ems 2010 August edition

SONATESTLAUNCH

" A NEW PHASED ARRAYINSTRUMENT IS NOWLAUNCHED, THE VEO

16:64."

SKFMAINTENANCE BECOMES

LESS OF A GRIND ATFLOUR MANUFACTURER

ENVIROREDUCE EMISSIONS BY

REVAMPING YOUR STEAMSYSTEM

ELECTRICITY!THE POWER OF OEE AND A

FEW DISCRETE ENERGYMETERS

CHRISTERIDHAMMAR

Engineering Maintenance Solutions, August 2010

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Engineering Maintenance Solutions, June 2010

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Contents

Publisher - Michael Dominguez

Email:[email protected]

Editors/Contributers - Jon Barratt,Christer Idhammar, Alan France, MickSaltzer, Mark Haarman


Ad Manager - Paul Clappison


Online Sales Director - Paul Miles


Website:

www.engineeringmaintenance.info

MSL Group, Cobalt House, CentreCourt, Sir Thomas Longley Road,Rochester, Kent, ME2 4BQ

Tel: +44(0)1634 731646

Fax: +44(0)1634 731644

www.engineeringmaintenance.info

Latest News & Products 7- 19

Maintenance becomes less ofa grind at flour manufacturer20 - 21

Reduce Carbon Emissions 22- 23

Insulation Testers 25

Condition Monitoring 26

OEE 28 - 29

MAINTAIN Preview 30-31Power Plant Maintenance 32- 33

Fastening Solutions AidCompliance 35 - 37

Improve Energy Conservation39

Training - 41

+ Buyers Guide, IR, Motors &Drives, Buyers Guide.........

August 2010


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I am no longer surprised to see reliabilityand maintenance improvement initiativesabandoned before the substantialresults, which are possible to achieve,are delivered and sustained for years tocome.

This phenomenon is recognized by manyof my colleagues in the reliability andmaintenance management profession.I recently came across the findingsillustrated in the graph below from theAmerican Society for Training andDevelopment. It illustrates what happenif training is not followed by practice andreinforcement. The findings show that87% of what you learnt is lost within 30days if training is not followed bypractice and reinforcement.

Their findings illustrates very well why somany reliability and maintenanceimprovement initiatives delivers goodresults, but only about 50% of theimprovement potential.

Reliability and maintenanceimprovements are one of the last majorimprovements opportunities theindustries have left. Everyone withaccess to capital can buy the sameequipment and technology, howproductive your plant is will to a verylarge extent depend on the reliability ofyour process and your equipment. If yourequipment runs, you make product, if itdoes not run your employees workharder, you pay more and you are notmaking product. So why does topmanagement not reinforce that even themost basic maintenance practices areexecuted better and better over longperiod of time to achieve sustainable and

outstanding financial results? Perhaps itis lack of patience and reinforcement?

Another good comparison is safety. In1994 the average overall incident rate inone process industry was 8.7. The lateststatistics I just researched is 3.8 in 2008.In 14 years this industry as an averagereduced overall safety incident rates byabout 64%. We all know that this isbecause of long term reinforcement andtraining.

Imagine if we used the same focus ontraining, implementation andreinforcement of basic maintenancepractices; could you have reducedpreventable maintenancework and down time by60%? The majority ofmaintenance work ispreventable and can alsobe executed in half of thetime so I know it ispossible, because I haveseen it happen and thekey to these successes hasbeen top managementlong term support andreinforcement. And on topof better maintenanceproductivity and higherproduction throughput youwould get an even bettersafety record.

The major reasonswhy reliabilityand maintenance improvementinitiatives do not deliver morethan about 50% of possible re-sults is according to my experi-ence:

· The new manager and newprogram phenomenon.

· Looking at reliability and main‐tenance improvements as aprogram with a start and anend instead of a process with astarting point but with no end.

· Confusion between concepts,whole systems and tools.

· New names on good mainte‐nance practices have confusedand delayed implementation.Why can we not call mainte-nance just maintenance?

· More focus on systems and

tools instead of on people.

· A lot of training and preachingnot followed by immediate ac-tions and implementation.

Sustainable reliabilityand maintenance

Christer Idhammar is a world renowned and awarded Reliabilityand Maintenance Consultant and Guru. He is the

founder and executive vice president with IDCON,INC in Raleigh NC, USA; A reliability and

maintenance training and consulting company toIndustry worldwide since 1972. www.idcon.com


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icro-Epsilon’s wireSENSOR range

of draw-wire (string pot)

displacement sensors uses three main

measurement methods: a multi-turn

potentiometer, an incremental encoder

or an absolute encoder. One of these

devices is mounted onto the drum axle,

converting the rotary motion of the

drum into a signal that can be

evaluated. The measured displacement

can be output as an analogue current,

voltage or potentiometric signal. For a

digital output, there is a choice of HTL

or TTL, with interfaces for most of the

common fieldbus systems, including

CANopen, SSI and Profibus.

As with traditional tape measures, the

wireSENSOR series is capable of measur-

ing around corners and edges. Micro-Ep-

silon supplies as accessories deflection

pulleys, which deflect the steel wire in

the desired direction. The sensors cover

a measuring range from 50mm right up to

50m. Options are available for harsh

environments (including subsea), with an

IP67 version available.

Chris Jones, Managing Director at Micro-

Epsilon (UK) Ltd comments: “Our draw-

wire sensors are being used in a wide

range of applications, from general

industrial machinery and scissor lifts,

through to more specific uses such as

pneumatic and hydraulic systems,

forklift trucks and subsea oil & gas

systems. Our wireSENSOR range is very

popular with machine builders and

OEMs, who require low cost, robust,

reliable sensing solutions that can be

easily integrated into their customer’s

existing machine, components or

control and automation systems.”

Unique eddy current sensors

Visitors to Micro-Epsilon’s stand will also

be able to see the company’s brand new

range of eddy current ECT (Embedded

Coil Technology) sensors. ECT is a

technological breakthrough in eddy

current sensor design and manufacture,

which overcomes the previous

limitations of using eddy current

sensors.

Due to its ultra-compact design and by

using new inorganic materials in its

construction, the new eddyNCDT ECT

sensors provide almost unlimited scope

in terms of the external design and

geometrical shape of the sensor. This

means that sensors can be adapted for

almost any use, including subsea, oil

and gas applications.

Micro-Epsilon’s eddyNCDT ECT sensors

offer extreme mechanical robustness,

resulting in longer service intervals and

higher temperature stability. The

complete circuit electronics are

integrated into the sensor itself,

providing a more compact solution for

OEMs and machine builders. The sensors

are suitable for

harsh

environments,

including high

vibration, impact

shocks, high

pressure/vacuum,

and high operating

temperatures up to 350 deg C. Sensors

have also been produced with extremely

low thermal drift and with temperature

errors of less than 20ppm/K.

Non-contact temperature

measurement

As well as displacement sensors, Micro-

Epsilon will also be showcasing a range

of non-contact temperature

measurement products, including

thermal imaging cameras and inline

process temperature sensors.

After recently setting up a partnership

agreement with Flir Systems UK, a

leading supplier of infrared

thermography systems, Micro-Epsilon is

now able to offer the thermoIMAGER i

series of handheld thermal imaging

cameras, as well as its own inline

process temperature sensors.

For more information on Micro-

Epsilon’s range of sensors, or to see a

product demonstration, please visit

stand 703 or call the sales department

on 0151 355 6070 or email:

[email protected]

Custom eddy current and draw wire sensors for

subsea oil & gas applicationsAt this year’s Instrumentation Scotland & Offshore Systems 2010 exhibition (8-9 September2010) precision sensor manufacturer Micro-Epsilon (UK) Ltd (stand 703) will be showcasinga range of displacement sensors and non-contact temperature measurement products forsubsea, oil & gas applications, including draw wire sensors, eddy current displacement

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The Naphtha Cracker project is reportedas the cornerstone for Indian Oil's entryinto petrochemicals and represents anew market for business growth for thecorporation.

Located in the Northern Indian state ofHaryana, the installation is an excellentillustration of AUMA working inpartnership with the customer to supplya comprehensive solution incorporatinghard wiring and bus technology backedby master station support.

The installation, which confirms thecompany’s expertise in supplying thepetrochemical industry, required 75actuators at the Cracker complex - whichhas a capacity of 800,000 MT/year ofethylene production. All actuators havebeen supplied with control modulessuitable for MODBUS RTU protocol.Additionally, SIMA master stations andhot standby master station with looptechnology have been provided. ESDfunctionality, achieved throughhardwired operation, is provided,tailored to meet the customer’srequirements.

The master stations in redundantconfiguration communicate throughMODBUS RTU protocol with YokogawaDCS CS 3000. Additional featuresprovided are PCs to monitor theactuators’ functions via the SIMA masterstations.

AUMA Riester GmbH & Co. KGThe global supplier of modularactuation solutions

Headquarters address: Aumastr 179379 Muellheim, GermanyTel: + 49 7631 809-0Web: www.auma.com

ELGA Process Water’s Aquamove MOFi is a

skid mounted ion exchange unit available

on short to medium term rental, to

support your condensate polishing

process.• Each MOFi unit is designed to

treat water to 0.1µs/cm at flows ranging

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

parallel or series to suit your needs, and

resin regeneration takes place off-site

eliminating the need for hazardous

chemicals.• MOFi’s can be operated to

80 C and generate no wastewater, making

this the ideal solution for your condensate

polishing needs.• With its small footprint

and flexible design, it can be installed and

brought online quickly and efficiently.

ELGA Process WaterMarlow International, Parkway,Marlow, Bucks SL7 1YL• UKTel + 44 (0) 1628 897000Email: [email protected]

Condensate RecoveryCondensate is a high purity, high heat content water that is a valuable resourceand even the recovery of small quantities is often economically justifiable. Anycondensate not returned needs to be replaced by cold make-up water, incurringfurther heating and water charges.• Returning more condensate to the feed tankreduces the need for blowdown, which in turn reduces the energy lost from theboiler.

Oil Industry growth for AUMA IndiaThe Indian arm of the AUMA actuator group reports growth of the company’s modularactuation solutions in the oil sector. The latest contract for AUMA’s valve controltechnology has been placed by the Indian Oil Corporation Limited for a Naphtha Crackerand Polymer complex.


