5-7
8 - 17
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Contacts
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Maintenance best practice – Reliability Improvements drive down maintenance Costs
Industry News pages
IRISS Case study – Paper Mill boosts RCM program with cost savings generated through IR program
Product Spotlight – Vibration Monitoring
Publisher Michael Dominguez
Editorial
36 - 37
PILZ – Harmonising Productivity with Machine Safety
38 - 39
Product Spotlight – Portable Calibrators
40 - 41
Industrial Doors
46 - 47
OEE
49 - 50
Buyers Guide
editors/contributing: Jon Barret, Christer Idhammar, Alan France
Advertising Paul Clappison - Magazine Paul Miles - Online Advertising
Email Info@engineeringmaintenance.info
Website www.engineeringmaintenance.info
Phone tel: +44(0)1634 731646 Fax: +44(0)1634 631644
Address MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ
MAINTENANCE BEST PRACTICE
RELIABILITY IMPROVEMENTS DRIVE DOWN MAINTENANCE COSTS An organization must focus on sustainable results, not just cutting costs. Three case studies illustrate. Results-oriented organizations focus first on the quality and volume of production throughput, followed closely by the cost to produce the required quality and volume. This approach will improve reliability performance, which will drive manufacturing costs down. Most organizations focus more on cutting maintenance
Case 2: Aggressive cost reduction The graph for this case shows results at a chemical plant, a high-cost producer in its market, where management decided to do whatever it took to cut costs, mainly in maintenance. When the cost-saving initiative started, market prices for the plant’s products were low and profitability in a short-term perspective was low compared to other plants in the corporation. The fastpaced cost reduction actions included: •
maintenance work that was judged absolutely necessary. •
discontinued. Scheduling was discontinued.
•
Maintenance prevention activities such as shaft alignment were abandoned and lubrication was handed over to operators without training and implementation of a
temporarily, only to increase much more than the initial savings. can be substantial. This behavior and results have been proven
documented program. •
inspect. The preventive maintenance inspectors were laid
of this phenomenon is often shortsightedness and what the late most serious diseases in American industry: “the mobility of top management.” The three case studies that follow demonstrate what happened in two organizations that focused on cost reductions and in a third organization that focused on Results Oriented Maintenance.
Case 1: Cost and head count reduction The accompanying graph shows a 3-year case study in a food processing organization with an aggressive cost reduction program. A key measure used in maintenance benchmarking exercises was the number of maintenance crafts people and first line managers such as planners and supervisors. The head count reduction was done through attrition and layoffs. The major mistakes by this organization were: •
To cut costs by reducing only the number of employees and not considering reducing the need for maintenance or improving work processes.
•
To focus on number of employees, instead of hours of maintenance work, including overtime and contractor hours. Case 2: Aggressive cost reduction
he preventive maintenance program was handed over to the operators, without training in what to do or how to
many times, especially in economic downturns. The root cause quality leader Dr. W. Edwards Deming described as one of the
Planners were laid off and planning of work was
•
costs, and, as a consequence, maintenance costs go down In addition, reliability goes down, paving the way for losses that
Operations took over maintenance and only did 
off. •
Shutdown crews were merged with another plant about 1 hr drive from the subject plant.
•
Painting programs were abandoned.
•
Training of crafts people was discontinued.
After realizing the catastrophic consequences of what had happened, the mill took initiatives to bring maintenance to world-class status. Results are very encouraging and the mill is today one of the top performers. Reliability is approaching 94 percent. Maintenance costs have gone up, so has quality production throughput, and manufacturing and maintenance costs per ton are lower. The actions taken to bring maintenance to world-class status included: •
Reinstating preventive maintenance inspectors and revising the preventive maintenance program.
•
Bringing maintenance back to a central maintenance function.
•
Developing a partnership between maintenance and operations instead of a customer-supplier relationship.
engineeringmaintenance.info June/July 2011
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MAINTENANCE BEST PRACTICE •
Focusing on planning and scheduling and front line implementation of these practices.
•
Developing employees’ capabilities toward joint goals.
•
Making capital investments in new equipment and restoration of worn out equipment.
•
Implementing front line management action indicators.
Case 3: Reliability improvements first, costs second This plant manufactures the same product as the plant described in the previous case, but it decided to focus on reliability
Case 1: Moving maintenance resources to operations and cutting craft personnel
improvements instead of only cost reduction. This included:  •
A clearly outspoken and established partnership between operations, engineering, and maintenance was forged.
•
A change was made from a reactive to a planned and scheduled maintenance organization. Less than 10 percent of all maintenance work was planned when the initiative was launched. Ten years later more than 85 percent of all work is planned and scheduled.
•
A strong vibration analysis program was implemented. When it started, the average vibration level was 0.23 in./ sec. Today it is down to 0.11 in./sec.
•
Lubricators were professionally trained. This resulted in better filtration and water removal, better seals, oil testing,
• • •
and fewer types of lubricants. Cost for lubrication was
reduced by 14.3 percent the first year.
reduced by 60 percent.
After 1 year, 6 percent were hired back.
All rotating equipment above 1000 rpm is balanced dynamically before it is put into service.
In the same period, contractor spending
Many equipment bases were improved and equipped with
went up 88 percent. Total maintenance
jack-bolts to improve alignment precision.
hours including overtime, contractor
Electric motors and rolls in storage are marked and rotated twice a month.
•
Alignment
training,
standards,
and
execution
were
implemented. •
•
hours, and in-house hours went up 10.5 percent. Total maintenance costs
Stores inventory and services were analyzed and improved.
went up 29.2 percent. On top of that,
Service level now stands at 96 percent and stores value has
reliability and production throughput
been reduced by more than 30 percent.
decreased 6 percent. This plant is now
Adherence to preventive maintenance schedules was increased to over 90 percent.
Reliability pays Reliability improvements increase production throughput and drive down maintenance costs. Maintenance cost reduction is a consequence of reliability performance; it is never the other way around. 6
The number of crafts people was
engineeringmaintenance.info June/July 2011
investing in hiring and training more maintenance people, implementing lost maintenance practices, and moving all maintenance resources back to professional maintenance management after initially decentralizing maintenance to operations.
MAINTENANCE BEST PRACTICE
Case 2: Lingering effect of 2 years of cost cutting
In the first 2 to 3 years maintenance costs dropped from $35 million/yr to $27 million/yr and results were hailed as good. However, reliability started to decline. When beginning this initiative, overall production reliability (OPR)—the product of quality performance, time performance, and speed performance— was 93 percent; it bottomed at 78 percent 6 years after the start of the initiative. At this time the market price for the plant’s products had doubled. The drop of 15 percent in OPR and quality production output corresponded to a loss of over 300,000 tons during some very good years when product could be sold at top prices. Financial losses because of low OPR resulting from shortsighted maintenance cost savings are conservatively estimated to exceed $1.2 billion over a 3-yr period.
Case 3: Focus on reliability
During the first 3 years, maintenance costs increased 8 percent (2.5 to 3 percent/yr). During the same period, reliability as measured by OPR, and consequently also production throughput, increased steadily from a low of 83 percent to 90 percent. Reliability continued to increase to 92 percent. In financial terms, a short-term increase in maintenance costs of about $3.3 million resulted in savings of $17 million annually. The value of increased and sold production represented $18 million annually. Total maintenance costs were reduced by 40 percent. Today this plant survives another economic downturn because of the reliability initiative it initiated and implemented. Article supplied by : Christer Idhammar Founder and Executive Vice President IDCON, INC For further information please contact us on: Tel: +1 919 723 2682 | Email: info@idcon.com Or visit www.idcon.com
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INDUSTRY NEWS
ENSURE RELIABLE GAS DETECTION WITH NEW DRAEGER WIRELESS SAFETY NET Operating as an all-round safety network, the new Draeger X-zone 5000 uses wireless technology to automatically connect multiple monitors for reliable, continuous detection of toxic, combustible and explosive gases. Ensuring that personnel have the confidence to work worry free, even in the most dangerous environments, these transportable units are quick to deploy and easy to set up. Issuing a loud alarm as soon as a gas is detected, they also change colour to clearly identify the alarm status. The areas where gas has been detected are indicated by red visual alarms. Safe atmospheres and, therefore, a safe escape route are confirmed by green visual alarms. By simply placing Draeger X-zone 5000 units around potentially dangerous areas or where maintenance or shutdown work is being carried out, these robust, waterproof units will ensure increased levels of safety in any application. As soon as one of the units detects a gas it immediately transmits an alarm to each of the others, warning everyone in the area that a danger exists. At the same time, a loud evacuation alarm is emitted and a patented 360ยบ alarm amplifier ensures that it is heard with the same intensity in all directions. Up to 25 Draeger X-zones can be used at any one time, forming a complete wireless network to suit the specific application, including those where an explosion hazard might exist. In addition to Zone 0 ATEX performance, they also offer a lower cost of ownership by combining flexible monitoring capabilities with a long sensor life and enhanced battery performance.
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Allowing gas ingress from every side, it can be fitted with up to four sensors to detect as many as five gases at once. The Drager X-zone 5000 provides simultaneous measurement of gases and vapours such as hydrocarbons, hydrogen and other explosive, combustible or toxic gases. Unlike portable instruments which usually leave the scene with the wearer, the Draeger X-zone 5000 can be left in situ for up to 120 hours continuous operation, issuing an alarm as long as the danger exists.
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.
