Date post: | 05-Apr-2018 |
Category: |
Documents |
Upload: | michael3511 |
View: | 216 times |
Download: | 0 times |
of 52
7/31/2019 EMS Aug 2012 Full Low2
1/52
Kuka Robotics And Optima
CS Team Up To Deliver
Maximum Reliability To
Paper Mill Page 6
5-8
12-20
28-33
Latest industry news
Product Spotlights
Thermal Imaging
August 2012$6.80
4.16
5.00
7/31/2019 EMS Aug 2012 Full Low2
2/52
7/31/2019 EMS Aug 2012 Full Low2
3/52
5 - 8 LATEST INDUSTRY NEWS
9 MAINTENANCE BEST PRACTISE
12 -20 PRODUCT SPOTLIGHTS
28-33 THERMAL IMAGING
36 & 37COMPOSITESUK TO HOST SESSION ON NON
DESTRUCTIVE TESTING OF COMPOSITES AT
THE NEC THIS NOVEMBER
39ENERGY MANAGEMENT - WIGAN INFIRMARY
EXPECTED TO SAVE OVER 48,000 A YEAR
47 - 50 BUYERS GUIDE
Contacts
Publisher
Michael Dominguez
Editorialeditors/contributing: Jon Barret, Christer
Idhammar, Alan France Paul Sacker
Advertising
Paul Clappison
Paul Miles
Brian Simpson
Production
Tom Britten
Website
www.engineeringmaintenance.ino
Phone
tel: +44(0)1634 731646
Fax: +44(0)1634 731644
Address
MSL Media LTD, Cobalt House, Centre
Court, Sir Thomas Longley Road, Rochester,
Kent, ME2 4BQ
7/31/2019 EMS Aug 2012 Full Low2
4/52
4 Engineering Maintenance Solutions
7/31/2019 EMS Aug 2012 Full Low2
5/52
5Engineering Maintenance Solutions
Latest News
Just launched by market-leading sensor manuacturer im electronic are new versions o their OG Cube
design photocells designed or AC operation.
The OG Cube is both a sensor with standard M18 thread tting and a compact rectangular housing,
depending how you look at it. From whichever viewpoint, the OG Cube is a robust metal sensor,available in through-beam, retro-refective sensor and background-suppressed diuse versions. What is
new is the ability to operate without problem on normal AC mains power up to 250 V AC, with leakage
current o only 1.7 mA.
The sensor is the optimum choice or a severe industrial environment. The powerul technology in a
compact and robust housing provides high fexibility when used in adverse applications where space i s
restricted. A minimum drit when light and dark objects are detected means the sensor achieves long
ranges which remain constant even with coloured backgrounds. Furthermore, the operation o the sensor is colour-independent or grey-scale
and black values. A high repeatability as well as xed ranges or a quick set-up are more positive eatures o this sensor.
im is committed to working closely with its customers to develop products which precisely match their needs, and the company provides
expert, readily accessible technical support to help users maximise the benets they gain rom im products.
Small And Robust PhotocellsNew AC photoelectric sensors in metal housing rom im electronic
For urther inormation, contact Gemma Castle, im electronic Ltd., Eector House, Kingsway Business Park, Oldeld Road,
Hampton, Middlesex, TW12 2HD.
Telephone: 020 8213-0000. Fax: 020 8213-2228.
E-mail [email protected]
The Carter Jonas Export Award was presented to Norbar by athletics star Kriss Akabusi at the recent
Awards Gala Dinner at Oxord Thames Four Pillars Hotel.
This Export Award ollows on rom Norbars recent recognition as Business o the Year 2012 at
the Cherwell Business Awards. The company has also twice won the Queens Award or Export
Achievement.
Norbar is a amily run rm and a world leading specialist in the design, development and production
o torque tightening and measuring equipment, exporting 75% o its production to over 100 countries
worldwide. There are Norbar sales companies in Australia, China, India, New Zealand, Singapore and
the USA, but manuacturing is carried out solely in Banbury, where Norbar has been established since
the 1940s.
Neill Brodey, Managing Director o Norbar, said that winning the Export Award was an exciting event
in a landmark year or Norbar. We are marking our 70th Anniversary with a relocation o our operations to a new actory in Banbury which
is three times the size o our current premises. The project will be phased and is due or completion in 2014. It is an important stage in our
growth plans and the move is essential or us to expand our manuacturing output in order to meet increased worldwide demand or our
products.
The Carter Jonas Export Award recognises signicant export achievements over the previous 12 months, with an organisation needing to
show increased sales revenue, market share or impact o export business in the overseas markets where it operates.
Norbar Is Oxordshires Exporter O Te YearNorbar orque ools o Banbury, celebrating its 70th Anniversary this year, has triumphed at
the Oxordshire Business Awards 2012 by being voted the countys top exporter.
For urther inormation about Norbar products and services, contact:
Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxordshire, UK OX16 1XJ
Tel +44 (0)1295 270333 [email protected]
Anixter announces A-LAB now ully commissioned
Independently audited by UKAS and accredited to
UKAS/ISO17025, the acility oers a comprehensive
range o astener testing and ailure investigation
capabilities.
Commenting on the new laboratory, Richard Hawker,
vice president o technical services, enthused, One
o Anixters core values is quality and our culture is
ocused to deliver a zero deects standard, whilst
Anixter Fasteners, the global expert in the sourcing and supply o asteners and C class
components, has announced that its independent testing laboratory A-LAB in Gloucester is
now ully commissioned.
supplying over 14 billion components annually, worldwide. As part o
this commitment we have invested heavily in our technical capability.