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The system records the overallcondition of a machine and inaddition watches over individualcomponents by monitoring thespecific damage frequencies in anarrow frequency band. Invariable speed machines it evenuses tracked frequency bands. Ifa threshold value is exceeded,the operator is informedimmediately and FFT spectra andtime waveforms are recorded forpurposes of damage diagnosis.

VIBNODE runs fullyindependently and can beoperated without a PC. Foranalyses and storage, thecollected data are transferredover the company network to the

OMNITREND PC software, aplatform shared by allPRÜFTECHNIK conditionmonitoring products. With itslow up-front cost and modularstructure that can be extendedas required, VIBNODE is theideal entry-level solution.

For more information pleasecontact PRÜFTECHNIKCondition Monitoring on +4989 996160 or [email protected].

VIBNODE is a small Condition Monitoringsystem for production-critical standardmachines, i.e. Motors, Fans, Pumps andeven low-speed machinery.

Perfect Online Condition Monitoringsolution for beginners and specialists

Clearspill Ltd have designed a spilltraining package with first responders inmind. In general, containment is the firstimmediate action required, subsequentaction will involve the correctapplication of absorbents that areavailable to you. The course can bemodified to suit supervisors ormanagement. Safety is a requirementand training is essential.

(Your trainer is anapproved ISO 14001manager with 20 yearshands-on experiencewith spills), havingprovided training for theNational Grid, Shell,Power Utilities andproject managed theBuncefield incident.

We can also arrange for a site inspectionand risk assessment prior to the course inorder to better tailor the course to yoursite specific needs.

The Training Package Covers:

• Identifying potential pollution

incidents, as prevention is better thancure. The course will identify the bestpractices with a brief understanding ofthe legislative requirements.

• As a priority the use of spill kits, firstlywith containment in mind. Then in thecase of small spillages, cleanuptechniques to include chemicalneutralisation methods and health &safety.

• Practical use of spillkits, containmentmethods, blocking drains,seal damaged drums anddeployment of Absorbents.

• Typical Course ContentFirst Responder LevelBuilding blocks tocompliance

• Your duty of care – order ofimportance, company policy to Health &Safety, legislation today ‘The polluterpays’. Understanding’ step by step therisks on your site environmentalassessments.

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

relative impact. Tailored to theguidelines set by the IP EnvironmentAgency in there 2004 Inland response.

• Spill management each person will begiven a task that will need managing as aspill develops, team role play providesunderstanding for management andoperation tasks.

• Understanding the colour coding ofabsorbents, white/blue hydrocarbons,grey maintenance / general purpose,yellow chemical. How to stop productentering drain systems, handling runwayrun-off lagoons, understandinginterceptors, and recovery techniques.

• Modules available First Responder, spillsupervisor, spill management,preventative planning. Preparation forISO 1400`1 “Get your site right” includessite environmental audit oil/chemical.

Certificates for spill response andcontainment will be issued to allsuccessful delegates after completion ofthe training.

www.clearspill.com

Clear Spill Ltd, 55 Spencer Street,Oadby, Leicester, LE2 4DQTel. 0116 271 9436 (4 lines) | Fax.0116 271 2143 |Email:•[email protected]

As lifting equipment and associated

components age, efficiency and

reliability are inevitably compromised,

often resulting in higher operating costs

and potential safety implications. To

address these issues, Demag Cranes &

Components Ltd recommends that its

lifting equipment should be subject to a

general overhaul at least every ten years

of its operational life.

Demag general overhaul programmes

have been designed to restore

equipment to optimum performance and

safety levels, providing a cost effective

alternative to investment in new

materials handling technologies. Such

regimes, backed by ongoing certification,

also help operators meet obligations

under workplace health and safety

legislation, including the Health & Safety

at Work Act 1974, LOLER 1998 and

PUWER 1998. At a time when health and

safety is high on the public agenda, in an

increasingly litigious society, accidents

or injuries arising from poorly

maintained plant and equipment, may

lead to the investigation and prosecution

of employers under these statutes. In

extreme cases, where a fatality occurs,

prosecution and expensive compensation

claims may be brought under the

Corporate Manslaughter & Homicide Act

2007.

Demag technicians are fully qualified to

repair, maintain and overhaul

proprietary products and those of other

original equipment manufacturers.

Overhaul programmes include an

assessment of materials handling systems

and the replacement of worn or damaged

components. Subject to assessment,

Demag also undertakes the replacement

or adjustment of mechanical, electrical

and optical controls, as well as

switchgear, brakes, chains, friction

clutches and rope staysWhere

appropriate Demag provides for the

upgrade and modernisation of lifting

equipment, which may include the

addition of features such as overload

protection, inverter controlled drive

systems, anti collision systems, remote

controls, capacity/load increase and

safety interlock systems.

Demag Cranes & Components Ltd,

Telephone enquiries to: 01295 676157 ·


Website: www.demagcranes.com

EXTENDING THE OPERATIONAL LIFE OF LIFTINGEQUIPMENT

Spill Training Programme FirstResponders


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Each ABB Instrumentation Alliancepartner has been carefully selected toensure that customers in every part ofthe UK will enjoy the same high levels ofservice and support. The ABBInstrumentation Alliance consists of JWFProcess Solutions in Scotland, JWFInstrumentation in Teesside, WH Good inLancashire, AM Sensors in Somerset andKC Controls in West Sussex and Sheffield.

“We are now able to provide everyone,wherever they are in the UK, with equalaccess to any of our instrumentationproducts, backed by easy ordering, rapiddelivery, training programmes, on-sitesupport and ready availability of sparesand repairs,” says John Thomson, ABBInstrumentation Alliance manager. “Allof our partners have been trained toensure that customers receive the samelevels of support as they would if theywere dealing with ABB directly.”

The ABB Instrumentation Alliance offers:

Fast, efficient delivery to anywhere inthe UK – Many products stocked by theABB Instrumentation Alliance areavailable with 24 hour delivery (fororders placed in mainland UK before 12midday). Any items of equipment thatare not stocked by one partner can bereadily sourced from throughout thenetwork.

Installation & Commissioning expertise -Each ABB Instrumentation Alliancepartner is able to provide help andguidance with installing andcommissioning instrumentationequipment.

Equipment health checks and lifecyclemanagement – ABB InstrumentationAlliance partners are able to assist withhealth checks on installedinstrumentation equipment, the resultsof which can be used to draw uppreventive maintenance plans andidentify and rectify potential problems.

Training – An extensive range of coursesare available through each ABBInstrumentation Alliance partner,covering topics such as productfamiliarisation and usage, installationand commissioning, fault finding and howto meet the latest relevant legislationand standards.

The web site also provides informationabout products and services availablefrom ABB Instrumentation Alliancepartners, together with details on how tocontact them. The site can also be usedto download application guides,brochures and other technicaldocumentation and has many useful linksto other ABB and external sites.

“The ABB Instrumentation Allianceextends our sales and support networkand provides our customers with greateraccess to ABB, its products andservices,” says John Thomson..

ABB Instrumentation Partnernetwork gets new look web siteABB’s Instrumentation Alliance partner network now has a new look web siteat www.abbiap.com, making it easy to find the products and services youneed and your nearest partner that can provide them.


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The first workshop, Wireless – providingthe key to unlocking strandedinformation in your field instruments,will commence at 12.30 pm onWednesday 8th September. Presented byABB’s process communications expert,Gareth Johnston, the workshop will showhow WirelessHART technology can beadded to existing field instruments toenable operators to access a raft of newprocess and maintenance information.Although wireless technology is unlikelyto replace analogue 4-20mA or fieldbuscommunications, it offers an attractivealternative in locations whereconventional communications would bedifficult or expensive to install.

The second workshop, presented byABB’s DP flow expert, Ian Robertson, istitled A solution to measure the flowrate of Wet Gas. In wellheadapplications, the mixture of fluids and

gases has traditionally been separatedinto its various phases to enable accuratemeasurement of each of the componentphases, a critical requirement indetermining production capabilities.

The event will also provide anopportunity for visitors to see ABB’slatest product offering for oil, gas andpetrochemical applications.

New features include the use of ABB’scommon HMI platform, which nowfeatures across its instrumentationproduct range. Enabling operators toeasily scroll through and select options,the HMI simplifies operation,maintenance and training, reducing costof ownership and providing a consistentuser experience.

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

Detection system (PILD). Incorporatedwithin the transmitter itself, the systemcompares the application backgroundnoise against a pre-programmed baselineto detect blocked impulse lines, with anyblockages being relayed as an alarm viaHART, Profibus or Foundation Fieldbus.

These products will be accompanied byABB’s surface mount temperatureassemblies for demanding applications,plus the SM500F field mountable datarecorder, an electronic data recorderthat can be installed anywhere with achoice of pipe, panel and wall mountingoptions.

For more information, [email protected] orcall 0870 600 6122 ref.‘Instrumentation Scotland’.

ABB Limited (stand 308) and its Instrumentation Alliance partner, JWFProcess Solutions Ltd (stand 118), will be hosting two workshops at theInstrumentation Scotland & Offshore Systems exhibition, as well asshowcasing the latest temperature, pressure, data recording andflowmetering technologies.

ABB and partner to highlight safety and flowexpertise at Instrumentation Scotland


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A compact Spirax Sarco EasiHeat™ steam-to-hot water system is proving to be a vitalcomponent in an innovative refurbishmentproject to help Harrogate Hospital save energyand improve patient comfort in itshydrotherapy unit.

By delivering improved heat recovery,temperature and humidity control, thescheme is expected to save over £2,000 peryear in heating bills. The new measures arealso expected to save almost 300 tonnes ofCO2 emissions over the 15-year life of theplant.

The EasiHeat system provides hot water to anintegrated Calorex Delta 10 unit, whichcontrols both the temperature of the pool andthe temperature and relative humidity of theair in the hydrotherapy and swimming pool.The Calorex system incorporates heatexchangers, an air handling unit and a heatpump. The heat pump recovers energy fromexcess moisture in the air above the pool toprovide up to 25% of the heating energyneeded in the pool room. The rest is providedby hot water from the EasiHeat system. Thesystem maintains the pool temperature atbetween 34 and 36oC and conditions the air toa comfortable 30oC and 60% RelativeHumidity.

The EasiHeat system was supplied as acompact, skid-mounted assembly, completewith all the necessary ancillary equipment. Atits heart is a plate heat exchanger, which ismore responsive and easier to control thanbulkier shell-and-tube versions.

