamic conditions.

monitortech.com or call 1-630-365-9403 for more details.

engineeringmaintenance.info Jan/Feb 2012

41

Induction Heat Treatment

Infrared Thermometers

Land Instruments International - Over 60 years of providing temperature measurement solutions LAND has been at the forefront of infrared (non-contact) temperature measurement for over 40 years.

Our standard infrared thermometer started back in the 1970s with the System 1, some of which are still in operation today. System 4 our latest range of infrared thermometers has evolved to be suitable for a wide range of applications, ranging from steel and glass to cement and road stone. We are now able to meet the majority of special customer requests for temperature ranges to meet their exact application requirements.

Please visit our website: www.landinst.com for further details.

Land Instruments International Email us on land.infrared@ametek.co.uk

Call us on +44 (0) 1246 417691 Visit us at www.landinst.com

engineeringmaintenance.info Jan/Feb 2012

43

Editors Choice

How CMMS Software Can Improve Your Chance Of Successful Implementation 80% of CMMS Implementations fail 80% of CMMS Implementations fail is a term that can be found in many articles. Those failures can be described in many ways, e.g. where the budget overruns, where only 20% the software is eventually utilised (then sometimes regarded as a great success), or where the changing of the original to the planned business process simply failed. The reasons for the latter can be attributed to difficult selection processes, incomplete requirement identification and/or a lack of implementation management.

Rigid CMMS software

screens, dialog boxes and wizards

Possible solutions

be configured, and even for different users, but take care, don’t abuse this

Possible solutions can be found in

capability. This allows a step-by-step

CMMS software that offers modules

process in moving from an existing

Rigid CMMS software with a lack

as your system grows, therefore

duplicate system to a new improved

of possible customisation can be a

allowing continuous improvement.

system. Indeed in many cases it can

significant reason. Another factor

Many suggest that configuration or

be the opposite, i.e. a need to reduce

is that the software does not have

customisation of the system is the

the number of fields on the screen

sufficient features, or in fact the

only way forward, but this can prove to be expensive, but not anymore.

or better still screens in the process.

opposite where it has far too many features and is simply too difficult to operate. Failure to operate in a manner that suits

In either case that’s continuous improvement, introducing a new field

The new solution

the “way we do things”, means you

44

are flexible. Flexible means they can

on the screen, month by month.

And the argument of web versus a network system is over. Do both with

have not achieved workforce and

The new solution is in modern

management commitment, and all

software creation technology. The first

efforts are on trying to use the new

step is to consider software that has

Contact Xetec on:

system in the same manner as the

all the possible features you would

old, the result being shelfware and

ever want but has 80-90% of them

By Phone: Manchester, M22 5XB: +44 161 408 7777 Bray, Co Wicklow: +353 1 442 9997

not software. But what if the software

turned off

could operate in both old and new

or invisible. The second and more

manners? Is that possible?

important requirement is that menus,

engineeringmaintenance.info Jan/Feb 2012

the one system.

By E-mail: sales@xetec.com or support@xetec.com

engineeringmaintenance.info Jan/Feb 2012

45

Heat Exchangers

Logichem Process Engineering Logichem Process Engineering (LPE) offers a wide range of Heat Exchangers – manufactured and supplied in various materials and designed with the most advanced process, thermal and mechanical software. All of LPE’s Heat Exchangers comply with the TEMA and ASME codes.

LPE’s Heat Exchanger range includes: •

• •

An Explosive Proof Syngas Ex d Heater.

• • •

Hygienic, Double TubeSheet Exchanger for the Pharmaceutical Industry.

Shell and Tube to all TEMA Classes and Types.

Electric heaters certified for use in Explosive Atmospheres, Ex d IIA T3, other gas groups and temperature class are available.

Condensers.

Re-boilers and Evaporators.

Atmospheric Vaporisers (Longitudinal Fins).

For more information, contact: Mr Ignatius Herbst (Managing Director) Email: info@logichemprocess.com Or visit us at: www.logichemprocess.com

Spare Management Software

Solutions for Parts and Service Information Use PARTS-PUBLISHER to automate parts catalogue creation, improve parts identification, streamline parts ordering and reduce mis-orders PARTS-PUBLISHER is a customisable standard software that enables equipment manufacturers and operators to assemble, distribute and automatically update parts and service information.

The application delivers all parts and service data – such as parts catalogues, maintenance

description, service bulletins etc. Built using industry

manuals, technical specs and sales collateral – pre-

standards, the product integrates seamless with key

filtered according to serial number, product line or

business applications such as ERP, PLM or CAD.

configuration/trim package. PARTS-PUBLISHER catalogues employ an intuitive user interface

For more information please visit:

that provides a synchronised view of assembly

www.docware.com

drawings or 3D models and associated parts lists,

Demo catalogues and videos online!

including detailed information such as pricing, part engineeringmaintenance.info Jan/Feb 2012

47

Buyers Guide

48

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Advertise Here

Buyers Guide

engineeringmaintenance.info Jan/Feb 2012

49 49

Buyers Guide

50

engineeringmaintenance.info Jan/Feb 2012