LATEST INDUSTRY NEWS
ABB WATERMASTER HELPS RWE REMAIN MCERTS COMPLIANT RWE NPOWER VERIFIES ENERGY READINGS WITH ABB FLOWMETERS AND VIDEOGRAPHIC RECORDERS The installation of a new ABB WaterMaster electromagnetic flowmeter is helping energy company RWE npower fulfill its MCERTS commitment. The 1,400MW power station, based in Didcot, Oxfordshire, has always monitored the amount of cooling water that it discharges from the site, but this extra tier of instrumentation will enable it to verify that the readings provided by the existing meters are accurate. “We’ve already got three meters on our cooling water purge system but we’d like to be able to verify their performance,” says Peter Harrison, Senior C&I Engineer. “We’re now installing an MCERTified WaterMaster electromagnetic meter from ABB at a point where all three flows come together. This means we can verify the readings from the other three meters, in addition to verifying the WaterMaster itself, insitu using the WaterMaster’s onboard verification system.” Launched in 2008, the WaterMaster was one of the first flowmeters to be awarded a Class 1 MCERTS conformity certificate for closed pipe flow measurement. MCERTS is the Environment Agency’s certification scheme to ensure that companies have effective measures in place to monitor their effluent flow. Industrial sites need to meet MCERTS requirements whenever their discharges must be monitored and controlled as part of their permits under the Environmental Permitting Regulations (EPR). Civil works are about to begin on the installation and the new, two-tier system should be up and running later this year. “I’ve used ABB flowmeters before in my previous work and I’ve always found that they perform well. I like to think this one will provide the same great performance,” says Mr. Harrison. RWE npower is also taking the opportunity to upgrade its data logging facilities with the addition of a ScreenMaster videographic recorder from ABB. ABB can also provide additional support in the form of annual verification services, including verification of installed WaterMasters utilising VeriMaster verification tools. This can assist with demonstrating an ongoing robust metering regime in preparation for possible quality management system (QMS) audits in the future. MCERTS and the self-monitoring of effluent flow is just part of a wider philosophy within the Environment Agency to promote “better regulation”. This means encouraging companies to
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comply with and even exceed legal requirements without constant supervision. “MCERTS is all about helping to protect the environment through more accurate monitoring and collection of data relating to emissions to air and discharges to water,” says Tony Hoyle, General Manager for ABB’s UK and Ireland Measurement Products business. “ABB has long been a supporter of the MCERTS scheme, having achieved the first ever MCERTS product approval certificate for its ZFG2/ZDT zirconia oxygen analyser system in 1999. We followed this tradition by making our WaterMaster flowmeter one of the first to be MCERTified for closed pipe flow measurements.” ABB has released a comprehensive new guide to the Environmental Permitting Regulations (EPR) and MCERTS, the Monitoring Certification Scheme of the Environment Agency (EA). Entitled MCERTS and EPR – a guide to environmental EPR legislation and monitoring systems and services, the guide is a useful point of reference for anyone responsible for the monitoring of emissions to air or water at an EPR regulated site. For more about ABB’s offering for MCERTS applications or to obtain a copy of ABB’s new guide, email: mroeinstrumentation@gb.abb.com or call: 0870 600 6122 ref. ‘MCERTS’ or ‘MCERTS guide’. For help with any technical terms in this release, please go to: www.abb.com/glossary For more information: Tony Hoyle Email: moreinstrumentation@gb.abb.com Tel: 0870 600 6122
LATEST INDUSTRY NEWS
NEDERMAN AND DANTHERM FILTRATION COMBINE IN THE UK Following last year’s acquisition of Dantherm Filtration by Nederman, the combined business began trading in the UK as Nederman Ltd on 01st April 2011. “We reviewed operations carefully and have now successfully integrated customer service, aftersales and project sales,” said Mark Hodgens, Managing Director. “Combining as a single business is an important milestone, our customers and suppliers will be receiving formal communication over the coming weeks.” Although Nederman have completed several notable acquisitions, both in the UK and internationally, following successful flotation on the OMX Stockholm Stock Exchange in 2007 this has been on a different scale, doubling Nederman’s size and positioning it as the global market leader in industrial air filtration. The group now makes combined annual sales of around £195 million in nearly 60 countries (with 27 fully owned companies) supported by manufacturing and assembly plant in 8 countries. Whilst Dantherm and Nederman have overlapped in the market, the systems are really complementary. Nederman’s industrial air cleaning systems typically run to 15,000 m3 where Dantherm’s reach 150,000 m3 and cover specialist market segments including foundries, smelters and wood dust. “In reality, many of our customers need a mix of systems,” said Mark Hodgens. “The overall expertise in industrial air cleaning is impressive, we can now meet the market with a broader and more complex product range.” Further information is available on request from Nederman by contacting 08452 743434 or at www.nederman.co.uk .
KABELSCHLEPP ON UK MANUFACTURING AND THE HANOVER FAIR 2011 KABELSCHLEPP presents new developments and improves existing ones. One plus one equals more than two, that´s how you could draw a balance after a year of collaboration between KABELSCHLEPP and the Tsubaki Group. Things have been happening in more areas than just the product range. The worldwide presence and customer service were also intensively expanded. Along with the sales and on-site service, the product program was also expanded. For example, in the universally applicable UNIFLEX Advanced plastic chain series, the type series 1665 with an inside height of 44 mm is now available in an additional inside width: 200 mm. That makes eight widths in total, covering measurements from 50 to 250 mm. Type series 1320 was also expanded; an inside width of 50 mm is now available, as well as models with new bending radii of 38 and 48 mm. The weight-optimised cable carriers in this series are well-suited for a broad range of applications. They are equipped with internal sound dampening for an especially quiet run and offer numerous possibilities for interior partitioning. An aluminium tray system is now available for the type series 1555 for vertical, hanging applications Amongst its many applications, it is suitable for use in fast-moving storage and retrieval machines with high lateral acceleration and is available as a complete system, ready for installation and connection, including carrier stop, cables and tension relief. The modular construction makes it especially easy to install. Standardised dimensions and basic components result in short delivery times and custom-modification for affordable solutions. For UK and Ireland, please contact: Kabelschlepp Metool, Metool Products Ltd. www.metool.com / www.kabelschlepp.co.uk postmaster@metool.com Phone +44 (115) 9225931 Fax +44 (115) 9258183
LATEST INDUSTRY NEWS
HYDRAULIC CRANE SYSTEMS ADAPTED TO USER REQUIREMENTS Where a hydraulic power system supply is available on site, then hydraulic cranes from J D Neuhaus can be a more practical option for all lifting and handling operations than their well established compressed air operated products. The range of cranes that can be supplied include both single and double girder overhead travelling cranes together with slewing jib cranes and underslung cranes incorporating special low-headroom trolley designs. Cranes with parallel hoists and synchronised lifting hoist arrangements can also be supplied, with individual hoist capacities up to 100 tonnes. J D Neuhaus specialise in the provision of crane systems adapted to suit individual requirements. This can include remote radio control of the crane lift and traverse operations, covering comprehensive application requirements and even simultaneous operation of multiple hoists. For lifting operations on offshore rigs or sea going vessels, crane systems can be fitted with rack and pinion drive systems to ensure safe operation during bad-weather conditions. Control boxes with receiver can also be customised to suit specific electro-hydraulic interface requirements, together with all necessary system tubing in stainless steel where required. All equipment is designed and rated for use in explosionendangered areas. The standard rating is EX II 2 GD IIA/II 3 GD
IIB T4 (X), with higher classifications also available on request. Super-silent operation is combined with sensitive, infinite controls including controlled load-lowering in the event of supply oil failure, together with an integrated overload switch-off function. Oil or HFC pressure fluids can be used at intake pressures of 100 to 180 bar. Only two supply connections are required per hoist with leakage oil drained internally for maximum safety. Further information is available on request to: J D Neuhaus GmbH & Co. KG, 58449, Witten-Heven, Germany Telephone: +49 2302 208-219 Fax: +49 2302 208-286 E-mail: info@jdn.de Website: www.jdn.de
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INDUSTRY NEWS
VEGA LAUNCH NEW REMOTE MONITORING SOLUTION FOR LEVEL AND PRESSURE A new transmitting and receiving unit, PLICSMOBILE, fits seamlessly into VEGA’s modular plics® system. It’s available as an integrated module for the new plics®plus sensor generation, or as a standalone instrument PLICSMOBILE T61, which can be powered from the existing signal cable, by battery or other renewable energy source. The SIM card and integrated modem allow worldwide data transmission via the mobile network GSM/GPRS – including ‘dial in’ remote diagnosis and service using industry standard PACTware FDT/DTM software. PLICSMOBILE is stand alone, nothing else needed, no other intermediate signal boxes or modems nearby. Cabling can also be left out too: an integrated energy system manages any battery supply of sensor and emitting unit ( an integral in-housing mini battery pack, providing once-aday readings for over a year, will follow in October this year) . This means PLICSMOBILE offers real capability and flexibility in deployment, especially in the area of Vendor Managed Inventory (VMI) they can be installed and operate independently with any VEGA technology - measuring liquid in tanks or silo levels up to 75m with battery power only, and sending data globally. With the options of ; PLICSMOBILE, PLICSRADIO and HART Wireless compatibility, VEGA can now cover practically any application in wireless communication from local to global.
PLICSMOBILE looks set to change the way remote inventory and VMI systems are deployed in future by integrating everything into the measurement device for level applications from water level to silo levels up to 75m
Doug Anderson-VEGA Controls Ltd Kendal House, Victoria Way West Sussex, RH15 9NF Web: www.vegacontrols.co.uk E-Mail: info@uk.vega.com Tel +44 1444 870055 Fax +44 1444 870080
INDUSTRY NEWS
LEADING SPECIALIST INSURER MARKEL LAUNCHES NEW BRAND AND WEBSITE TO ASSIST ENGINEERING SECTOR MARKEL DIRECT TO SIMPLIFY AND STREAMLINE INSURANCE WITH ONLINE QUOTES IN 90 SECONDS A leading business insurance specialist today announced it was launching a new direct-to-market brand, enabling engineering businesses to arrange instant and competitivelypriced cover online, directly with the company. Markel UK, which boasts over 20 years’ experience in offering business insurance for professionals, confirmed that Markel Direct would simplify the process of setting up business insurance, offering new product innovation and some online quotes in just 90 seconds, courtesy of its new website – www. markeluk.com Markel Direct will offer clients in the engineering sector easy payment options. Customers will benefit from online documentation and a more streamlined approach to arranging business insurance than is currently available. Key products available include cover for professional indemnity, employers liability, public and product liability (general liability), directors and officers liability, office buildings and contents and business interruption. Specialist policies for homeworkers and
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home based businesses are also available to buy online. The Leeds based company, a division of A-rated Markel International, revealed the launch of Markel Direct would offer engineering businesses the opportunity to arrange specialist cover directly with Markel for the first time. Steve Carroll, managing director of Markel UK, said: “We are delighted to announce the launch of Markel Direct today, which is a significant development for us and promises to assist those in the engineering industry looking to take out cover. “Our aim in creating the new website is to enable customers to buy cover direct from us in a simple and straight-forward way. Setting up business insurance is often considered to be a complex and daunting process, so we wanted to assist customers with an easy to use website and the quickest quote turnaround in the industry. “Markel Direct represents a fantastic opportunity for engineering businesses of all sizes, but particularly SMEs, to take advantage of our extensive range of products at competitive prices.” For more information, visit www.markeluk.com
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LATEST INDUSTRY NEWS
MICRO FLOW SWITCH AND BUBBLE DETECTOR FOR LIQUIDS
NOR-RAY-VAC SIGNALS A NEW ERA AT NEW CROSS GATE
The new LG01 for the detection of liquid flows and air bubbles. The Swiss sensor manufacturer Sensirion AG is launching the LG01 micro flow switch for ultra-low liquid flow rates and bubble detection.
When the new train maintenance depot at New Cross Gate required a heating solution, Emico-Rail and consultants BBP Building Services Ltd working in conjunction with AmbiRad, specified Nor-Ray-Vac radiant tube heating. With effectiveness and economy as top priorities, the highly efficient system would provide the ideal working environment for vital train maintenance.