The Spirax Sarco unit was chosen because itcan use plant steam to provide a reliablesupply of on-demand hot water at a precisetemperature. “We need rapid availability andclose control of low-temperature hot water ata constant 82oC,” says Bob Howie, CapitalDesign and Project Manager. “The plate heatexchanger provides very good close controland hot water on-demand. It also has a muchsmaller footprint than other heat exchangers,freeing up space in the plant room.”

Another reason to opt for a heating systembased on steam was the ready supply of plantsteam, which was previously used in theshell-and-tube calorifier that heated the poolbefore the refurbishment.

As well as the new pool room systems, therefurbishment also includes a second airhandling unit bringing fresh air into theadjacent rest area, while an integratedbuilding control system monitors andoptimises the energy performance of theentire hydrotherapy unit.

All the new systems are designed to complywith the latest recommendations forhydrotherapy units laid out in NHS HealthTechnical Memorandum Health Building Note8 for Facilities for Rehabilitation Services.“These regulations weren’t around when thehospital was built in the mid-1970s, becauseno one worried then about climate change,”says Mr. Howie.

Sharon Graves, Marketing CommunicationsManager

Tel: +44(0)1242 521361; Fax: 01242 573342

Email: [email protected]

Web: www.SpiraxSarco.com/uk

Spirax Sarco heat exchanger helps Harrogate

cure high hydrotherapy heating bills

The technology specialist incorporatesSIPOS’ actuation products into itsturnkey solutions across a range ofsectors including major utilities, districtcooling and construction in the UAE.

Commenting on the synergies of SIPOS’actuation technology with Torento’sproduct portfolio, Mr Ahmed Sobhi, adirector of Torento Energy Systems, said:

“SIPOS, with its focus on high levelservice and bespoke solutions, is aperfect match for our business and ourcustomers’ requirements.

“The extreme heat of the UAE makes thecentralised production of cooling energya highly attractive solution and this hasmade district cooling, a technology thatis supported by SIPOS’ actuators, aparticularly strong growth market.”

Chilled water delivered via anunderground pipeline is recognised asmore cost-effective and environmentallyfriendly than distributed, buildingspecific cooling technology. SIPOS’actuation technology plays a key rolecontrolling valves that manage thecooling water flow and protecthydraulics from water hammer.

Regions supported by Torento EnergySystems include Oman, Qatar,Saudi Arabia, Yemen, Bahrain, Kuwaitand Pakistan.

SIPOS Aktorik GmbH

Im Erlet 2, D-90518 Altdorf, Germany

Tel: +49 (0) 9187 / 9227- 0

Fax: +49 (0) 9187 / 9227-5111

Web: www.sipos.de

Middle East expansion for SIPOSSIPOS Aktorik, supplier of specialist variable speed and standard actuatorsolutions, reports the success of its Middle East agent. Torento EnergySystems, a member of the Al Dhafra group, was appointed as the exclusiverepresentative for SIPOS for the region in 2008.

Photocaption: SIPOS Aktorik actuatortechnology installed in UAEinstallation at Mohamad Bin Zayed


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The company, a world supplier of cableglands, EXE GRP Enclosures, EXEstainless steel enclosures, EX connectorsand transformer breathers, needs tomove machine tools and other heavyplant round the workshop.

As Production Engineer, Carl Heitmar,explains:

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

“In the past the most common methodwould be to pay contractors to use theirheavy moving equipment to take care ofthe job. However, access for therequired fork lift trucks of 10 tonnes pluscapacity is often restricted, and heavymoving plant cannot be used. In these

cases an alternative method would be touse winches (tirfors) and low techskates, which require the shop floor tobe drilled in numerous locations foranchorage. This is both time-consumingand labour intensive.

“Over the years I have been responsiblefor moving a number of heavy machinetools, and I have found that the bestsolution is to use heavy duty skates suchas those supplied by Movetech UK.Heavy machinery can be moved veryquickly and at little extra cost once theequipment has been bought.

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

More information is available fromMovetech UK on tel: +44 (0)1204537681, email:[email protected] or fromthe website atwww.movetechuk.com/industrial.

JUNG jacks and skates make lightwork of moving lathe

A package of JUNG hydraulic jacks, castors and steerable trolley supplied by Movetech UKis helping Hawke International UK to move and install heavy machinery quickly and safely

at their plant in Ashton under Lyne, Greater Manchester.

While the hot weather in the summersends many of us want to cool off in thewater at the local pool, the high levelsof humidity caused by the water vapourand heat in indoor swimming poolscreate a nightmare for the facilitiesmanagers. Without effectivedehumidification and ventilation systemsto keep the air dry, indoor pools faceattack from a host of humidity-relatedproblems such as mould and corrosion –not to mention complaints from visitorsthat it is uncomfortable.

Failure to keep control over levels ofhumidity of may eventually causestructural damage as the warm aircarries the moisture into the walls andceiling. When combined with chlorinefrom the pool chemicals, the humid airbecomes highly corrosive, attacking bothmetal and concrete.

Controlling the humidity levels of the airin a pool room is easier said than done,when the surface of the pool itself actsas a giant humidifier each time the dewpoint of the air falls below thetemperature of the water. Withouteffective dehumidification systems, theair ‘sucks’ vapour from the surface ofthe pool to create just the humidatmosphere you want to avoid.

The WM33 and WM261 from MichellInstruments work as an integral part of adehumidification system to help ensurethat the surface temperature of thewater remains lower than the airtemperature, and the relative humidityis kept at a constant 50 to 60%. Bothinstruments are work effectively withlong-term exposure to the aggressiveatmosphere created by the poolchemicals. They are also cost-effective,

easy to re-calibrate and maintain forlong-term accuracy and reliability.

Sarah Lawrence

Michell Instruments

Lancaster Way Business Park

Ely, Cambridgeshire

CB6 3NW

UK

Tel - +44(0)1353 658 000

Fax - +44(0)1353 658 199

e-mail – [email protected]

Michell’s WM33 and WM261 relative humiditysensors are used to keep thousands of swimming

pools around Europe dry.

Effective climate control in indoor poolsreduces risk of structural damage


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AMEC’s Power and Process Europeprovides a range of project managementsupport to customers in the power andrenewable energy sectors.

As part of its facilities managementarrangements at two of its largest sitesat Birchwood Park, Warrington andBooths Park, Knutsford, the company isusing a PowerPlus 1557 combinedelectrical testing and certificationsystem to ensure that new electricalinstallations comply with the 17thEdition wiring regulations.

The PowerPlus 1557 is a new concept inelectrical test instrumentation andcombines the functions of a conventionalmultifunction electrical installationtester with a data logger to enable test

certificates to be created as testing isundertaken.

It does this by storing an electronicversion of the test certificate within thetester, eliminating the need for ‘dummy’certificates and manual or PDA recordingof test results.

At AMEC the testing is carried out on siteby specialist electrical contractors andwhen complete the data is output ontoNICEIC test certificates as proof ofcompliance with the 17th Edition wiringregulations.

Peter Smith, Facilities Officer, Electricaland Mechanical, at AMEC’s Power andProcess Europe’s business, said: “Thenew electrical test and certification

system has improved our testing andrecord keeping systems considerably.

“The test process itself is much morestreamlined and we now have both paperand electronic records of all installationand periodic testing undertaken on bothsites along with the necessary testcertification.

“This has made it much easier todemonstrate our compliance with thenecessary wiring regulations and prove toelectrical inspectors and externalauditors that everything is as it shouldbe.”

Full details of the PowerPlus 1557 areavailable atwww.seaward.co.uk/products/PowerPlus_1557_Installation_Tester.asp

AMEC's Power and Process Europe business is usingadvanced test instrumentation from Seaward toimprove the compliance testing of its own electricalinstallations.

SMARTER ELECTRICALTESTING AT AMEC


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The veo is a fully capable Phased Arrayinstrument with multi-techniquefunctionality, including TOFD; fast datarecording, a simple to use interface andrugged housing design renders the veo aperformance leader from the beginning.Combine this with Sonatest’s outstandingcommitment to customer support andproduct service; the user experience is awinning one. Typical applicationsinclude Pipeline Weld Inspection,Corrosion Mapping, Aerospace andComposite Testing.

Key design elements considered in thedevelopment of the veo series are userand performance focussed which includesimple controls and a workflow drivenMenu structure. The 3D Scanplan featuredisplays a full 3D view of the user’s testset up including probes, wedges, theweld and geometry, with phased arraybeams. There are also on-board probeand wedge databases for fast setups.

Power & Performance perfectlypackaged.

This 16:64 Phased Array instrument hasTCG and ACG, a superior encoding speedwith fast A-scan recording and excellentreporting functionality. There are twoseparate conventional channels providingsimultaneous Phased Array and TOFDscanning to speed inspection and ensurecorrect data referencing for improveddefect characterisation. Real Time FocalLaw calculations allow the user tochange scanning parameters instantly,

reducing the time spent on setup anddefect investigation.

The veo enclosure has been designed towithstand the tough environments inwhich NDT inspections are carried out,achieving IP67 standard for water anddust ingress and employing internal shockmounts to withstand impacts. Themarket sectors largest sunlight readablescreen, enables the technician to seeand interpret results with ease andefficiency, especially when complexinspections need multiple probeconfigurations. The veo batteries give upto 6 hours use, and are hot swappable forcontinuous use.

Wayne Woodhead, Managing Director ofSonatest Ltd “Phased Array is an excitingtechnology that is becoming regarded asthe future of Non Destructive Testing forcritical inspections and productivityimprovement. The new veo bringsSonatest’s design values of Simplicity,Capability and Reliability into this rapidlyexpanding market, giving users an

effective, efficient tool to meet theirdemanding needs. The veo builds onSonatest’s success in the ultrasonic flawdetector market, with a global salesnetwork supporting our customersthroughout the world. Launched at theEuropean Conference for NDT (ECNDT) inMoscow June 2010, initial reaction hasbeen very positive and we are lookingforward to a very successful future.”

Sonatest will be at various exhibitionsover the next months with the veo,including the UK NDT 2010 showbetween September 14-16th and theASNT Fall Conference in the USA,Houston, between November 15-19th.For further and dedicated informationon the new Sonatest veo please visitwww.sonatestveo.com

Email: [email protected]

As a result of Sonatest’s drive to bring desirable and innovativeproducts to the NDT market, a new Phased Array instrument is

now launched, the veo 16:64.

Sonatest launch the veoPhased Array flaw detector.


20

Indeed, as opposed to being seen as anecessary evil, maintenance is nowviewed by Allied Mills as a fullyintegrated element of the company’sbusiness effectiveness model. Perhapsmost importantly, the implementation ofSKF’s maintenance programme hasmeant that the ratio of unplanned vs.planned maintenance at the companyhas been completely reversed, withplanned work now accounting for 90% ofthe total, while significant reductionshave also been made in Allied Mills’stores value and stock holding costs.

Duncan Lawson, Group EngineeringManager at Allied Mills, explained, “Withso many rotating elements within ourprocessing facilities, we needed acompany with a vast level of globalknowledge and experience in the field.As a result, we invited SKF in to see whatthey could offer and whether they couldassist us in the design of an accurate andeffective maintenance strategy.

“Our existing processes and procedureshad delivered significant benefits, but

in an increasingly challengingmanufacturing environment, our focuswas shifting towards providing long-term sustainability and a value addedservice from our manufacturingteams.”

The first step in the preventativemaintenance programme was to performdetailed Client Needs Analyses (CNA) ateach of the three Allied Mills’ plants inBelfast, Manchester and Tilbury.

The CNA analyses were conducted duringdiscussions between key managers andengineers at Allied Mills and a team ofSKF professionals to gain a snapshot ofthe current maintenance strategy and itsefficiency.

The CNA process uses a sequence ofassessment questions from each of thefour main facets of SKF’s Asset EfficiencyOptimisation (AEO) process, whichfocuses on improving processes, cultureand technology: maintenance strategy,work identification, work control andwork execution.

Using the data gathered from the initialassessments, SKF engineers were able toanalyse the results and create an actionplan and route map for Allied Mills toadopt.

Described as, “A real eye-openinglearning process”, by Lawson, it askedwhat challenges existed towardsmaintaining current performance, whatAllied Mills was doing well and, just asimportantly, what the company could dobetter.In many instances, the CNA processhighlighted preventative activities thatAllied Mills was able to undertake usingits own in-house expertise; but it alsohighlighted the need for a significantmaintenance strategy review, somethingthat both Lawson and his ManagingDirector already suspected.

With the help of SKF Asset ManagementServices, a thorough review of allmaintenance tasks was justifiedtechnically to promote the efficient useof labour. One advantage was that Allied

Allied Mills, part of Associated British Foods, has been able to turnits perception of maintenance on its head thanks to in depthanalyses undertaken by SKF, the world’s leading knowledgeengineering company.

Maintenance becomesless of a grind at flourmanufacturer


21

Mills used similar equipment at all threeof its plants so company-wide processesand procedures could be standardised.

“The team at SKF examined the majorityof the plant,” Lawson explains, “usingFailure Mode and Effect Analysis (FMEA)to determine the best maintenanceapproach for all of our assets. They thenstudied each piece of equipment andmachinery, breaking it down into itscomponent parts, in order to envisagethe impact that a failure might have.They then looked at the spares stock, theexisting maintenance schedule andwhether it was reactive or predictive.We also looked at the generalperformance of the maintenancediscipline. From these results we wereable to make the first major changes inour maintenance ethos.”

Lawson explains, “We quickly realisedthat we were weak at interfacingbetween production operations andmaintenance. They were very muchperceived as two separate entities and,at times, operated as such – with themetaphorical brick wall, as so oftenseen in many other companies,between them.”

The first step, therefore, was tointegrate them into one department,having them both report to a newinternally appointed manufacturingmanager. The benefits wereimmediately apparent, almost instantlyboth had visibility of each other in termsof agenda and operations and, perhapsmost critically, team working wasenhanced.

“In addition, the integration of the newconcepts introduced by SKF, saw ourComputerised Maintenance ManagementSystem (CMMS) transform into amanufacturing tool, greatly enhancing itsbenefits and effectiveness to theenterprise as a whole,” Lawson added.

“We also realised that there were areasto which we had given too muchprominence in our maintenancestrategy. It quickly became clear thatSKF was helping us to work smarterrather than harder. In some instances,we learnt that it was okay simply to letsomething come to the end of itslifecycle and then replace it; it was notdeemed a critical component and didnot warrant the level of support wewere giving to it. In other cases thereverse was true.”

For further information, please contact:Phil Burge, Communication Manager, SKF(U.K.) LimitedT: +44 (0)1582 496433 M: +44 (0)7770647591 [email protected]


22

The CRC Energy Efficiency Scheme is

designed to drive energy efficiency and

carbon saving by combining the financial

incentive of emissions trading with Cor-

porate Social Responsibility incentives by

publishing a league table showing how

the participants perform. A recent report

from the Environment Agency suggests

that it could reduce CO2 emissions in the

UK to around 11.6 million tonnes per

year by 2020, which is the equivalent of

taking 4 million cars off the road.

For those in the CRC energy efficiency

scheme, failure to meet the carbon

targets set will mean buying carbon

credits at £12 per tonne and then trying

to claw the money back by improving

performance. The payouts from one

company effectively become revenues

for another, so that the most energy effi-

cient are rewarded and the most waste-

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

ness genius to see which side of the

equation it’s better to be on.

Steam is used to distribute energy widely

across industrial sites and other big

installations, such as hospitals and offic-

es. It should therefore be a prime candi-

date for anyone looking to save energy.

In fact, some steam users have already

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

Reduce carbon emissions byrevamping your steam system


23

carried out projects that will give them

a head start when carbon trading begins

in earnest.

Boiler gas use cut by 25%

For instance, in 2008, Abbey Corrugated

became one of just 12 organisations

across England and Scotland to be

awarded the “Carbon Trust Standard”,

thanks in part to the installation of an

energy recovery system from Spirax

Sarco. Organisations holding the Carbon

Trust Standard certificate for the CRC

period will gain an initial advantage with

an improved league ranking and there-

fore an increased share of the recycled

allowances.

Abbey’s success centres on a type of

engineered system from Spirax Sarco

known as FREME (Flash Recovery Energy

Management Equipment). By recycling

the energy from liquid condensate and

flash steam, Abbey estimates that the

FREME system has cut the amount of gas

it uses in its steam boiler by 25%. A

great advantage of the FREME system is

that it can be supplied as a pre-engi-

neered, skid-mounted system, taking the

stress out of designing, specifying, build-

ing and installing it. This approach

makes it an “easy win” to deliver big

savings for users.

Visibly more environmentally friendly

In another example, an engineered flash

steam recovery system is delivering di-

rect energy savings of 10% plus a further

10% in indirect savings at De Mulder &

Sons in Nuneaton. The system from

Spirax Sarco has also dramatically cut

visible plumes of flash steam from the

site, which is one of the UK’s largest

processors of meat and poultry residues.

The pre-assembled approach to steam

improvements also works well for sys-

tems designed to provide heating and hot

water. For instance, chocolate manufac-

turer Bendicks (Mayfair) now has an un-

limited supply of hot water for washing

down its equipment, thanks to the instal-

lation of a Spirax Sarco EasiHeat™ Engi-

neered System. EasiHeat systems rely on

a compact plate heat exchanger that

uses plant steam to produce hot water

on demand. Not only does this ensure a

constant supply at peak times, it also

eliminates the need for hot water stor-

age and increases energy efficiency, typ-

ically saving at least 6%.

Smaller investments produce

big savings

Installing major new items of plant may

not be an option for everyone –

especially while cash flow remains an

issue for many organisations. However,

there are probably still significant

savings to be made if you know where to

look, so calling in steam specialists such

as Spirax Sarco will almost always be

beneficial.

Spirax Sarco steam experts can show you

how to optimise your system to lower

your energy consumption. Starting with

a tailored steam system audit, Spirax

Sarco engineers can suggest a variety of

energy saving measures to improve the

efficiency of your steam system. This

was evident with Dairy Crest, which re-

duced gas consumption at its Kirkby fac-

tory by 18%. Steam system optimisation

played a major role in achieving the

overall savings, leading to an extremely

rapid payback of just a few months for

Spirax Sarco’s audit.

These examples show how organisations

can act now to get ahead in the race for

a good place in the CRC Energy Efficien-

cy Scheme league table. For those that

succeed the end result will be a cost sav-

ing, not an expense. The payouts from

the scheme are just one element, with

energy savings and CO2 reductions having

even more potential to boost the bottom

line.

Find out how Spirax Sarco can

help to improve your process and

reduce carbon emissions by con-

tacting:

[email protected]

alternatively visit

www.SpiraxSarco.com/uk or

phone 01242 521361.

Steve Mckie , Manager for carbonand environment Spirax Sarco

FREME is provento achieve energy

savings of up to26%


24


25

The new Fluke 1555 and redesigned Fluke

1550C Insulation Resistance Testers ena-

ble users to conduct tests over a wide

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

year warranty and CAT IV 600V safety

rating. With their measurement storage

and PC interface capabilities, they are the

ideal tools for engineers, maintenance

managers, industrial electricians, sub-sta-

tion specialists and linemen using predic-

tive and preventive maintenance

programmes designed to identify poten-

tial equipment failures before they occur.

The Fluke 1550C Insulation Resistance

Tester enables testing up to 5kV, while

the Fluke 1555 tests up to 10kV. Test

voltages are selectable in 50V steps from

250V to 1000V, then 100V steps thereaf-

ter. A ramp function enables breakdown

testing, and timer settings of up to 99

minutes allow timed tests. A warning volt-

age function alerts the user that line

voltage is present and gives the voltage

reading up to 600V AC or DC for increased

user safety.

Measurements can be stored in up to 99

memory locations. Each location is as-

signed a unique, user-defined label for

easy recall. An optical interface cable

enables easy downloading to a PC run-

ning the FlukeView® Forms software

that is provided with the insulation test-

er. FlukeView Forms allows the user to

document, store and analyse the read-

ings, and present them in professional-

looking documents.

The Fluke 1555 and Fluke 1550C feature

a large digital/analogue LCD display for

easy viewing. They provide automatic

calculation of Dielectric Absorption Ra-

tio (DAR) and Polarisation Index (PI)

without additional setup. They also offer

capacitance and leakage current meas-

urement, as well as resistance readings up

to 2T Ohms. A guard system eliminates

the effect of surface leakage current on

high resistance measurements.