The sensor makes fluidic systems more reliable by enabling the detection of liquid flow within the range of a few ml/min and less. For such measurements the sensor offers a short response time below 100 ms. Its output signal of either 0 or 5 volts indicates whether the current flow rate is above or below the specified flow switch level. At continuous flow rates above this limit the identification of air bubbles within the flow channel is equally consistent. Maximum flow rates are accepted up to 220 ml/min. Fluidic connections can be made via 1⁄4-28 standard fittings, suitable for connecting plastic tubing with outer diameters of 1/8” (3.2 mm) or 1/6” (1.6 mm). Barb connector adap- ters are available as an alternative. The tiny, light sensor is designed for integration into biomedical applications and general process control solutions. An ex- cellent chemical resistance and bio-compatibility are ensured by its non-invasive measurement through the wall of the straight, internal glass capillary (diameter 1.8 mm) and fluidic connectors made of PEEKTM high-end plastics. The new prod- uct is based on a digital MEMS chip and expands Sensirion’s existing line of high-quality liquid flow products by employing a simple and cost-efficient solution. LG01 website: www.sensirion.com/lg01 LG01 datasheet: www.sensirion.com/lg01-datasheet
The state of the art rail depot is part of a £363 million contract to build the new East London Railway in time for the 2012 Olympic Games. The depot is divided into a series of separate working areas, located across two large buildings. The two-road wheel lathe shed and heavy cleaning building, measuring 90m x 17m, as well as the primary maintenance facility building measuring, 105m x 37m, that also features a main workshop, heavy stores and workshop area and a small parts store. For further information, please contact Tracey Lawrence at CFA on: Telephone: 01622 754295 | Fax: 01622 758485 Email: tracey@cfa-group.com
LATEST INDUSTRY NEWS
UNIQUE MODULAR HEAT EXCHANGER FOR PERFORMANCE AND SAVINGS Clix Cooler from Forward Industrial Products is a new, completely unique, modular forced air heat exchanger that is significantly more efficient and cost effective than traditional copper tube aluminium finned coil type heat exchangers. With its patented design encompassing special aluminium multiport tubes and fins currently used in the aerospace heat transfer sector, the Clix Cooler provides energy efficiency along with reliability. Fully welded tube to header joints and autonomous sections reduce the effects of stress caused by cyclic pressure and temperature changes. Multidirectional airflow also helps keep the heat exchanger face clean so maintaining a longer optimum working performance, so extending service life, minimising unscheduled downtime and resulting costs. Forward Industrial’s team of experienced engineers will also maintain the Clix Cooler unit, with servicing and cleaning every 12 months to ensure maximum efficiency, particularly suitable for those businesses who do not have staff available to undertake maintenance.
Unlike traditional heat exchangers, the Clix Cooler can be delivered in virtually ‘flat pack’ form meaning it can be assembled in most locations. The modular construction means less need for heavy lifting gear during initial assembly as well as ongoing servicing and repairs, so giving further cost savings. Forward Industrial is offering Clix Cooler with five years on site warranty cover on the matrix and three years cover on the system motors, giving customers additional reassurance. For more information on Clix Cooler contact Forward Industrial on 0121 708 3070. Email: sales@clixcoolers.co.uk; www.forwardindustrial.co.uk
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INDUSTRY NEWS
Get More From Floors – Get More Durability Leading industrial flooring manufacturer Flowcrete is putting on a robust show of strength with the development of a marketing campaign that firstly highlights how durability is the foundation of a fit-for-purpose system underfoot for plant managers. Flowcrete has vast experience within the industrial flooring industry - carrying out projects for Blue Chip clients including Bentley Motors, the RAF and BAE Systems - backed up with best in class customer and technical support services. When a plant manager requires a strong, robust coating for a flooring project, Flowcrete has the expertise to deliver a system able to stand up to heavy-duty traffic movement, bulky machinery and physical attack, through the installation of an industrial flooring system from our toughest flooring range. Our systems are engineered to ensure plant managers get more from their floors, with formulations geared up for specific areas within individual manufacturing environments to maximise longevity and extend the life-cycle of the finish. Flowcrete UK Ltd has rigorously tested its industrial floor coating systems and selected the strongest materials to offer plant manager clients hardy, resilient and powerful resin floor surfaces that represent the best in class approach to durability. The company’s extensive product offering includes the industryleading Industrial Floorzone concept, unique to Flowcrete UK.
This system delivers the damp-proof membrane and high strength Isocrete floor screed, topped off with a performance resin floor finish – all from a single source and installed by Flowcrete’s approved contractor network. Flowcrete’s flooring systems also include anti-slip, acrylic and epoxy based floor finishes made-up of durable quartz beads and polyurethane resin floor screeds, as well as polyurethane terrazzo systems that contain tough flint and granite aggregates.
For further information please contact: uk@flowcrete.com Or visit us on the web at: www.flowcrete.co.uk
INDUSTRY NEWS
NORBAR LAUNCHES HYDRAULIC WRENCH TESTERS Norbar Torque Tools has launched a new range of products for testing hydraulic torque wrenches from 250 N.m up to 80,000 N.m. Comprised of a Hydraulic Tool Calibration Fixture and a Transducer, which link to a Torque Measuring Instrument, these devices will accurately calibrate both square drive and hexagon link torque wrenches. The Hydraulic Wrench Testers will be invaluable to a variety of end users, such as: • • •
Organisations with many hydraulic wrenches wishing to avoid the costs and potential delays of using a calibration sub-contractor Tool hire companies needing to ensure that their wrenches are calibrated before being hired out for a job Calibration and tool repair companies or laboratories specialising in providing expert calibration services
Hydraulic torque wrenches use either square drive or hollow hexagonal link outputs, so Norbar has produced a wide range of hex to square drive adaptors to ensure that their test pots are compatible with most hydraulic torque wrenches. The three versions of Norbar Hydraulic Tool Calibration Fixtures have capacities of 7,000 N.m, 50,000 N.m and 80,000 N.m respectively and are compatible with a range of Norbar transducers extending from 1½ inch up to 3½ inch square drives. Transducer capacity ranges are from 250 - 2500 N.m
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up to 8,000 - 80,000 N.m. The lightweight and compact design is easy to transport and the built in bench or deck mount points provide operational flexibility. Philip Brodey, Sales & Marketing Director of Norbar, comments: “This is the first time that Norbar has produced an off-theshelf range of products for testing hydraulic torque wrenches. These test pots are compact and robust and enable optimum performance to be achieved from this important torque product group. Users also have the assurance of traceability, which is essential for confirming that a torque tool is producing the required torque.” For further information: Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxfordshire OX16 1XJ Tel 01295 270333 sales@norbar.com
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ENERGY MANAGEMENT
ELANTAS ENJOYS SIGNIFICANT STEAM SAVINGS WITH GEM®
ELANTAS Deatech S.r.l, a member of the
global
specialty
chemical
group
Altana AG, and a leading producer of insulating materials for the electrical and electronics industry, has revealed that it is achieving significant savings in steam consumption at its site in Ascoli Piceno, Italy following the installation of Thermal Energy International’s GEM® steam traps.
“Thermal Energy International has supported the project throughout with a survey of the steam traps, a payback report and bucket test”, says Mr Giorgio Monni, Plant Manager at ELANTAS Deatech’s Ascoli Piceno plant. “The GEM® venturi steam system has provided us with real savings and the prospect of a large reduction in maintenance costs”. Such has been the success of the GEM® technology at the Ascoli Piceno site that Thermal Energy International received an additional order for GEM® steam traps for the company’s site in China and this year received a further order for GEM® traps for the Ascoli Piceno plant.
ELANTAS Deatech has now replaced all of the mechanical steam traps on its process, utilities and steam distribution pipeline with the GEM® venturi orifice design. Prior to the installation of the GEM® steam traps, the mechanical traps regularly failed open, closed or partly open, necessitating regular replacement and maintenance. It was calculated that due to trap failure ELANTAS Deatech was wasting a large proportion of its steam production, which in turn was increasing energy costs. Thermal Energy International organised a bucket test to measure the live steam loss through the trap at various condensate load conditions. This proved that the GEM® technology was significantly more efficient over varying loads.
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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, eliminating the need for repair or replacement. The GEM® steam traps can provide a fast payback from reduced energy costs and increased equipment reliability. In addition it can improve product processing by enhancing process control, and can also reduce equipment repairs, downtime and replacement costs. Thermal Energy International Inc, 1 John Street, Bristol, BS1 2HR Tel: 0117 917 7010 Fax: 0117 917 7011 www.gemtrap.com
INDUSTRY NEWS
18th WORLD CONFERENCE ON NON DESTRUCTIVE TESTING NOW is the time to start planning your involvement in the 18th World Conference on NDT in Durban, South Africa 16 -20 April 2012.
The 18th WCNDT will be a “once in a working lifetime opportunity” for many of us to take part in a major NDT event in Africa. The World Conference is organised every four years and moves around the globe with ICNDT members from Europe, Asia-Pacific, Pan America, and Africa bidding for the privilege so arguably Africa’s next turn will not come before 2028. The conference theme “NDT IN SERVICE OF SOCIETY” reminds us of why our discipline is so important and why we need to share our knowledge, technology and experience for the benefit of all. ICNDT therefore want to do everything possible to maximise the benefits of this opportunity to the whole African NDT community. ICNDT events to be held during the conference: 1) Open Session in the conference on IAEA projects in the NDT field • to allow IAEA to showcase its work • to promote discussion on future projects 2) Workshop for Regulators designed to inform regulators of the value of NDT and how to ensure its reliable delivery.
3) Workshop on Qualification and Certification of NDT personnel including the proposed ICNDT Multilateral Recognition Agreement 4) Open Session in the conference on IAEA projects in the NDT field • meet “buddy” societies willing to be mentors • meet Certification Bodies willing to be partners • website shell scheme 5) ICNDT Research workshop • Opportunities to meet researchers from large international laboratories For More event details And to register online please visit: www.wcndt2012.org.za
INDUSTRY NEWS
DC DRIVES AVAILABLE EX STOCK Arundel, England, June 2011. DC drives from Sprint Electric are available ex stock. The drives manufacturer offers 1 phase and 3 phase DC drives from stock up to 2250 Amps. Up to 87 percent of orders get dispatched from the factory in Arundel on the day of ordering. Sourcing DC drives is becoming more and more difficult. „Most of the major drives manufacturers are publishing longer lead times. In a breakdown, this could pose users a serious problem“, explains Gary Keen, Sales Director with Sprint Electric. “Exstock availability on DC drives is one of our founding principles. And because we know how important it is for our customers to receive their orders without delay, we never stop improving how we manage our stock levels in response to their needs.” The ex-stock availability of Sprint Electric dc drives, often with direct equivalents for competitor models, allows users to source the DC drives they need without having to suffer a lengthy lead time. Sprint Electric offers a wide range of DC motor control, with over 150 models covering both 1 phase and 3 phase, regenerative
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engineeringmaintenance.info June/July 2011
and non-regenerative DC motor applications together with digital slip ring motor controllers. Sprint Electric’s full range of products include analogue and digital DC drives from 12 Amps up to 2250 Amps. Whether in retrofits or original equipment, DC drives from Sprint Electric are being used in many different applications around the world. Mr. Gary Keen Rudford Industrial Estate, Ford, Arundel, West Sussex, BN18 0BD Tel: 0044 (0)1903 730000 Fax: 0044 (0)1903 730893 E-mail: gary@sprint-electric.com Internet: www.sprint-electric.com
INDUSTRY NEWS
SPM INSTRUMENT INTRODUCES INTELLINOVA® COMPACT SPM Instrument, leading worldwide provider of condition monitoring technology and products, now announces the arrival of Intellinova Compact, the latest addition to the successful Intellinova family of products for online condition monitoring of rotating machinery. Intellinova Compact is a high performance system, well suited for remote monitoring or industrial environments with measuring points in spread-out clusters. Wind turbines, pumping stations and auxiliary equipment in the pulp and paper industry are a few examples where Intellinova Compact is the ideal condition monitoring solution. Fans and gear boxes are other typical applications. Because it implements the new and sophisticated SPM® HD measuring technique, it is also the appropriate choice for any low speed application, such as agitators, crushers and conveyors. The system is available in three versions, each with a fixed channel configuration for shock pulse and vibration measurement. All versions come with multiple rpm and analog inputs as well as status outputs. The size of the industrial enclosures is merely 300*300*155 mm (11.8*11.8*6.1in) or 380*300*155 mm (15*11.8*6.1in), making the system easy to install. As an option, all units have wireless communication capability, enabling remote monitoring, service and support. Utilizing all the channels, Intellinova Compact is a very cost efficient solution. By installing multiple smaller units, connected through a standard Ethernet cable, the costs for transducer cabling can be significantly
reduced. When configured with application specific data, Intellinova Compact also works as a standalone unit, using the status outputs for alarm purposes. SPM Instrument UK Ltd. Tel +44 1706 835 331 http://www.spminstrument.co.uk info@spminstrument.co.uk
INDUSTRY NEWS
ERIKS ACQUIRES BUSINESS ACTIVITIES OF SODECO ARMATUREN GMBH IN COLOGNE, GERMANY Yesterday ERIKS concluded an agreement with the owners of the Sodeco group in Belgium regarding the acquisition of the German business activities of the Sodeco subsidiary Sodeco Armaturen GmbH in Cologne. The acquisition was carried out by the ERIKS Core Competence Centre for fittings and actuators in Germany – AMG Pesch GmbH in Cologne – which itself was acquired by ERIKS at the beginning of 2011. AMG Pesch GmbH is expanding its German supply and delivery offerings with this acquisition of the business activities of Sodeco. As a result, AMG Pesch will become an authorised distribution partner of the JC (ball valves) and TTV (butterfly valves) brands in Germany. Existing employees of the former Sodeco Armaturen GmbH will be fully integrated into the organisation of AMG Pesch GmbH in Cologne. AMG Pesch GmbH will then be supported by a reliable team of around 90 employees, offering wideranging know-how, with many years of experience, a proven
and extensive product range and the latest in the field of valve technology. These factors, in combination with a well-stocked depot, make the company one of Germany’s leading providers in this industry. The activities of AMG Pesch comprise the construction, design, manufacture, marketing and sale of high-quality actuators, special fittings, standard fittings and assemblies in the fields of valve and flow technology. The company’s customers are original equipment manufacturers (OEM) and end users, particularly in the chemicals, energy, pharmaceuticals, mechanical engineering, food technology and pump and plant construction market segments. This acquisition represents a continuation of ERIKS Germany’s strategy of consistently strengthening and expanding its market position in the area of valve and flow technology. For further information, please contact: Robyn Bradley, Marketing Executive, ERIKS UK T: +44 (0)121 508 6219 M: +44(0)7740 452743 robyn.bradley@eriks.co.uk
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CASE STUDY : IRISS
PAPER MILL BOOSTS RCM PROGRAM WITH COST SAVINGS GENERATED BY ITS IR WINDOW PROGRAM Overview: A paper mill in Georgia had run a very successful infrared inspection program for a number of years using a local, contract thermographer working with the mill’s in-house electricians.
Although the program had a good track
record, senior management was concerned about the potential impact of NFPA 70E requirements, and how best to comply with them. The plant commissioned IRISS Inc. to conduct a cost-benefit analysis -- and present its recommendations.
Analysis of Inspection Program:
The annual infrared surveys focused on the power distribution equipment as detailed in Table 1. Table 1: Application
Total Qty
Qty Insp
13.8 kV Primary Switch
27
15
Secondary Switchgear
48
48
Transformers (13.8 kV)
22
14
MCC’s
50
50
Miscellaneous Switchgear
26
26
Generators
6
9
179
159
Total Assemblies
Twelve of the 27 pieces of 13.8kV primary switchgear were not included in the inspection due to the presence of switched interlocks (which automatically de-energize the gear upon opening). In addition, the thermographer was unable to inspect eight HV (High-Voltage) transformer cable compartments under load due to the energized work restrictions implemented by the plant safety manager. The review showed that 11% of the plant’s critical assets were never inspected during the annual survey. A time study was completed detailing the man-hours and the costs involved in completing the annual IR inspection based on NFPA and OSHA safety mandates.
Cost Analysis of Traditional Inspection:
The client had been using a contract thermography company for more than seven years, and was very happy with the service. The IR survey crew consisted of two in-house electricians and one contact thermographer. The hourly wrench time (time spent on productive labor) rate for the electrician was calculated at $68, and the contract thermographer’s rate was $150 per hour ($1,200 a day). Traditionally, the whole inspection required 29 days to complete. This translated into 787 billable hours (as seen in Table 2). The entire inspection team dressed in 40 Cal/cm2 PPE (personal protective equipment) in accordance with NFPA 70E and OSHA
mandates for energized work. They spent on average 30 minutes to suit-up and dress-down -- twice a day. This was a total of 88 hours related to PPE over a 29-day cycle. The thermographer spent 186.4 hours waiting for panel covers to be opened/closed to provide him with access. Similarly, the electricians spent 93.2 hours (46.6 hours x two men) waiting for the thermographer to complete his work once the panels were removed. After analyzing the time studies, facility management was surprised to learn that a staggering 367.6 hours (46.7%) of the total project time for the traditional open-panel surveys was nonproductive (PPE suit-up, thermographer wait-time, electrician wait-time, etc.). A task breakdown is shown in Table 2. Table 2: Man-Hours Total Assemblies
159
Inspection Compartments
233
PPE Suit-up Time
0.5Hrs
88.0
Time Taken to Remove Covers
0.4Hrs
186.4
Time Taken for IR Inspection
0.2Hrs
46.6
Time Taken to Replace Covers
0.4Hrs
186.4
Electrician Waiting Time
93.2
Thermographer Waiting Time
186.4
Total Billable Man-Hours
787.0
Unproductive Man-Hours
367.6
engineeringmaintenance.info June/July 2011
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CASE STUDY : IRISS
Table 3 details the man-hour costs for the infrared survey using a contract thermographer without infrared windows or viewports. The following assumptions are made: • Total man-hours per inspection of “inspectable” equipment: 787 hours (29 days) • Staff electrician internal charge-out rate $68 per hour • Contract thermographer charge-out rate $150 per hour • PPE suit-up twice daily, per man (30 minutes per man, per suit-up) • 48 minutes per compartment panel for safe removal, refitting, (per man for a two-man team) • 12 minutes per panel for infrared scan. • 233 individual panels to inspect (Table 2) Table 3: Removal and Replacement of Panels
373
$25,316
Infrared Inspection
47
$6,990
Electrician Wait-Time
93
$6,329
Contract Thermographer Wait-Time
186
$27,960
PPE Suit-up Time
88
$8,324
Infrared Windows:
$74,919
In search for an alternative approach that was both safer and standards-compliant, the corporate reliability engineer investigated how infrared inspection windows (commonly referred to as IR windows, viewports or sight glasses) might be utilized. It was determined that: • Use of IR windows would provide non-intrusive access to electrical applications. Surveys could be conducted during periods of peak-load without elevating risk to either plant assets or processes. • Use of IR windows or “sightglasses” would eliminate the
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engineeringmaintenance.info June/July 2011
•
•
Total Cost of Traditional Inspection
Total
•
•
need for a supporting cast of electricians to remove and reinstall panel covers. These critical personnel would then be available to perform other tasks which were often being outsourced. Use of IR windows and closed-panel inspection would eliminate high-risk tasks during inspections -- increasing safety for thermographers. Use of infrared windows for routine inspections of healthy equipment did not require the elevated levels of PPE required in 70E, since as stated in 70E 100: “Under normal operating conditions, enclosed energized equipment that has been properly installed and maintained is not likely to pose an arc flash hazard.” In NFPA terms, an IR window maintains electrical equipment in an “enclosed” state and it maintains energized components and circuit parts in a “guarded” condition. Therefore, the hazard/risk category would be equivalent to reading a panel meter, using a visual inspection pane for lockout/tag-out confirmation, or walking past enclosed, energized equipment. Use of infrared windows would improve inspection efficiency. It would allow increases in inspection frequency for those mission critical or suspect applications.
Investment:
The facility’s 179 applications with 263 inspection compartments required 312 infrared inspection windows (Table 4) in various sizes: 143 units, two-inch diameter (VPFR-50) 107 units, three-inch diameter (VPFR-75) 62 units, four-inch diameter (VPFR-100) The 312 windows represented an investment of $51,405.00. IRISS, inc. also provided a cost-benefit analysis comparing inhouse installation versus out-sourced.
CASE STUDY : IRISS
Table 4: Application
Table 6: Quantity
13.8 kV Primary Switch
27
Secondary Switchgear
48
Transformers (13.8 kV)
22
MCC’s
50
Miscellaneous Switchgear
26
Generators
6
Total Assemblies
179
Inspection Compartments
263
IR Windows
312
Table 5: IR Window Supply & Contracted Installation Team Infrared Windows
$51,405
Install Costs for 312 IR Windows
$19,760
Total
$71,165
Out-sourced installation (Table 5) was based on the following assumptions: • A two-man installation team can comfortably install 40 inspection windows in one shift • 312 infrared inspection windows would require eight shifts to install completely (shutdowns permitting) • The cost of the contract installation team was calculated as follows: eight days at $625 per man, per day (total cost $1,300 per day) for a total of $10,400 • Installer would charge a flat $30 fee per window -- in addition to the daily rate ( 312 windows x $30 = $9,360) • Total installation charge: $19,760
IR Window Supply & Internal Installation Team
Infrared Windows
$51,405
Install Costs for 312 IR Windows
$8,893
Installers Training Course
Total
$995
$61,293
In-house costs (Table 6) were calculated using the following assumptions: • A two-man team can comfortably install 40 inspection windows per shift • 312 infrared windows would require eight shifts, or 128 man-hours, to install • The complete project could be managed around shutdowns • In-house team costs were calculated as follows: 128 manhours at $68 per man/per day for a total cost of $8,893 • No additional charge incurred per window Client would retain IRISS for a day of on-site installation training at $995 The client decided to use in-house manpower for the installation due to the savings. The Jumpstart Installation training was scheduled for the first day of the shutdown so the in-house electrical staff could be properly trained. Total savings to the customer by adopting an in-house install program were $9,872.00 -- almost a 14% savings over an outsourced installation team. engineeringmaintenance.info June/July 2011
27
CASE STUDY : IRISS
The Installation:
The installation of the inspection panes was conducted during a seven-day shutdown, using two install teams. The majority of the windows were installed while equipment was de-energized, in what NFPA terms an “electrically safe work condition”. However, some installations involved energized gear and needed to employ the traditional safety measures such as use of PPE, energized work permits, etc. The work occurred during normal business hours since this allowed more flexibility. The plan called for two teams working a twelve-hour shifts. Installers were quickly and safely working at a rate of approximately six windows per hour. As they progressed through the learning curve, the teams became more proficient, hitting an install rate of seven to eight windows per hour (versus the budgeted five per hour).