Kit versions are also available which offer

an IP67 hard case, heavy duty alligator

clips and a calibration certificate. For

more information about all Fluke products,

visit www.fluke.co.uk

Fluke introducesInsulation Testers for

up to 10kVFluke, the global leader in handheld electronic test and

measurement equipment, has introduced two insulation resistancetesters offering digital insulation testing up to 10kV for testing a

wide range of high voltage equipment including switchgear, motors,generators, transformers and cables.


26

Used in combination with Finite Element

Analysis (FEA) tools, the new complex,

multi-body simulation (MBS) model

enables designers to optimise the design

of individual powertrain components and

establish how these interact with other

systems across the entire powertrain.

The simulation tool, which can be used

at the initial wind turbine design stage,

will help to make wind turbine designs

more reliable and cost effective under a

wide variety of load conditions.

Simulating dynamic

operating loads is a

critical factor in the

design of wind turbines.

Despite new wind

turbine designs, which

have stemmed from

new alternative main

bearings and gearbox

design concepts, as

well as greater

demands in terms of

performance and

reliability of turbines,

up to now load

simulations have been

conducted using

relatively simple design

calculation models.

These simplified models

consider only the

effects of load over

time for specific

internal stress

variables, independently rather than for

all powertrain components and how they

interact. This means that complex units,

such as gearboxes, which have multiple

dynamic components, are treated as a

‘black box’. The design of the gearbox

and how it affects other parts of the

powertrain is not taken into account by

this over-simplified model, which could

result in an unreliable wind turbine

design.

In order to gain a better understanding

of the dynamic loads acting on the

mechanical powertrain components in a

wind turbine, the four project partners

have brought together their respective

mechanical engineering and software

expertise to develop a complex MBS

model.

BEARINX® enables users to make bearing

calculations, including shaft deflections

and stress calculations of complex

bearing and gearbox arrangements. The

software allows users to optimise their

designs by seeing the effect of any

changes rapidly. Various bearing designs

and shaft deflections can be considered,

and then allow the results to be

compared with FEA calculations.

BEARINX® takes everything into

consideration, including non-linear

elastic deflection behavior of bearings;

the elasticity of shafts and axles; the

influence of fit, temperature and speed

on bearing operating clearance, preload

and contact angle. The software also

takes into account load-related contact

angle shifts. Even for complex gears, the

contact pressure on each rolling element

is considered in the calculation.

Lubrication conditions, contamination

and actual contact pressure on fatigue

life are also taken into account.

[email protected]

A collaboration project between four companies has led to the development ofnew simulation software that is able to calculate the dynamic operating loadsacting on wind turbine powertrains.

New powertrain simulation tool willimprove wind turbine performanceand reliability


27

[email protected]

[email protected]

[email protected]


28

That transmitter links via wireless to asmall screen which is probably placed inthe lounge. The screen then displayskilowatt hour (kWh), cost or CO2 usage,and you can set targets to help persuadethe kids to put on an extra jumper,rather than firing up the heating system.The meters seem to work very well andgive you an insight into what applianceszap the most energy. As I have replacedmost of my traditional bulbs with LEDlamps, my base house load is quite lowat a few hundred watts, but start up thebig screen TV and surround sound systemand you can see just where the moneygoes. When my kids bring round with acouple of Pizzas for Saturday lunch itcosts a surprising 9 pence to heat themin the electric oven. (I now collect themoney at the door.)

Taking this concept to the factory floorpresents some interesting opportunities.It is pretty easy to measure overallfactory kWh and providing there areenough meters it is possible to measureeach zone or area. But until recently,unless you spent big money, it wasn’t soeasy to measure the energy consumed byindividual bits of equipment.

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

Let’s think through the normal energyreduction process. Most manufacturershave already implemented a wide-rangeof energy related programmes withvarying degrees of success, includingswitch-off campaigns or installing sensorsto turn lights off automatically. In fact, Iremember training at IBM in the early80s, and after 5pm I had to use a phonein order to turn on the lights for my deskwhile the rest of the office remained intotal darkness. Other energy-reductionmeasures have included intelligentproduction scheduling at a lower time-tariff, the installation of new energy-efficient equipment, and improvingmaintenance procedures to reduce leaks.

All of these programmes are necessary toreduce energy consumption but they arenot sufficient on their own to providestep-changes in energy efficiency. Weneed to address a bigger issue –equipment effectiveness in relation toproducts made.

A meter in each area will show howmuch electricity the entire area uses,and give a good indication of energycosts per product, but what is the truecost and level of usage if for instance wesuffer a breakdown and the kit is leftrunning at the end of production? Inessence, how does our energyconsumption compare to the productsmade?

The graph below illustrates the point.

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

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

Production starts at 6am and ourkilowatts increase in line with a healthyproduct count, we experience shortperiods of slow running but then a majorfailure occurs at 10am. The productcount stops immediately but ourkilowatts continue because we don’t turneverything off. In any event the glueheaters will need to stay on to ensureproduction when we manage to fix thebreakdown. By 11am we manage tobegin production again until the end ofshift at 2pm. It then appears that weforgot to turn off the glue heaters andthe rest of the plant, as kilowatt valuescontinue, albeit, at a slightly lowerlevel. We can see from the zero productcount that no products are being made –and the energy used is pure waste.

There is clearly a perfect link betweenOEE performance measurement andenergy usage and, as such, there are anumber of analysis points for thisexample factory’s continuousimprovement team, including:

1. Between 4am and 6am, is itpossible for the electricity

The power of OEE and a fewdiscrete energy metersThe energy companies are giving away small meters toaccurately measure domestic electricity consumption; I guessyou will have seen the advertisements. It’s a simple process -you place a small clamp around a cable near the electricitymeter which is then cabled to a transmitter.


29

supply to be limited to only theglue heaters?

2. Is it possible and more efficientto turn the heaters on later?

3. Is it possible to speed up theplant to make more productsfor the same amount of energy?

4. Is it possible to turn off any ofthe assets during a majorbreakdown?

5. Is it possible to automate plantshut-off at the end ofproduction?

And the obvious question:

Can we use OEE & loss analysis toreduce slow running, and preventbreakdowns?

There is significant logic in linking simplecurrent transformer (CT) type meters toan OEE application. OEE softwarealready includes the asset structure,running hours and a product count. Ifwe then include the output from anumber of meters, at least at line level,we can ‘read’ the electricityconsumption at defined intervals andcompare the value to productsproduced. We can then consolidate thevalues at higher levels for effective sitereporting.

If we go further and link meters at assetlevel we provide even more

opportunities for analysis. We can thensee which machines consume the mostenergy and which should be switched offduring a breakdown. Also think aboutfixing plates to each machine to showoperators the energy consumed by eachpiece of equipment.

And let’s not forget the impact of slowrunning; a filling machine running at 150bottles per minutes instead of the300bpm it’s designed to run at usesvirtually the same amount of electricity.But for that same energy cost you onlyhave 9,000 bottles to sell at the end ofan hour instead of 18,000. Quite someloss if the product is Vodka.

These types of meters are becoming veryeconomical and they can be easilyaccessed via an Ethernet IP Address.Surprising what you could learn, andimprove, from a few discrete meters anda product count!

Alan France, Operations Director ofIdhammar Systems, has extensiveexperience in lean manufacturing witha background that includes severalyears as Engineering Systems Managerfor the largest food company inEurope. A systems specialist, he nowconsults on the importance ofunderpinning lean initiatives withrealistic targets and sound metrics.

Contact him by e-mail,[email protected], orvisit www.idhammarsystems.com formore on CMMS and OEE software.

The annual Manufacturing Performance

Masterclass is proving an ideal forum for

sharing best practices across industries,

as well as providing an excellent

networking opportunity. This year's

Agenda has been shaped by an Advisory

Group - comprising members from

Premier Foods, Constellation Wines,

Saint-Gobain, and Willmott Solutions - to

ensure that the seminar addresses the

most topical issues that UK

manufacturers are facing...

Wednesday 13th October 2010Heritage Motor Centre, J12 M40

Warwickshire

The theme for MPM’10, held on 13th

October at the Heritage Motor Centre, is

'achieving competitive advantage

through sustainable improvement' and

will be focusing on how manufacturers

can compete post-recession as they are

required to do more and more, with less

budget, time, and resources.

NEW for 2010, an exclusive half-day TPM

& OEE Workshop (12th October, Heritage

Motor Centre) precedes the Masterclass

and will be jointly facilitated by Peter

Willmott, a recognised leading authority

on the application of Total Productive

Maintenance (TPM), and Alan France of

Idhammar Systems, a specialist in OEE

and OEE Systems. Following feedback

from last year’s Masterclass, the

Workshop has been designed to take an

in depth look at measuring equipment

effectiveness and includes syndicate

exercise to highlight key learning points,

question & answer sessions, and several

case study examples.

Full details for both MPM’10 and

Workshop2010 are available online

- www.MPM2010.co.uk – and

delegates booking before 31st July

will benefit from an earlybird

discount. Please direct telephone

and e-mail enquiries to +44 (0)

1179 209405 /

[email protected].

MANUFACTURING PERFORMANCE MASTER-CLASS 2010


30

MAINTAIN 2010Europe’s most important event for the industrial maintenancesector Tuesday 12 – Thursday 14 October – Munich MOC (MunichOrder Centre), GermanyAbout MAINTAIN

Held in Munich, Germany, MAINTAIN isthe industry's most important gathering.As such, it brings together all decision-makers in the manufacturing andprocessing industry, who use it as aforum to reach their common goal: topromote technical innovation, efficientmanagement and service solutions.

MAINTAIN is the marketplace forimpetus, strategies, concepts and sector-specific solutions in industrialmaintenance.

Since German industry remains strongand its engineering capacity is still theenvy of the Western world, visitorsshould expect an extremely highstandard of presentation. VisitingMAINTAIN will give you the opportunityto study at close range the extensiverange of products and services that OEMsand service-providers have available inspecific categories.

MAINTAIN emphasises solutions thattranslate into concrete competitiveadvantages and factors for success.Maintenance management and relatedservices are becoming increasinglyimportant in the maintenance industry,so in addition to high-quality componentsand special solutions, more and morecompanies rely on complete and systemsolutions.