Cost Analysis with Windows:
With the infrared windows installed, there was no requirement to remove panels or wear increased levels of PPE. In addition, inspections were now performed on the 11% their applications that had previously been considered “uninspectable”. Finally, the entire task became a one-man job. The windows also increased efficiency and economy-of-motion. Total man-hours to complete an inspection dropped to just 53. As a result, the new survey dropped from almost $75,000 to just under $8,000 (as detailed in Table 7). Because of the efficiencies achieved, the mill saves $68,964 per inspection -- a 92% savings.
Total Cost of Inspection Using IR Windows
28
Inspection Time
53
$7,950
PPE Suit-up Time
0
$0.00
engineeringmaintenance.info June/July 2011
Table 8 combines the data from the previous tables to illustrate the ROI (return on investment) that the mill realized from its infrared window program. The table details the total investment using three scenarios: 1) traditional open-panel inspections with a contract thermographer and two staff electricians; 2) the same contractor using infrared windows; and 3) an inhouse thermographer using infrared inspection windows. It then compares the ROI that the mill was able to achieve using windows and either a contract or in-house thermographer. Switching to infrared windows is shown to pay dividends in just one inspection cycle. Over $5,600 in savings can be put back into the budget by the end of the first cycle. After just five inspection cycles, the mill shows a savings of over $273,542. Plant management was encouraged by these projections, so they decided to invest in an infrared camera and training for two of its engineers (one electrical and one mechanical). Two engineers were enrolled in a Level I thermography course at $1,250 per man. An additional $1,500 per man was budgeted for travel and expenses. The new camera totaled $8,000. The total investment to start up the new internal inspection team was $13,500. The cost of in-house inspection (47 hours x $68.00) amounted to $3,196 per inspection, yielding a savings of $3,794 per inspection (or 54%) compared to a contractor. ROI of the new program using internal resources was achieved within the second inspection cycle; by the fifth cycle, the ROI was over $280,000.
Table 7:
Total
ROI:
$7,950
Because inspections can now be completed with greater ease and without increased risk to plant, personnel and processes, the mill increased the frequency to quarterly, reflecting bestpractice recommendations that originally were not considered feasible.
CASE STUDY : IRISS Table 8: Contractor Traditional
Contractor Windows
ROI Contractor Windows vs/ Contractor Traditional
In-House Windows
ROI In-House Windows vs/ Contractor Traditional
ROI In-House Windows vs/ Contractor Windows
312 Windows: One-Time Investment
None
$51,405
$51,405
Window Installation: One-Time Investment
None
$9,898
$9,898
IR Training & Camera: One-Time Investment
None
None
$13,500
Labor Costs: Per Inspection Cycle
$74,919
$7,950
$66,969
$3,196
$71,723
$4,754
Investment: Inspection Cycle 1
$74,919
$69,253
$5,666
$77,999
$(3,080)
$(8,746)
Investment: Inspection Cycle 2
$149,838
$77,203
$72,653
$81,195
$68,643
$(3,992)
Investment: Inspection Cycle 3
$224,757
$85,153
$139,604
$84,391
$140,366
$762
Investment: Inspection Cycle 4
$299,676
£93,103
$206,573
$87,587
$212,089
$5,516
Investment: Inspection Cycle 5
$374,595
$101,053
$273,542
$90,783
$283,812
$10,270
5 yr. Investment: QUARTERLY Inspection Cycle
$1,498,380
$220,303
$1,278,077
$138,723
$1,359,657
$81,580
Management succeeded in: •
Increasing safety
•
Facilitating
inspections
of
previously
“uninspectable”
equipment (11% of critical assets were not inspected in the old program) •
Increasing the frequency of inspection --
while saving
money •
Safeguarding profitability by eliminating high-risk behavior that posed a risk to plant assets and production
The purchase of the IR camera and training for the maintenance engineers quickly paid dividends. It allowed the plant to improve the maintenance program while operating in full compliance with the requirements of NFPA and OSHA. An infrared window program provides a cost-effective and safer alternative to traditional open-panel inspections. To learn more,
Conclusion: The new inspection process using infrared windows brought significant ROI to the plant in just one quarter, while reducing the risk of catastrophic failure among the plant’s critical power distribution systems.
visit www.iriss.com where you will find more case studies and white papers.
Martin Robinson Level 3 Thermographer, President & Chief Engineer, IRISS, inc.
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INDUSTRY NEWS
VITON® EXTREME™ SEALS OFFER HIGH pH RESISTANCE Dichtomatik Ltd, the sealing specialists, can now offer Viton® fluoroelastomer sealing products that have been subject to DuPont™ proprietary Advanced Polymer Architecture (APA) technology. These products, called Viton® Extreme™, feature base-resistant polymers to ensure improved long term performance in the presence of high pH chemicals. Chemical solutions that have been introduced over the past few years incorporate bases which inhibit metal corrosion caused by the long term effects of acid build up. Chemicals used to clean or purge industrial and food processing equipment can also have strong bases which are similarly detrimental to the performance and life expectancy of fluoroelastomer sealing products. However, the DuPont™ high performance elastomers utilised for Viton® Extreme™ production are capable of meeting the highest challenges by providing: • Overall fluids resistance • Exceptional base resistance • Significant processing advantages compared to existing TFE/Propylene polymers Dichtomatik is an authorised DuPont™ licensee and approved UK source for all Viton®, Vamac®, Kalrez® and Zalak® O-rings, seals and finished products. As a customer focused supplier, they are able to offer full technical support, service and supply for specific applications in the aerospace, chemical processing, oil & gas, energy, utilities, automotive and heavy duty/offroad markets, together with the food and pharmaceutical Industries. Performance enhanced variations of Viton® Extreme™ products are also available to cover specific applications, while maintaining the superior processing attributes of the Viton® Extreme™ range. Viton® Extreme™ TBR-S A totally base-resistant Viton® polymer that utilises APA technology and a revolutionary bisphenol cure site for an improved TFE/Propylene copolymer. This provides: • Inherent resistance to caustics/amines • Good resistance to hydrocarbon oils, acids and steam • Superior compression set resistance and lower volume swell for longer seal life and wear resistance • Superior processing versus other TFE/Propylene polymers Viton® Extreme™ TBR-605CS This elastomer can be used in oil and gas, chemical processing, utilities, automotive and heavy duty/off highway applications. Due to its chemical structure, like all other TFT/Propylene products, it is not recommended for automotive or aircraft fuel sealing. Viton® Extreme™ ETP-S This is an upgrade to ETP-900 that significantly improves processing and end-use performance, while retaining the excellent fluid resistance of its predecessor. It provides:
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engineeringmaintenance.info June/July 2011
• • • • •
Excellent resistance to acid, hydrocarbon and low molecular weight esters, ketones and aldehydes Inherent resistance to base attack and volume changes in highly caustic solutions, amines and hot water Low-temperature flexibility (Tg –10°C) Improved compression set and physical properties for superior seal performance Better mould flow, faster cure rates, and improved mould release and fouling for efficient manufacturing
Viton® Extreme™ ETP-600S While officially classified as an FEPM by ASTM D1418, the performance characteristics of Viton® Extreme™ ETP-600S combine the best characteristics of an FEPM and a specialty type Viton®. In complicated environments and chemically aggressive applications where standard FKMs or FEPMs are not an option, ETP-600S is the fluoroelastomer of choice. ETP-600S truly is the best of both worlds, with very low swell in hydrocarbons, it provides exceptional service for automotive oil seals and oil field applications, as well as automotive and aircraft fuels. Dichtomatik is a leading worldwide supplier of sealing solutions to many diverse industries and is able to offer outstanding customer service and support. Working closely with DuPont™ Performance Polymers European technical centre in Geneva, the leading global supplier of speciality elastomers and supporting technologies, they are able to provide innovative solutions to help customers stay ahead of the competition. For fast and friendly technical information and service, please call 0845 463 1039, with full technical information on the Viton® Extreme™ range available on www.viton-extreme. co.uk. The brand names Kalrez®, Viton®, Zalak® and Vamac® are all registered trademarks of DuPont™ Performance Polymers. Further information is available from: Dichtomatik Ltd, Donington House, Riverside Road, Pride Park, Derby DE24 8HX Telephone: 01332 524401 Fax: 01332 524425 e-mail: kalrez@dichtomatik.co.uk www.dichtomatik-kalrez.co.uk
PRODUCT SPOTLIGHT - DRY LUBRICATION
SAVING MORE BY USING LESS
MILLERCOORS TO MOVE AWAY FROM WET LUBE. It can take as much as eight pints of water to produce one pint of beer. High water and sewerage prices as well as greater environmental awareness have increasingly put brewing under pressure to improve its sustainable performance and in particular its use of water, energy and transportation. At MillerCoors, water is everything. From brewing to pasteurizing to shipping, water is essential to run the factories. “It’s the main ingredient in our beer. It helps clean our brew kettles. It helps water our crops,” states Kim Marotta, Vice President of Corporate Social Responsibility for the company. As part of its environmental commitment the company is determined to reduce its water usage without impacting on its products. In order to create “America’s Best Beer Company” MillerCoors wants to “grow its business the right way”. One initiative is to move away from wet lube! Converting many of its lines to dry lubrication is to be a significant contributor in the company’s 2015 water goal of reducing its water usage by 15%.
For example, in the Fort Worth brewery 9 out of 10 lines are converted to Dry Lube. The brewery is now on target to save 9 Million gallons of water a year. By using 3.40 barrels per barrel of beer produced, Fort Worth uses the least water across the eight Miller Coors breweries. It is also the third-lowest water consumers within its parent company, SAB Miller, with 77 large breweries worldwide. Dry Lube Ltd is proud to have helped MillerCoors reach this standard and is positive it can continue this excellent relationship; to save more by using less. Dry Lube Ltd, 93 George Street Edinburgh, EH2 3ES T: 0131 240 1292 W: drylube.co.uk E: jheyse@drylube.co.uk
PRODUCT SPOTLIGHT - VIBRATION MONITORING
HANSFORD SENSORS LTD SEE INCREASE IN THE POPULARITY OF VIBRATION MODULES FOR MONITORING INDUSTRIAL MACHINERY High Wycombe, Buckinghamshire, UK (7th June 2011) - Hansford Sensors Ltd announced today that it has seen an increase in the popularity and usage of their broad range of vibration modules. The modules act as an interface between an accelerometer and a control system and are used as part of the predictive maintenance process in industries such as, but not limited to, steel, quarrying, food and pharmaceuticals. Vibration modules are a cost effective solution for monitoring the condition of industrial machinery giving the facility to provide multiple outputs, for example, RMS velocity, enveloped or peak ‘g’, 0-10V, 4-20mA and buffered acceleration. They introduce additional signals which can be scaled to suit the specific application in order to achieve the best results. Popular models in the range include the HS-530 and HS-535 which are DIN rail mounted, offer a choice of triple or quad output and require a 24 V DC supply. The range of vibration modules provide flexibility with input 100mV/g from a constant current accelerometer operating over a typical frequency range from 2Hz up to 10kHz. Filters are also included for gE, g pk-pk and velocity, depending on the required model. Select modules are available with a BNC so any
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engineeringmaintenance.info June/July 2011
commercially available data collector can be inserted to retrieve signals for data analysis. With a compact design, the modules can be easily built and configured into a multi-channel system that can also act as a protection monitor for critical machinery. In addition to the above, the vibration modules can be interfaced using wireless technology which reduces the cost of installation and overall maintenance. For more information on the extensive range of Hansford Sensors products, please visit: www.hansfordsensors.com.
VIBRATION MONITORING
A NEW PORTABLE VIBRATION ANALYZER — WITH FULL COLOUR DISPLAY, FAST DATA ACQUISITION AND POWERFUL DIAGNOSTICS TOOLS. The VIBXPERT II handheld vibration analyzer combines the advantages of a rapid processor with a brilliant energyefficient colour VGA display. Enhanced with an Fmax of 51KHz and up to 102,400 Lines of Resolution, all machinery problems can be captured and easily analyzed on the VIBXPERT II large colour screen. The VIBXPERT II Basic platform is a 1-channel vibration data collector which can be upgraded at any time to 2 individually configured channels via a special pass code it’s user upgradable and does not require hardware changes. All forms of machine vibrations, bearing conditions, process data and visual inspection information can be collected and stored on the expandable Compact Flash Card (up to 8 gigabyte) for report generation or for later transfer to the OMNITREND software for further analysis, reporting and archiving.
functionality including dynamic balancing, extended time waveform recording, transient data capture, UFF file export, Modal/ODS support and more. As with all Pruftechnik vibration data collectors with the new VIBXPERT II you will enjoy the benefits of free updates, low ownership cost and unlimited tech support from the proven leaders of maintenance technology.
The VIBXPERT II vibration analyzer provides an easy-touse icon driven platform that offers comprehensive analysis
Optionally available:
functionality for the diagnosis of simple or very complex
Modules for Dynamic Balancing, Recording, Modal
vibration problems. Capabilities include order spectrum,
Analysis and Operation Deflection Shape (ODS)
phase, cepstrum, cross-channel phase, orbits, run-up
and VIBCODE automatic measurement location
and coast-down measurements, bump test, negative
identification.
averaging and more. Analysis tools, including various cursor types, machine-specific frequency markers, signal post processing, and extensive bearing databases are included for evaluating each spectrum. Alarm notifications based on ISO standards or user-defined standards are
For details and our free 180 page guide to Condition Monitoring, Laser Shaft Alignment
visually identified with the aid of coloured LEDs.
and Dynamic Balancing contact
VIBXPERT II is lightweight vibration meter —only 1.2Kg!
Pruftechnik Ltd, Plant Lane Business Park,
Its robust housing is dustproof and water resistant (IP65). VIBXPERT II is delivered with a carrying pouch with includes a breakaway shoulder strap for safety during data collection. The VIBXPERT II vibration analyzer features modular
Burntwood WS7 3GN or phone 01543 448350, Fax 01543 275472, email pposte@pruftechnik.co.uk
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PRODUCT SPOTLIGHT - VIBRATION MONITORING
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engineeringmaintenance.info June/July 2011
PRODUCT SPOTLIGHT - VIBRATION MONITORING
SCIENTECH STRESSWAVE SYSTEMS Scientech ushers in the next generation of Condition Based Management with the Scientech StressWave System.
conditions that allow you the user to determine optimum operating conditions of the asset while
Scientech uses Stress Wave Analysis which provides
maximizing availability and minimizing fatigue on
the earliest available indication of failure-causing
critical components.
conditions while also providing a continuous picture of the stresses being applied to the overall system and their impact. Unaffected by rotational speeds and providing lubricant status, StressWave provides information unavailable from traditional vibration
For More Information Please Contact: 200 South Woodruff Ave. Idaho Falls, ID 83401
system. Acting as a stand-alone system, integrated with advanced pattern recognition software like the Scientech PdP product or your own existing process control system, you can accurately determine asset
Phone: 208.529.1000 Fax: 208.524.9282 http://scientech.cwfc.com/ PRODUCT SPOTLIGHT - LEVEL SENSORS
FLUID MANAGEMENT SOLUTIONS USING COSENSE ULTRASONIC TECHNOLOGY Gain a higher sense of reliability and a lower cost of ownership with Cosense Ultrasonic Liquid Level, Air-in-Line and Precision Measurement sensors. Select from various series of sensor products, including both non-contact and contact type solutions. Cosense sensors have no moving parts, therefore no wear and no chance of mechanical failure. Cosense offers a wide range of sensors for OEM applications, both standard and custom, to meet fluid detection requirements in tubing as small as 1.6� ( 1.6 mm) in diameter to tanks 25 feet (7.6
Cosense Inc. 155 Ricefield Lane
meters) in depth and all configurations in between. In
Hauppauge, New York 11788
addition, Cosense ML series transmitters can be utilized
631-231-0735
for non-contact fill verification in bottles, test tubes, microplates, etc. with accuracies of +/-0.007� (0.18 mm).
johns@cosense.com www.cosense.com
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MACHINE SAFETY
HARMONISING PRODUCTIVITY WITH MACHINE SAFETY Safety gates, protective covers and machine guards prevent hazards associated
with
moving
parts.
However, the correct functioning of a safeguard can only be guaranteed by using the appropriate sensor technology. Manager
Alex at
Pilz
Bryce,
Sales
Automation
Technology, considers the sensor systems currently available and the selection criteria that designers should consider. Designers of plant and machinery are normally responsible for implementing the safety-related requirements and for selecting the components used for safe monitoring. However, designers are spoilt for choice, which makes choosing the most appropriate safe sensor or actuator/sensor combination a difficult task. Sensor systems operate using different principles and so it is important that designers fully understand the implications of using each type. The challenge is to try to harmonise productivity with machine safety and user-friendliness. If a safeguard is not user-friendly, there may be a temptation to manipulate a safety guard, putting the machine operator at risk. Designers need to identify potential cases in which safety devices might be manipulated and then to eliminate these at the machine development stage. Certain considerations will help the designer to decide which components should be used for the safe monitoring of movable guards in accordance with EN 60947-5-3. Typical questions that should be asked include: is the cover frequently opened and closed? Does the process need protecting as well as the operator? Are components exposed to high vibration or extreme temperatures, or are they used in potentially explosive areas? Mechanical safety switches For simple safety gate applications where there is no increased risk of manipulation, mechanical 36
engineeringmaintenance.info June/July 2011
safety gate switches are widely used. These are used for simple safety gate monitoring or with a mechanical guard locking device, which uses increased extraction force on the actuator to prevent the gate or cover from being opened unintentionally. Many applications require two mechanical switches to guarantee the required level of safety, which increases engineering costs significantly. Another consideration here is that swarf can quickly be deposited on the sensor, restricting its function. Also, if safety gates drop over the course of time, the lifetime of a mechanical switch is reduced considerably. Mechanical safety bolts are complete solutions comprising a safety switch, handle and bolt. These provide protection where safety gates are difficult to adjust, as well as on safety gates that are frequently opened and closed. A mechanical guide on the actuator ensures that the actuator engages with the safety switch correctly when the safeguard is closed. Mechanical hinge switches provide an elegant solution for rotating or hinged gates and flaps. These provide better protection against manipulation compared to other mechanical solutions because they are concealed within the hinge, which also saves on installation space. Non-contact safety switches Gates, covers and flaps often need to be opened repeatedly for operational or assembly purposes, to enable operators to access or reach into the protected area.
MACHINE SAFETY
Here, the risk of a gate being mechanically misaligned is high. The disadvantage of mechanical guard locking devices is that they only have limited tolerance for misaligned gates. For this reason, non-contact safety switches provide an attractive alternative, particularly if there are high vibrations. These switches have a higher response tolerance, allowing greater flexibility in the way they are attached to the machine. Rugged non-contact switches are also suitable for applications that require protection types higher than IP67. These switches are able to meet safety requirements up to PLe of EN ISO 13849-1, and SIL 3 of EN/IEC 62061, or Category 4 of EN 954-1. When it comes to deciding on the acting principle of the sensor, important distinctions need to be made. Whilst magnetic safety switches provide only limited protection against manipulation due to the technology used, coded safety switches achieve up to 100% protection against manipulation. As a result, magnetic safety switches should be concealed or installed in such a way that they are invisible to operators. If a safety switch cannot be concealed or if 100% protection is required, RFID coded safety switches are ideal. RFID technology enables a clear assignment between sensor and actuator. RFID coded safety switches operate in accordance with the ‘key lock principle’ whereby only one key – a unique version – fits a lock. Given that the actuator is installed using one-way screws – which can only be loosened via a special tool – a very high level of protection against manipulation is achieved.
It is also important to understand that magnetic safety switches have limited suitability if metal swarf is present, which can be attracted to the magnet and deposited on the switch, leading to operational problems or even failures. Although a safety-critical situation cannot arise as a result, plant availability and productivity will suffer. Here, coded switches are ideal, as RFID is unaffected by metal swarf. Various coding types mean that different levels can be achieved in terms of security against manipulation. The greatest protection is provided by systems in which an actuator is uniquely assigned to a switch. Sensors with ‘normal’ coding are also available if the demands on manipulation protection are less stringent (one lock, many keys). Gate closed in case of danger Risks can remain even after a machine has been shut down, due to moving parts. In ‘hazardous overrun’ cases such as these, the use of a safe guard locking device is mandatory. This means that the gate cannot be re-opened until standstill has been safely detected or a time delay has elapsed. Here, mechanical guard locking devices with spring interlocks are typically used. The spring interlock guarantees that the gate can only be opened when it is safe to do so. Integrated systems More can be achieved by using integrated safety gate systems that combine safe monitoring, safe guard locking and control elements, including additional functions such as E-STOP and escape release. All components – whether mechanical or electronic – are integrated. Complete systems such as these help to reduce the time and costs associated with project configuration, design, documentation, purchasing and installation. Furthermore, if sensors and evaluation devices are sourced from a single supplier, this means that the interfaces between the various components are already compatible. For More Information Please Contact Pilz: Pilz Automation Technology Telephone: 01536 460766 Fax: 01536 460866 E-mail: j.harris@pilz.co.uk Website: www.pilz.co.uk
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PRODUCT SPOTLIGHT - PORTABLE CALIBRATORS
THE ISOTECH FAST-CAL RANGE OF TEMPERATURE CALIBRATORS Rugged on site calibrators to provide a solution for the fast calibration and checking of thermocouples, platinum resistance thermometers and other temperature sensors over the range -35°C to 650°C. The 35mm removable calibration volume has room for several probes with both standard and custom drilled inserts available to suit all probe sizes. One model is ideal for the validation of Washer Disinfectors, Steam Sterilisers and Autoclaves and uses a fixed block with pockets for a reference probe and the type of test sensor commonly used in validation applications.