In 2009 3,500 visitors attended from 36countries – 94% of whom had an impacton the decision making process - andthere were 230 exhibitors from 9countries. A total of 160 companies fromAustria, Belgium, China, Croatia, France,Germany, Great Britain, Korea, theNetherlands and Switzerland havealready registered for this year’s fair.Once again, exhibitors will occupy allthree exhibition halls and some 10,000square metres of exhibition space.

You can find a full database ofexhibitors, and online visitor registrationis now open.

Ensure you visit MAINTAIN this year,since after 2010 it will be switching to atwo-year cycle. The decision was takenin a move to meet the industry’srequirements after consultations withexhibitors, leading associations, andpartners. The next MAINTAIN willtherefore be held in October 2012.

How to buy your entrance ticket

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

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

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

• the now famous free Bavarian snack!

• free further training - free entranceto the exhibitor forum

• free branch-specific information –the opportunity to participate in GuidedTours


31

• free copy of the exhibitioncatalogue

How to get there

The MOC exhibition centre is situated inthe north of Munich and is easily reachedby underground train or taxi. Take theU6 underground line to Kieferngartenand follow the signs to the MOC – abouta seven minute walk. Hotelaccommodation is plentiful in thebeautiful Bavarian city of Munich, andflights operate from all UK airportsfrequently. Contact Pressplan Travel on01727 833291 for a quote. Alternatively,if you are in Munich just for the day,take a taxi to the MOC from the airport,since it lies directly between the airportand the centre of town. The taxi faretakes around twenty minutes and willcost about 50 Euro.

Come and network!

MAINTAIN gives maintenanceprofessionals a comprehensive view ofthe industry and its trends. However,exhibitors and visitors also appreciateMAINTAIN’s strong networking character.Gerhard Gerritzen, deputy managingdirector at Messe München GmbHexplains: “MAINTAIN has a strongnetwork character, which is why we alsoplace special emphasis on the exchangeof ideas and information within the

industry. We have instituted a numberof changes for this year’s fair. Forexample, for the first time ever thisyear’s fair will feature speciallydeveloped seminars and contact pointsin the halls for groups of internationalguests. The “Makers&Markets”programme of related events featuretechnically founded presentations thatwill educate participants and sparklively discussions. A long-standingtradition is the free Bavarian middaysnack, which has been inviting visitorsto get to know one another andexchange ideas in an informal settingsince the first MAINTAIN in 2005.”

The new “Makers&Markets” programme

The fact that all presentations are beingheld at a central location in Hall 3 is notthe only thing about theMakers&Markets that is new. Dividingthe lectures up into various themeblocks such as Methods and Tools forMaintenance Management;Maintenance, Retrofitting andModernising or Personnel Leadership,Personnel Management and TalentManagement give visitors access to arange of presentations that meet theirneeds and are easy to integrate intotheir visit to the fair. The compactrange of events allows trade visitors tochoose between direct examples ofspecific applications in the products

sector and process-oriented topics thatapply to all companies.

Guided Tours at MAINTAIN 2010

Guided Tours round out the programmeof events at MAINTAIN 2010. Specialistsfrom FIR (Research Institute forOperations Management at RWTHAachen) will take users and otherinterested parties on a tour to thestands of exhibitors that sell CMMSsolutions. During the tours, softwaremanufacturers will examine concreteproblems and answer questions. Thetours will be held on all three days ofthe fair, are free of charge for visitors,and will be available in English andGerman.

Further information

For all further information,please contact Pattern (TradeFairs) Ltd, agents in the UK andIreland for Messe MünchenInternational, tel +44 (0) 20 89404625; [email protected]


32

New VisIR thermal Imaging Camera forPredictive Maintenance VisIR thermalimaging cameras are designed for today’sindustrial Predictive Maintenanceprogrammes – with crystal clear imagesfrom a highly sensitive uncooled infrareddetector, real time visual images andprecise temperature measurement withthe most powerful range of easy to usecamera tools and unique Condition RED®database and software for routinePredictive Maintenance inspections.

VisIR Condition RED In-Camera ScreenVisIR 640’s unique Condition RED assetbased thermography system guides thecamera operator through surveys toensure consistent, repeated inspections.Reference images of each asset aredisplayed alongside the live image atevery inspection point to ensure thecorrect equipment is being surveyed.Condition RED then compares the asset’scurrent condition against its historicaldata to assess whether any action needsto be taken.

Thermoteknix Condition RED softwarecombines PC based database storage and

procedure handling with automatedroute based image inspections to

generate trending and prediction forearly fault identification and plannedservice. A wide range of customisablereports are generated automatically withrepair recommendations includingreinspection intervals and criticalequipment work lists.

Thermal Image of motor displayed oncrisp DayBrightTM Touch ScreenInterface With a unique rugged industrialhousing, an articulated central opticspod for ergonomic and safe operationand high contrast DayBright™ touchscreen, VisIR provides high definitionthermal and visual image clarity in anylighting conditions.

Stunning clarity with VisIR 640 – HighVoltage Power Lines High VoltageTransformer viewed using VisIR’spowerful Image Fusion Mode Boilers andHot Vessels

� Heat Loss from Insulation

� Steam Trap

� Pipes and Valves

� Electrical Switchgear

� Pumps, Bearings, Motors

VisIR’s high resolution detector anddigital colour camera make surveysmore efficient and cost-effectivewith integral LED illuminator/flash,laser pointer and voice recording.For carrying out PredictiveMaintenance on the pre-heater,motors, drives, switch gear, andmuch more equipment, VisIR is theideal thermal imager. Both 320x240

and 640x480 models are available.

ThermaScope High Temperature CameraThermoteknix will also be showcasingtheir range of ThermaScope® hightemperature cameras which helpimprove efficiency, increase combustioncontrol and reduce pollution.ThermaScope SLK is a high performanceradiometric temperature imagingsystem. It displays bright clear videoimages within high temperature

processes and measures thetemperatures at every point in theThermaScope field of view.

The ThermaScope processor softwaregives the process engineer or operatoradvanced analysis tools with controlinterface signals for advanced closedloop control.

Tools for Power PlantMaintenanceFirst time exhibitors at the Energy Event this year,Thermoteknix Systems Ltd will be showing theirimpressive range of thermographic tools forPredictive Maintenance for all areasof the power plant.


33

ThermaScope SLK view in a 16-burnerheavy fuel fired power station boilerHigh temperature boiler, kiln, furnace oroven operating conditions arecontinuously monitored by theThermaScope SLK. Abnormal conditionssuch as over or under temperature, poortemperature distribution or irregularflame shape is instantly shown.

These can be alarmed and interpretedby the Operator or Process Engineer withuser-friendly analysis tools andtemperature displays.

ThermaScope HTV is an alternative lowcost non-radiometric high temperaturevideo camera which will also be ondisplay on the Thermoteknix stand 301.The Energy Show takes place 8th-9thSeptember in Birmingham (UK).


34


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The latest legislation, which isconcerned with the mechanical andelectrical safety of machines, representsa consistent message of safety formachine builders across Europe - theymust design safeguards to protectequipment operators, while providingservice that minimises downtime! In thiscontext, machinery is described as “anassembly of linked parts or components,at least one of which moves, with theappropriate actuators, control andpower circuits etc joined together for aspecific application, in particular for theprocessing, treatment, moving orpackaging of a material”.

The rationale behind the framework ofthe strict measures laid out within thislatest legal requirement for equipmentmanufacturers globally selling within theEU, is to ensure the safety of individualworkers whoever or wherever they maybe. The fastening of machine guardingand the ergonomics of operatorequipment are both high on the list ofsafety requirements imposed by the newdirective.

Specifically, the directive states that toobtain CE accreditation, machinery andequipment must be restricted byattaching protective devices such asfixed, adjustable and movable guards.Such protection devices should be of

robust construction, not be easy tobypass and must be used to protect riskssuch as moving parts. Fixed guards needto be held in place by fixings which canonly be opened or removed with tools,movable guards should be interlocked,and adjustable guards should be readilyadjustable without the use of tools.

Compliance – the right choice

This new legislation has created adilemma for machine builders, operatorsand purchasers across the industrialequipment market place as they struggleto decide on the most effective choicefrom a plethora of different options, interms of meeting the new safety

Southco fastening solutions aidcompliance with new EUMachinery DirectiveFor machine builders worldwide, operator safety is of paramountconcern. Now, with the advent of the new Machinery Directive2006/42/EC which became effective on December 29, 2009, safetyattitudes are further emphasised.


36

requirements in the most cost effectiveway. As the global leader in the provisionof access hardware solutions, Southcobelieves it is ideally positioned to helpmachine builders adhere to these newregulations.

Ulrike Sturman, Industry MarketingManager for Diversified Technologies atSouthco, takes up the story: “Theindustrial machinery and equipmentmarket is a very fragmented industry andcovers a vast and diversified range ofsectors. At Southco, we can offerdesigners, suppliers and purchasers ofindustrial equipment the completesolution, in terms of fastening devices,technical expertise and a wide andlocalised distribution network to supportthe requirements of a segmentedindustry to comply with the EU directive.As well as having the industry’s widestrange of captive and quick accessfasteners available globally for machineguarding, as the market leader inpositioning technology we can alsoprovide a host of hinges and positioningcontrol devices for positioning adjustableguards, and for allowing monitor screensand control panels to be moved smoothlyand effortlessly with zero backlashthrough controlled torque mechanisms.”

Southco fully recognises that compliancemeans extra costs to a business and istherefore a price sensitive issue. Thisfact is reflected by the ‘quick fix’ andDIY solutions being adopted by manysmall to medium-size industrial

equipment manufacturers and operatorsto stay on the right side of the law.Sturman: “We believe those who adoptthese short-term approaches will createa lot of problems for themselves longerterm. However, those willing to invest inour reliable and easy to use captive andquick access hardware solution, ratherthan plump for cheaper options, will notonly comply with the directive but alsoenjoy additional benefits as a result ofthe company’s industry-leading technicalvalues. These include a longer life cycle,enhanced product performance and long-term cost savings.”