For more information visit:
The Fast-Cal includes a PC interface with cable and
http://www.isotech.co.uk/fast-cal
software, padded carrying case and traceable calibration
Or contact Isothermal Technology Limited directly on
certificate.
Tel: +44 (0)1704 543830, E-mail: info@isotech.co.uk
PRODUCT SPOTLIGHT - PORTABLE CALIBRATORS
RELIABLE HAND-HELD METERS FOR VARIOUS INDUSTRIAL ENVIRONMENTS Regardless of industry, make maintenance and spot-checking easy, fast and reliable with Vaisala’s portable measurement instruments for dew point, relative humidity, temperature, moisture in oil and carbon dioxide. Two parameters, e.g. humidity and carbon dioxide can be measured concurrently. All hand-helds are compatible with Vaisala’s fixed units for easy in-situ checking. For compressed air applications, the perfect choice is the lightweight 750g dew point hand-held DM70. It has the fastest wet-to-dry response time on the market - just minutes - it’s immune to compressor oil and recovers quickly from saturated conditions. The probe can be directly inserted into pressurized pipelines. For lubrication and hydraulics oil filled systems, the ideal preventive maintenance tool is the hand-held meter MM70. MM70 measures moisture in oil, indicating the margin to free water formation and thus enabling corrective actions before water causes problems. To control environmental conditions quickly, but reliably in life science industries like pharmaceutical and biotechnological research, manufacturing and storage, a hand-held humidity and temperature meter HM70 is ideal choice. It is handy also for
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calibrating Vaisala’s fixed transmitters. The Vaisala CARBOCAP® Hand-Held Carbon Dioxide Meter GM70 is perfect for demanding spot-measurements in laboratories, greenhouses and mushroom farms. The meter can also be used in HVAC and industrial applications, and as a tool for checking fixed CO2 instruments. All of these hand-helds have multilingual user interfaces and graphical displays with data logging capability. Long operation in the field is guaranteed via low power consumption. www.vaisala.com tel. +44 1638 576200 uksales@vaisala.com
PRODUCT SPOTLIGHT - PORTABLE CALIBRATORS
GET A SMARTER, MORE EFFICIENT AND ACCURATE SOLUTION FOR CALIBRATING! The Beamex® Integrated Calibration Solution (ICS) improves the quality and efficiency of the entire calibration process through faster, smarter and more accurate management of all calibration assets and procedures! The heart of the Beamex® ICS is a powerful combination of calibration hardware; pressure, temperature and multifunction calibrators, automatic temperature baths, automatic pressure regulators and standard off-the-shelf calibration management software configured by Beamex to your exact requirement, facilitating seamless lines of process and data flow from your business and maintenance management systems to your calibration technicians and back. Beamex calibrators, workstations, calibration software and professional services form the most integrated, automated calibration system available on the market.
Address: Beamex Limited Newtown Grange Farm Business Park Desford Road, NEWTOWN UNTHANK Leicestershire, LE9 9FL, United Kingdom Phone: 01455 821 920 Fax: 01455 821 923 E-mail: beamex.ltd@beamex.com Internet: http://www.beamex.com
PRODUCT SPOTLIGHT – TEMPERATURE MEASUREMENT
MKT 50 MILLIKELVIN 2 CHANNEL THERMOMETER High-precision temperature measurement with measuring accuracy up to 0.001 °C (1 mK) at an attractive price. MKT 50 in combination with platinum resistance thermometers (Pt 100 and Pt 25.5) is designed for temperature measurements of the highest accuracy and calibrations (comparison or fixed point) for industry, laboratories and research. It has a measuring range of -260 °C to +960 °C and is traceable to national standards. Using calibrated thermometers you can achieve a measurement uncertainty (instrument and sensor) in the range 1-10 mK. Fully compliant to ITS-90 and IEC 751. The MKT 50 measures the temperature, resistance, resistance ratios, standard deviation and mean values. Up to 30 sets of calibration constants for individual PRTs can be stored, allowing plug & play operation. MKT 50 is a robust, mains or battery operated with Ethernet and RS-232 interfaces for remote operation and data collection.
Anton Paar Ltd 13, Harforde Court, John Tate Road Hertford SG13 7NW - UK
Tel: +44(0) 1992 514730 Email: info.gb@anton-paar.com Web: www.anton-paar.com
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PRODUCT SPOTLIGHT – INDUSTRIAL GEARBOXES
HIGH-TORQUE INDUSTRIAL GEARBOXES COME IN HIGH-INTEGRITY SINGLE-PIECE HOUSINGS Single casting with integrated bearing seats, allowing higher shaft loadings, longer lifetimes, delivers superb efficiencies of up to 96% and minimises oil leakage possibilities, available with helical or bevel gear combinations. Nord Drivesystems has extended its family of high-integrity industrial gearbox units, adding a family of high-power models with maximum torque ratings up to 200000 Nm. The Industrial gearboxes employ Nord’s proven Unicase concept. The gearbox case is a single piece casting, with all bearing seats integrated and machined in a single process. This optimises strength and eliminates sealing surfaces that could deflect under the effect of torque or radial forces — minimising the possibility of oil leakage and ensuring precise bearing alignments. The resulting highintegrity gearboxes deliver smooth, low noise operation with an extended long product life.
There are four choices in the High Power Unicase family, offering maximum torques of 60000, 90000, 135000 or 200000 Nm. Available in helical-parallel shaft or helical/bevel right-angled drive configurations, a very wide range of gear ratios can be specified using two-, three-, or multi-stage reductions. The gearboxes are ideal power transmission solutions for material handling and processing equipment in applications such as steel manufacture, aggregates, mining and grain handling. The low losses of the helical gearing technology means that Unicase gearboxes can deliver excellent energy efficiencies of up to 96%-plus. For More information Go To: http://nord.com/
PRODUCT SPOTLIGHT – INDUSTRIAL DOORS
INDUSTRIAL ACOUSTIC DOORS FROM A WORLDWIDE MANUFACTURER IAC is the world’s largest manufacturer of noise control products and the UK’s leading supplier of industrial acoustic doors. With over fifty years experience in design and manufacture, architects and specifiers prefer IAC acoustic doors. IAC doors are precision engineered and can be opened and closed by one person, regardless of size. IAC offer a wide range of door models - including several available from stock, or can design and manufacture to suit specific applications. All IAC doors are fabricated from steel and come complete with high quality acoustic seals, hinges and furniture options. IAC have recently developed a new acoustic sliding door, excellent for maximising usable space while still protecting areas from noise disturbance. Over 1,000,000 IAC acoustic doorsets have been installed in industrial buildings throughout the world for some of the
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world’s leading industrial brands including Rolls-Royce, Air Products, FG Wilson, Cummins, Volvo, Yara, Bajaj, Suzuki, MoD, BMW, Ford, Westland Helicopters and many more. IAC House, Moorside Road, Winchester, SO23 7US, United Kingdom Tel: +44 (0) 1962 873000 Fax: +44 (0) 1962 873111 Email: info@iacl.co.uk
PRODUCT SPOTLIGHT – INDUSTRIAL DOORS
INDUSTRIAL DOORS SUPPLIED, INSTALLED AND REPAIRED Local Engineers working throughout the Northwest, Carrington Doors is a well established firm with a wealth of knowledge in the INDUSTRIAL Door business. Over the years we have successfully installed and repaired thousands of industrial doors. We offer a comprehensive service with prices that cannot be beaten. Industrial Door Repair – 24 hour Call out. Let our experience save you time and money. We offer a fast professional service to keep your loading areas working and your products moving. Our technical surveyors offer free advice and, when necessary we can despatch a rapid response repair team to deal with emergencies. We carry large stocks of spare parts for all types and makes of doors. Our experienced engineers are fully trained and based locally in your area. Our low cost, no strings service agreements can reduce down time and help you budget. Our Professional maintenance and repair service is available 24 hours a day.
In the unlikely event that a door or shutter is beyond ecomonical repair, our factories can quickly manufacture a replacement for installation with minimum inconvenience to your operations. Manual doors can be converted to electric operation by our factory trained personnel. Choose from a wide range of control options - from simple push buttons to sophisticated remote controls and induction loops. • •
Reliable 24 hour Emergency call out and same day repair service Fully trained maintenance teams carry up to date safety passports Call us to discuss your needs on: +44800 581890
OPTEX INDUSTRIAL DOOR SENSOR The Optex OA-4500 is the new active infrared door sensor standard for industrial doors up to a mounting height of 4,5 meter. The sensor is developed as a combination sensor for safety and activation, the active infrared presence detection protects against early closing of the door, while the activation area
The OA-4500 increases the safety around the door by preventing it from closing when someone or something is nearby. The flexible setting of the detection area offers a large variety to comply with the needs of the industrial door market.
activates the door when entering the detection area. The detection area covers a depth of 3900mm by a width of 5700mm at an installation height of 4500mm. The presence and activation area are independently adjustable to fit the needs of every installation. Standard the OA-4500 comes with 2 relays, one for activation and one for safety.
Optex Technologies BV
Tel. +31 70-4194100
Tiber 2
Fax +31 70-3177321
2491 DH The Hague
email: info@optex.nl
The Netherlands
website: www.optex.nl
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PRODUCT SPOTLIGHT – ENERGY MANAGEMENT EQUIPMENT
ENERGY-EFFICIENT COMMERCIAL LIGHTING SYSTEMS Some facilities use up to 50% of their electricity load for lighting. This can be significantly reduced by using highperformance skylights for natural lighting and energy-efficient solid-state LED for electrical lighting in place of traditional gas discharge bulbs. LED can replace sodium, HID & fluorescent bulbs to reduce energy consumption 50-80% and last many times longer. Money is saved by reduced electricity, reduced maintenance and reduced heat gain, without containing any toxic mercury. Silvermere International offers the highest performance commercial LED systems available with up to 150,000 hour lifespan, and represents several product lines to source the right product for each application. Our LED retrofits can be installed into almost any existing fixture, making it easy to transition to LED and save energy. Wherever you are located, Silvermere can help you improve lighting efficiency for commercial/municipal applications. Please contact us today to request more info or discuss your lighting needs.
SILVERMERE INTERNATIONAL GROUP – LIGHTING DIVISION
St. Paul, MN USA Email: ryan@silvermeregroup.com web: www.silvermereinternational.com Raise Your Standard of Lighting!
PRODUCT SPOTLIGHT – FLOW METERS
BELLE GREVE PUMPING STATION T-T TO THE RESCUE! Cheshire based Aquaflow a division of T-T Pumps are always prepared to leave their comfort-zone to deliver solutions that exceed expectations! Belle Greve Pumping Station is undergoing an upgrade to prolong its lifespan, work started in 2008 and it is crucial to the island’s future sewage management programme.
Aquaflow
a division of T-T Pumps were approached by the principal contractor working on behalf of Guernsey Water because three DN600 wedge gate valves that had been supplied a few years ago by a framework manufacturer, had heavily corroded due to being in a saltwater environment. These valves play a crucial role in controlling the flow and therefore it was very important they were put right as soon as possible. Following extensive discussions between Aquaflow and themselves, to ascertain hydraulic parameters and installation characteristics we proposed a solution endorsed
with technical argument. T-T Pumps Aquaflow secured an order to supply three replacement DN600 gate valves that would with stand these arduous conditions. Aquaflow upgraded the seat and spindle nut material to aluminium bronze and spindle in super-duplex stainless steel. The ductile iron bodied valves were tripled coated in a marine grade two-pack resin to greater than 800 microns.