Fixed guards

For fixed guards, the directive has threekey stipulations:

• fixed guards must be fixed bysystems that can be opened or removedonly with tools

• their fixing systems must remainattached to the guards or to themachinery when the guards are removed

• where possible, guards must beincapable of remaining in place withouttheir fixings

Engineered fixing systems usingSouthco’s established and proven rangeof captive screws minimise problemscommonly experienced with loosescrews, nuts, or bolts dropping intooperating equipment. And from aproductive perspective, engineeredfixing systems that utilise captive, self-aligning designs, improve assembly speedand convenience. The company’sextensive range includes screws with asmooth knob action, screws that areflush fitting for safety, and smooth headscrews for use in a limited space. Foradded safety, differently colouredheadstyles are available.

Also, for quick and easy access - which isparticularly advantageous for repeat-access applications – and high strengthand economical performance, the Dzusquarter-turn and fast-lead captivefasteners ranges provide differentoptions for tool-restricted access, andflush or low-profile installations. Alsoavailable are self-ejecting options thatprovide a visual indicator for unfastenedguards, while the spring-ejection featurehelps clear fasteners out of the way inmultiple fastener applications.

Adjustable and movable guards

For adjustable guards restricting accessto those areas of the moving partsstrictly necessary for the work, thedirective states that they must be readilyadjustable without the use of tools.

For these applications, Southco has arange of controlled-torque positioningdevices providing the ability to raise,lower, tilt, swivel, and positionadjustable guards for better safetyprotection during equipment operationand for easy access when necessary.

Southco offers the industry’s widest range of access hardware

solutions and most innovative positioning technology products

Southco’s access hardware solutions aid machine builders

adhere to the new EU regulations for machine guarding


37

These devices, which include therecently launched AV-D30 mounting arm,can also hold guards in a partially orfully open position without secondaryhardware, to provide unrestrictedmaintenance access.

According to the directive, "interlockingmovable guards must, as far as possible,remain attached to the machinery whenopen, be designed and constructed insuch a way that they can be adjustedonly by means of an intentional action,and be designed in such a way that theabsence or failure of one of theircomponents prevents starting, or stopsthe hazardous machinery functions”.

For such applications, Southco can offertethered quick-access pins with simplepush-button actuation for lockingmovable safety guards into place, as well

as for activating electronic lockoutsensors on movable guards.

Additional devices such as captivespring-loaded plungers also allow forquick positioning and fixing of slidingguards.

Sturman: “Initially, our main focus is onmachine guarding applications acrossfive key segments - namely printing andlabelling, textile, processing andpackaging, materials handling andcompressors.

These specific sectors have beenidentified as those that we believewould best benefit from Southco’saccess hardware solutions.”

Southco Europe Ltd;TouchPoint, Wainwright Road,Warndon, Worcester, WR49FA, UK •

Tel: +44 (0)1905 346500 •Fax: +44 (0)1905 346501

AV-D30 Mounting Arm


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39

As part of the steel making process,Trostre Works operates a continuousannealing (CAPL) process line to give thesteel its required hardness. The CAPLprocess line uses around 600 tonnes aweek of saturated steam supplied at 8BarG. As the name suggests, theoperation is continuous process achievedthrough the use of two entry and exitreels. At any one time there will be over1,000 metres of strip running through theline. The furnace section of the lineheats the strip to a selected temperaturewithin a 650°C to 690°C range. Thistemperature is maintained through themid section and the strip is graduallycooled in the final furnace. By passingthe strip through cooling chambers and aquench tank further cooling is achieved.Finally the strip is recoiled for furtherdownstream processing.

The site had previously installed a GEMVenturi steam trap following a buckettest on a line drainage trap, which hadprovided 60% savings. Following theappointment of Dr Darryl Lewis as EnergyOperations Manager, TEI was asked tosurvey the CAPL process line and V StandMill. This found that of the 12 steamtraps surveyed 25% had failed closed and17% had failed open.This was increasingenergy and having an environmentalimpact by creating additional amounts ofCO2 emissions each year. Now a total of18 GEM Venturi orifice steam traps havereplaced the existing mechanical steamtraps.

“I have been extremely pleasedboth with the operation of thetraps and, equally importantly,the after sales service providedby TEI’s engineers”, said DrLewis. “The site was the firststeel works and heavy industry inthe UK to win a Carbon TrustStandard Accreditation inJanuary 2010 in recognition ofour commitment to reducingenergy and CO2 emissions. Thetrap improvement programmewas an important element inachieving this”.

Based on nominal consumptionrates of 600 tonnes of steam aweek, the GEM traps areproviding around 5% energysavings which equates to £0.5K aweek based on a gas tariff of£4.4/GJ and condensate wastetreatment costs. These savingswill provide a payback on theGEM steam traps in around 30weeks.

Available in a wide range of sizesfor a full cross section ofapplications, the hardwearingGEM steam traps aremanufactured from corrosionresistant stainless steel and areguaranteed for 10 years. Thermal Energy International Inc., 1

John Street, Bristol, BS1 2HS Tel: 0117917 7010 Fax: 0117 917 7011www.gemtrap.com

CORUS INSTALLS GEMSTEAM TRAPS TOIMPROVE ENERGY

CONSERVATION ANDREDUCE CO2

Corus’s Trostre Steel Works in South Wales has installed Thermal Energy International’sGEM Venturi orifice steam traps as part of the plant’s continuous improvement programmeinto energy conservation and CO2 reduction. A leading supplier of high quality light gauge

steels, the site produces over 400,000 tonnes annually of packaging steels for the UKmarket.


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At Ametek Solidstate Controls we takeclient service to a level far beyond thatof a traditional field service departmentby offering a variety of customizedmaintenance and technical training pro-grams worldwide to cater to our custom-ers’ specific needs.

Maintenance

Our preventive maintenance programsare designed to keep your UPS systemsand other critical power equipment inoptimal condition and minimize down-time. We also provide equipment rentalservices in emergency situations. All ofour services are provided by factorytrained personnel to ensure the highestlevel of service.

Training

Our UPS & Battery Technical TrainingSeminars present excellent learning op-portunities for our clients. Seminars canbe presented at our training facility orat the clients’ site. Our facility featuresa variety of equipment that allows train-ees to gain practical hands on experi-ence in a learning environment. Allseminars are designed for the equip-ment the client has at their facility.More information is available athttp://www.solidstatecontrolsinc.com/support/training.htmlOur factory trained experts are ready toprovide highly customized training solu-tions upon your requested time and lo-cation.

Contact Information

Training: 800-635-7300/ 614-846-7500or Email: [email protected]

Service & Maintenance: 800-222-9079

For more information, please visit usat:http://www.solidstatecontrolsinc.com

"AMETEK Solidstate Controls is not only known for its ruggedand reliable products but also its world renowned client

support.

Ametek Solidstate


42


43

KPM UK, the UK arm of KPM’s HeavyIndustries Group, focuses on the supply ofhydraulic motors and pumps worldwide.It also provides a maintenance service.And it is in this field that KPM’sinvestment in a FLIR T425 thermal imagingcamera is really helping the company topredict mechanical faults before theybecome costly failures.

“We are actively developing newprogrammes to improve our overallequipment efficiency (OEE) by reducingunplanned downtime,” explained RayWilson, Assistant Manager – Maintenancewith KPM. “To that end we are movingfrom a reactive- to a pro-active approach.So we have appointed a PPM engineer andit’s his job to encourage machineoperators and production managers to usepredictive maintenance tools. Thermalimaging is now one of the tools at hisdisposal.”

An important ingredient in this initiativeis the introduction of a ‘birth certificate’for each of the KPM machines. This recordis retained on KPM’s own IT system and ahard copy displayed on the installedmachine. Once this project is completedit will form an essential part of the PPMprogramme and provide a benchmarkagainst which regular checks will be made.

Indeed it was in the creation of one ‘birthcertificate’ at a customer’s site that aproblem with a breaker to a machine toolbecame evident. “The FLIR T425 cameradetected the fault in time for us to get areplacement from Japan,” Ray Wilsonexplained.

“This part had to be made to order, so ifthe camera had not flagged up theproblem and the breaker had failed, wecould have had a machine down for weeks.Worse still, if the faulty breaker had

caused an outbreak of fire, the electricals y s t e m

would havebeen damagedand the safety of the workforcecompromised.”

The FLIR T425 was introduced for theexpress purpose of reducing energyconsumption and minimising downtimethrough highly efficient electrical andmechanical fault-finding. Features suchas auto-focus and digital zoom lensenhance its flexibility. Ergonomic designcombined with low weight, picture-in-picture fusion, touch screen, tiltable lensunit, laser pointer and interchangeableoptics made it the best choice for KPM.

“We tried a selection of differentbrands,” Ray Wilson added. “The FLIRcamera and the training support providedby FLIR best suited our needs”

One of the greatest advantages of thermalimaging is the wide range of applicationsto which it can be applied.

And this is a benefit which KPM is nowexperiencing. The company is now alsostarting to use its FLIR T425 in thecommissioning new equipment and alsofor evaluating health and safety issuessuch as fire risk.

THERMAL IMAGINGMAKES KAWASAKI PRO-

ACTIVEAround the world, in virtually every area of construction,marine and manufacturing industry, Kawasaki PrecisionMachinery (KPM) provides quality power and control solutions.

The website and magazinededicated to engineersworking in hazardous

environments:

www.hazeng.com


44

Now available in 150 and 250cc models,Parker's F12 series motors feature anenhanced design to ensure lower loads ofinternal friction, reduce operatingtemperature and noise levels, andimprove reliability and productivity.

The F12 series of high-performancemotors delivers high shaft speeds andcan operate at pressures of up to 480bar

Featuring a spherical piston design, themotors offer high shaft speeds with thecapability of operating at pressures of upto 480 bar, while producing high torqueat start-up and low speeds.

Featuring piston-lock technology and aminimal number of moving parts, the F12Series piston motors are said to be veryrobust, providing long service life withhigh reliability.

Parker's timing-gear design synchronisesthe shaft and cylinder barrel, meaningthat the motors can tolerate high G-forces and torsional vibrations, while theheavy-duty roller bearings ensure high

external-axial and radial-shaft-loadcapacity.

The 40deg angle between the shaft andcylinder barrel allows for a particularlycompact design.

The F12 Series motors also feature high-precision valve plates for increased self-priming speed and low-noise operation,with options for left- and right-handrotation.

The use of laminated piston ringsensures low internal leakage, highthermal-shock resistance and a longoperating life.

With the addition of these latestmodels, the F12 Series bent- axispiston units are now available in 23,30, 40, 60, 80, 90, 110, 125, 150and 250cc sizes.

Standard options for the motorsinclude a choice of CETOP, ISOand SAE mounting flanges, andshaft-end configurations, with a compactcartridge version also available.

Parker Hannifin's new bent-axis hydraulicpiston units are ideal for open- and closed-loop circuits in demanding industrial andoffshore applications, including winches, piledrivers and cranes.

New bent-axishydraulicpiston units


45

A range of rubber anti vibration dampersfor small flange-mounted industrialmotors, such as steppers and servos, hasbeen introduced by motion controlspecialists Astrosyn InternationalTechnology.

The mounts are ideal for applicationswhere motor noise and vibration need tobe minimised, such as in securitycamera controls, sample movement

systems in analytical instruments or inmarking and engraving machines.

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

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

lightweight, the dampers can bemounted directly onto the motor flange.

Threaded mounting holes are providedon the damper metal mounting face. Thecentral access hole is large enough toaccommodate a spigot and gear orpulley. The hole diameter is 22 mm onthe smaller sizes and 40 mm on thelarger models.

Anti-vibration mountsfor industrial motors

A range of rubber anti-vibration dampers for smallflange-mounted industrial motors, such as steppersand servos, has been introduced by motion control

specialists Astrosyn International Technology


46

One option is gaseous sterilisation.Ethylene Oxide (EO) gas kills all knownbacteria and their endospores, mouldand fungi and is highly effective insterilising materials that would bedamaged by, for example, pasteurisationor Gamma radiation. Unfortunately, EOis carcinogenic, toxic, highly flammable,potentially explosive and gasifies at10oC. It therefore requires great care inits utilisation and the design of EOsterilisation plant is a highly specialisedone whereby all electrical andmechanical equipment must be fullycompliant with hazardous areastandards.

Getinge UK of Sutton-in-Ashfield are acentre of excellence in the design andconstruction of EO sterilisation systemsand install bespoke sterilisation plantsworldwide for manufacturers of medicaldevices, sterilisation contractors andother healthcare product manufacturers.

In a typical system, pallets of theproducts to be sterilised are placed in aconditioning area where the temperatureis raised to around 55oC and thehumidity to around 70% RH. This‘activates’ any microbes and rendersthem more susceptible to the EO gas.The pallets are then loaded into thehermetically sealed sterilisation chamberand the integrity of the chamber is

confirmed with a vacuum test. Thechamber is then flooded with EO gas atbelow atmospheric pressure and thetemperature maintained at theconditioning level by circulating heatedwater round a water jacket surroundingthe chamber. During the typically 12hour period the goods are exposed, it iscritical that the EO gas is maintained asa homogenous environment throughoutthe chamber. To achieve this a speciallydesigned explosion-proof Halifax Fanblower is used to continuously circulatethe gas through manifolds on the sidesand top of the chamber, changing theentire volume of the chamber typically 8to 10 times per hour, eliminating gas

With MRSA and C. Difficile seemingly endemic in our hospitals, this might wellbe called the age of the superbug. For that reason sterilisation of everythingused in a hospital is absolutely critical and most of us visualise sterilisationas a high temperature process. However, not everything medical canwithstand the high temperatures necessary to bring about absolute sterility.Items such a soft rubber goods, surgical implants, intravenous kits and thelike would all be damaged by high temperatures.

Halifax ATEX blowers kill allknown germs


47

stratification and ensuring that the gaspenetrates every nook and cranny.

Once sterilisation is complete, thechamber must be progressively flushedwith nitrogen while the EO gas mixture isbled off through a catalytic converterthat converts the EO to CO2 and water.The Halifax blower continues to circulatethe gas mixture in the chamber as thegases are of different densities andwould stratify if not actively circulated.Once the concentration of EO is reducedto the point where it is safe to introduceair to the chamber, the pallets aremoved to the post-condition area wherethe temperature is elevated to aid thedegasification process.

The potentially explosive nature ofEthylene Oxide means that thecirculating blower has to be designed tomeet the exact needs of everyinstallation, and to full explosion-proofstandards. Halifax’s design is based uponmany years experience building fans andblowers to handle explosive gases andfeatures spark-proof features such asbrass rubbing strips and a coupling guard.The stainless steel 316 shaft is fittedwith a dual cartridge mechanical shaftseal purged and cooled with water.

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

high integrity, gas tight, stainless-steelcasing is designed to +10Bar and testedto +11Bar. ATEX certified stainless-steel inlet and outlet flame arrestorsprotect against potential flamepropagation beyond the fan in the eventof internal combustion. ATEX certifiedaccelerometers and vibration monitorsare included for early detection of anyimbalance in the fan impeller thatmight lead to contact with the casing,potentially causing a spark.

According to Shaun Riley, EO ProductSpecialist at Getinge, ‘Although some ofour competitors build their ownblowers, we attach so much importanceto this item that we wanted it designed,built and certified by specialists andsupplied as a reliable fit-and-forget fullycertified component. The hazardousnature of Ethylene Oxide meant that wewanted to deal with a manufacturerwith a proven expertise in ATEX andhazardous gas applications. Halifaxworked closely with us to develop arange of bespoke blower sizes that wecan use for quotation purposes andthen, once we have a contract settled,the blower design is fine tuned to theexact specification of that application.Although the blower comes to us fullycertified to ATEX 94/9/EC for Category2G, Zone 1, it is actually fully rated forduty at Category 1G, Zone 0, meeting

the most demanding specifications of allour applications. We’re happy withHalifax Fan’s self certification for Zone 1as this satisfies the environmental andgas groups with which we must complybut we also draw confidence from theincreased safety margin of the Cat 1,Zone 0 rating to which Halifax builds thefans.

Ian Crum

Halifax Fan Ltd

Mistral Works

Brookfoot Business Park

Elland Road

Brighouse, W Yorks HD6 2SD

Tel 01484 475123

Fax 01484 475122

e-mail:- [email protected]

web:-www.halifax-fan.co.uk


48

Logimatic

Logimatic is an internationalengineering and IT company withmore than 20 years of experience

of sales, implementation andsupport of in-house developed

software solutions. In addition tothat we focus strongly on system

integration and consultingservices.

Logimatic Aalborg (coporateoffice)

Tel.: +45 9634 7000

Fax: +45 96 34 7001

E-mail: [email protected]

www.logimatik.dk

PMI Software has been established since 1987providing Engineering & Safety Software Solutions to

businesses Worldwide. Best known for its CMMSproduct PEMAC, we also supply Permit to Work, Risk

Assessment & Accident Report Systems.

We also provide innovative Custom Software solutionsthrough our Custom Division, servicing those customers

with specific software requirements that are not beingmet by the marketplace.

www.pmisoftware.co.uk

353(0)1404 0000

Siveco Group have been developing andproducing CMMS (Computerised

Maintenance Management Systems)solutions since 1986 for companies within

the Industrial and Tertiary sectors.Tel: (44) 1 25 684 38 33,

Fax: (44) 1 21 684 37 67,E-mail :[email protected]

T. 0161 495 4600

F. 0161 495 4690

E. [email protected]

For more information please contact:

By Email: [email protected] Approved Doors

Call our 24 Hour Call Centre:

01536 482187

[email protected]

www.stanair.co.uk

Engineering Maintenance Solutions, June 2010

Asset Mngmt/CMMS

Cayman Venture is a Britishbased engineering software

company who have beendeveloping and supporting

maintenance and engineeringsystems since 1991.

Telephone: 0191 296 3816

Fax: 0191 296 3856

e-mail: [email protected]

website: www.cayman.co.uk

Buyers Guide 2010


49

Steam has been generated byCERTUSS steam generators for

over 50 years, technically perfect,economical and utilised in a

controlled manner.

[email protected]

+44(0)121 3275362

www.certuss.co.uk

Telephone Number

+44 (0)1494 816569

+44 (0)1494 812256

[email protected]

Boilers ConditionMonitoring

Buyers Guide 2010


50

SPM Instrument has 40 years ofexperience with machine condition

monitoring and close cooperation withour customers in all fields of industry.

SPM Instrument UK Ltd.

Tel +44 1706 835 331 | Fax +44 1706260 640

[email protected]

Increase efficiency – reduce costs -These targets are set daily for industrial

managers. We have found solutionswhich have quick pay-backs and which

will give you decided competitiveadvantages. Rely on our experience and

competence – which we have gainedover 25 years.

www.chambers-company.com

ReliabilityConsultants

Mutual Consultants Limited specialise inassisting clients to apply Reliability-Centred Maintenance (RCM) in the

United Kingdom and the Republic ofIreland through world class RCMtraining, RCM consulting, RCM

facilitation and the supply of dedicatedRCM software.

As a member of the Aladon Network ofcompanies we can draw on experience

from (and provide contact with)Reliability-Centred Maintenance (RCM)

users world-wide. Our approach is toimpart knowledge of Reliability-Centred

Maintenance (RCM) to clients viaTraining Courses and Technical Support.

Our support may include projectmanagement and contract facilitation.

Tel: +44 (0)1788 555000

Fax: +44 (0)1788 555010


Thermography

testo Ltd.

Tel.: +44 1420 5444-33

Fax: +44 1420 5444-34

E-Mail: [email protected]

Web: www.testo.co.ukHire - Sales - Calibration - Thermal

Imaging

Tel: +44(0)1772 815 600

[email protected].

WFE Hydraulic ServicesLtd are designers andbuilders of bespoke

hydraulic cylinders, rotarycouplings and power packsystems. Our 35,000 sq ft

manufacturing base issituated in North Sheffield

adjacent to the M1 J34.

Tel: +44 (01142) 430 931

Garry Marsh for repairs on:

Tel: +44 (01142) 430 936

Fax: +44 (01142) 425 516

E-mail:[email protected]

Lubrication

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

Isograph software is in use in a widevariety of industries at around 10000 sites

worldwide.

Isograph products are used extensively inindustries such as rail, nuclear power,automotive, defense and aerospace to

improve safety and reliability. They arealso used to optimize the maintenance andto improve asset performance in industriessuch as utilities, petrochemical, mining &

mineral processing.Sales: +44 1925 43 7001

Support: +44 1925 43 7002

Fax: +44 1925 437010

Training

Hydraulics ReliabilitySoftware

Buyers Guide 2010


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