E-mail: response@ttpumps.com Tel: 01630 647200
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PRODUCT SPOTLIGHT - GAS TURBINES
LEARN FROM THE GAS TURBINE EXPERT DR. MEHERWAN P. BOYCE, PHD, P.E., C.ENG (UK) DR. BOYCE, BEST-SELLING AUTHOR, CONSULTANT, AND DEVELOPER OF THE FIRST TOTAL CONDITION MONITORING SYSTEM (MECHANICAL & AEROTHERMAL), WILL PRESENT TWO LIMITED ENGAGEMENTS IN LONDON IN 2011. Improving Efficiency, Productivity and Reliability of Centrifugal Compressors and Gas Turbines July11-13, 2011 Advanced Technology Gas Turbines & Planned Optimization of Combined Cycle Power Plants November 22-24, 2011 PRODUCT SPOTLIGHT - COUPLINGS
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A world recognized expert in gas turbines, centrifugal compressors, and combined cycle power plant systems, Dr. Boyce has designed systems for offshore platforms, refineries, natural gas facilities, pipelines, and power plants. Major corporations, the EPRI, and the U.S. Department of Energy consult with Dr. Boyce on designing and recommending systems. Dr. Boyce’s short courses are interactive and provide practical information with minimal theory. Participants are encouraged to bring challenges specific to their environment for Dr. Boyce to solve. Total Condition Monitoring and turbine and compressor characteristics are discussed in-depth. Secure your spot today! www.boyceconsultancy.com 2121 Kirby Drive, Houston, TX, 77019, USA 1-713-807-0888 zmboyce@boycepower.com
PRODUCT SPOTLIGHT - NON DESTRUCTIVE TEST EQUIPMENT
ULTRASONIC WALL THICKNESS MEASUREMENT EVEN FOR COATED MATERIAL KARL
DEUTSCH
introduces
the
new
ECHOMETER 1076 TC (TC = Through Coat) thickness gauge for exact wall thickness measurement. The disturbing influence of paint and varnish is compensated by assessing consecutive back wall echoes (“BE-BE”-mode). With this feature steel constructions can be inspected without surface treatment such as bridges, cranes and masts, ship hulls and conveyor installations or other safety components like gas cylinders, compressed air reservoirs and manufacturing-plants (chemistry, pharmaceutics, oil, gas, energy). The easy and comfortable menu navigation keys are very user-friendly and in a comprehensible plain language. The readings are displayed in large and clear digits and a backlight illumination of the display ensures a convenient operation also for poor light conditions.
KARL DEUTSCH Prüf- und Messgerätebau GmbH + Co KG Otto-Hausmann-Ring 101 42115 Wuppertal, Germany www.karldeutsch.de info@karldeutsch.de Phone (+49-202) 7192 - 0 Fax (+49-202) 71 49 32
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OEE
OEE – THE QUALITY MEASURE. My previous articles have focussed primarily on how to improve the ‘Availability’
and
‘Performance’
elements that form part of the OEE calculation (A x P x Q = OEE); today, we examine ‘Quality’. It may be an urban myth, but Henry Ford is supposed to
place, so to measure and check quality using another system is simply duplication of effort. Some companies still use paper based inspection methods; perhaps an A3 sheet with the checks to perform down the left hand side with the rest of the page split into 15 segments. Quality Operators then perform the inspection tasks at 15-minute intervals, and enter a pass or fail value in each of the segments. Completed sheets are then filed, usually with some data entered into a spreadsheet for analysis, and only ever looked at again during a crisis related to batch traceability.
have said “Quality means doing it right when no one is looking.” An interesting thought, but can we really expect to achieve perfect quality in a modern operation
without
regular
sample
checking? Probably not. Historically, many manufacturing processes have tended to overlook ‘Quality’ as a ‘constant’, or simply a KPI for the QC department, rather than an opportunity for manufacturing process improvement. This mind-set has changed significantly in the past few years with the price of raw materials reaching an all-time high, a real drive towards RFT manufacturing, and increasingly demanding customer-driven audits. Today, quality inspections range from automatic inspection on CNC machines through final inspection of every product, to checks on an agreed number of examples. (Some operations even rely on the customer making the quality checks but this is a risky and often expensive strategy!)
Automate this process, and not only does it take the pain (and margin for error) out of data entry, but it also means that the data collected can be used to inform the manufacturing Improvement Agenda. There are two basic requirements to automate the process: an administrator to manage the check creation and an operator console to capture the results. Lets start with what we want to inspect. For a specific asset and product combination, five elements need to be defined. 1: What is the measure? It could be moisture content, weight, length, colour, temperature, visual comparison, or calibration test. 2: What is the range for pass or fail? If legislation dictates the weight must be 100 grams, the pass
With so many shop-floor systems available, the question is whether quality checks and record keeping should be paper based, part of a large ERP system, or a stand-alone application? There are business cases for all of these options, but logically, building quality checks into OEE measurement makes perfect sense, as ‘Quality’ is a vital part of the calculation.
options could be 100, 101, 102, 103, whilst 99 and 104 grams
Quality is directly linked to the assets that make the product, and the number of products made, which are both essential elements in OEE. Moreover, the following information is already available in any comprehensive OEE System:
4: What do we do when a fail is registered?
• • • •
Asset structure Product definitions Number of rejects Reject reasons and locations.
are both fails. 3: What response do we expect? It may be a value, text, yes or no, signature or pin number sign off
Send an automated alert, send an advisory message, or stop the plant? 5: What is the frequency? It could be by time, shift, product or ad hoc. Of course, the ‘quality’ check does not have to be directly related to assessing the quality of the product; it could, for
We are also likely to have employee definitions of ‘rejects’, a touch screen interface, and two-way communications already in
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instance, require the operator to check and top-up an oil mist bottle every shift. In this case we just need to know the task
OEE has been completed within the required frequency. (It’s now clear to see the logic of including quality inspections in the OEE management framework.) Next we select a range of products or asset combinations, and group the quality checks that are likely to be similar across the plant; so the set-up process can be fairly quick. Once the quality inspections are defined they can be scheduled to automatically remind the Quality Operators when the checks are due. We can then show when the checks are due, and react to any ‘missed’ inspections. With a touch screen it’s quick and easy to enter the data, and the results can be made visible across the plant: ‘ideal’ and ‘fail’ values can be clearly displayed so that the operator can just touch the value of the measured sample.
can use the existing hardware framework of touch screens for both activities, reducing our infrastructure outlay and improving return on investment. We can also remove much of the paper and provide instant reports, without duplicating the data analysis process. Much of the quality data is already captured in the system; the asset structure, product definitions, company calendars and employee definitions are already present. We can even use the existing employee security structure and pin codes for sign-off. One final point, the operations team has access to stoppage and quality alerts in the same system. They can review production problems and successes and match them to quality results. Good production runs should deliver good quality statistics; the opposite may also be true. When urgent traceability is required; all the run parameters, people and products are accessible in a single place, which is especially useful during a customer audit. John Ruskin famously said that ‘Quality is never an accident; it is always the result of intelligent effort’. The key word for me here is ‘intelligent’. Maintaining perfect quality doesn’t have to be arduous – with intelligent systems in place many factories could relieve the pressure on their manufacturing and operations teams, especially during audits. Convinced? Ditch some of the endless paper trail, and try it; when the measurement systems are highly visible, and easily traceable, operations teams may agree with Ford that “Quality means doing it right when no one is looking.”
Once the task creation and results are captured we need a few reports to measure adherence: • Did we meet the target frequencies? • Statistically how well are we doing? • Are we giving too much away? With the values filed digitally, batch traceability is comprehensive. We have a record of the plant conditions when the results were captured, and we know which operator was logged on at the time. Because the quality element is recorded by the OEE System, we also know when production started and when it ended, how many products were made and the number of rejects. Crucially, we can also review every stoppage event or problem that occurred so we may be able to see which problem caused the quality issue in the first place. The key advantage of building quality checks into the OEE System, is the ability to generate fully automatic alerts, so as soon as a critical fail is recorded we can send a text message and email to an individual or group, informing them that the values have fallen well below set parameters. This ensures that the quality issue can be rectified as soon as possible. It also means that there is no place to hide; the alerts can also be recorded so that we have a robust audit trail. Of course quality measurement and recording can exist outside the OEE framework, but it makes sense to bring the two together as it results in time, resource, and financial savings. We
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. Contact him by e-mail: alan.france@idhammarsystems.com, or visit www.idhammarsystems.com for more on CMMS and OEE software.
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PRODUCT SPOTLIGHT – LEAK TESTING
WHAT IS PRESSURE DECAY? Probably the most common (and one of the oldest) forms of leak detection as, in terms of sensitivity, it is generally utilised to find liquid leaks. There are two basic types of pressure decay measurement methods:
THE GAUGE METHOD This method employs a single sided measurement device (transducer). The technique employed is to connect the product to be tested to a regulated gas supply, with the sensing device (transducer) in circuit to indicate the pressure achieved. The pressure is then ‘locked’ into the system by use of a shut-off valve, and the transducer continually interrogated for a drop in pressure. The main drawback with this method, is the sensitivity, and because of this is more susceptible to temperature and other external effects.
Typical specification of such a transducer : Sensitivity
0.1 Pa
Range
2000 Pa
Accuracy
1%
Repeatability
0.5%
Speed of response
<100 ms
Most modern pressure decay systems utilise the differential method:
THE TEST CYCLE We need to carry out the following steps: • FILL the component to the required test pressure with air. • TEST for leakage from the product (measure the pressure decay). • EXHAUST the air from the component, (vent to atmosphere) to allow safe removal. However when a confined volume (the component under test) is pressurised there are a number of effects, such as temperature increases, which can cause false readings in the measuring cycle, so we must add a further stage: •
STABILISATION in between the fill and test phases to relieve the ‘adiabatic’ effects.
CONVERTING TO FLOW UNITS Pressure decay measurement can easily be related to flow by considering the universal gas law. PV = constant (At constant Temperature)
THE DIFFERENTIAL METHOD With this technique, the component is pressurised in the same way however the difference is that both sides of the measurement transducer are also pressurised to the same level as the product. One side of the measurement transducer is then connected to the component and the other to a sealed reference. Very small changes in pressure then cause an imbalance (pressure difference) which can be directly measured.
From this basic gas law we can derive the formula: Flow = Rate of change of Pressure x Volume tested Atmospheric Pressure
From this we can derive: cc/s = mB/s x VOL(cc) 1013
Many systems have this formula built into the software, so that the equipment can display the leakage directly in terms of Flow. Fisher Leak Systems Ltd Unit 7 Tame Road Industrial Estate Witton, Birmingham, B67HS Tel: 0121 328 2515 http://www.fisherleaksystems.com
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BUYERS GUIDE 2011
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BUYERS GUIDE 2011
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