Our UKAS accredited laboratory not only tests products that we
supply, but also provides an independent investigation and productverication service.
Tel: (+44) 1452 880500
Email: [email protected]
Web: http://www.anixter.co.uk/Fasteners
7/31/2019 EMS Aug 2012 Full Low2
6/52
7/31/2019 EMS Aug 2012 Full Low2
7/52
7Engineering Maintenance Solutions
Latest News
All pumps with dynamic seals could all oul o the dry running problem. The liquids that
these pumps move also act as the lubricant and cooling system or the pump. Friction o
the mechanical seal aces running together without lubrication or the shat packing running
against the shat without cooling by liquid seepage causes overheating, seizure and
catastrophic ailure.
Hydra-Cell high pressure pumps are dierent. They operate with hydraulically balanced
diaphragms and thereore have no dynamic seals to overheat and ail during dry running.
Wanner claims that Hydra-Cell pumps can run dry indenitely without problem.
Hydra-Cells seal-less design also enables them to pump liquids that contain abrasive
particles and other non-lubricating fuids that would cause damage to pumps with mechanical seals.
Operators too busy to notice that the eed tank is empty costs industry many millions o pounds each year. money that could be
saved by using Hydra-Cell pumps.
The design o the new bag is a major advance on existing designs with increased ltration
surace area, F8 classication to BS En779:2002 standard and a 75% reduction in stitched
seam length. This dramatically reduces the cost o manuacture and also the potential or
leakage through the seams.
New saety eatures, including an inlet non-return device to prevent dust rom escaping
during removal, allows an improved ltration standard plus other saety eatures, enabling
enable the application o the CE mark or the rst time to be used on lters o this type.
Features o the new bag include an new extended card inlet device and oam rubber
seal, which enable single handed installation and removal as well as eliminating any hand
contact with the contaminated lter suraces, whilst the olded structure makes the lter sel
supporting.
The lie o each lter can be extensive, because the bag can be easily and saely removed, inverted and shaken to dislodge collected
dust into a V shaped end pocket. Another eature is that compartment astening tags prevent uneven infation and reduce the
bellows eect which can cause dust ejection when lters are removed and compressed or disposal.
The philosophy behind the award is that everything around us started with somebody
having an idea. That idea then needs to be taken and made into reality, to orm it intosomething tangible. The scope o the award is broad so that innovation suggestions are
not limited. Director Global Marketing and Communications, Trelleborg Sealing Solutions,
Robert Zahiri, says: Open innovation is one o Trelleborgs core values and we know that
there are lots o ideas out there that can add value to existing applications today and those
in the uture.
Were not just interested in suggestions or products, technology and materials but
anything that relates to improving our business or the way we do business, or instance,
novel suggestions or online tools, manuacturing processes or logistic related services.
As well as receiving a 5,000 EUR prize, the winning idea will be converted into a tangible project i easible. iPads will be
awarded to the ideas in second and third places. Further details on the award and how to submit ideas can be ound by
going to www.seals-innovation.com.
Pumps Can Run Dry IndenitelyPumps ailing through running dry is not an uncommon problem but one that can be eliminated by using
Hydra-Cell seal-less pumps rom Wanner.
New Multi-Compartment Fume And Dust ExtractionFilter Bags From Flextraction
Flextraction Ltd, supplier and manuacturer o Local Exhaust Ventilation (LEV ) products has designed a
new low cost, multi-compartment lter bag with an innovative olded construction, labyrinth, designed
to t into existing laser and solder ume extractors being used on laser, solder and other industrial ume
and dust extraction applications.
Lee Darton, Managing Director Flextraction Ltd | Telephone: +44 (0)1664 410641
Fax: +44(0)1664 480244 | e-mail: [email protected]
For more details please call us on +44 (0) 1252 816847
relleborg Sealing Solutions Is Looking For Ideas: Launching Terelleborg Sealing Solutions Innovation Award
relleborg launches the relleborg Sealing Solutions Innovation Award. As relleborg continues to pioneer
new sealing developments, ideas are being sought that can provide engineering, technology and design
solutions or today and tomorrow. Te competition is open to anyone, with prizes or the best submissions.
7/31/2019 EMS Aug 2012 Full Low2
8/52
8 Engineering Maintenance Solutions
Latest News
Flexicon Integrate Bulk Handling Systems at PPMA
Flexicon Europe will deliver the greatest insight into its
comprehensive range o bulk handling equipment and systems on
stand F27 at the orthcoming PPMA exhibition taking place 25-27
September 2012 at the NEC, Birmingham. Production directors and
managers looking to improve in-house eciencies in the handling
and transerence o powders, fakes and granules should make the
Flexicon stand F27 an essential scheduled stop.
On stand F27 Flexicon will introduce a number o bulk-bag delivery systems
including a combination Bulk Bag Filler with Pallet Dispenser and Powered Roller
Conveyor or sae high capacity, simultaneous lling o two bulk bags. There will
also be an opportunity to see the latest pneumatic gain-in-weight lling system
designed to automate delivery o ree-fowing bulk solids rom down-stream silosor processing lines to individual bulk bags.
This renowned specialist in bulk handling will also be eaturing alternate types o
high-speed conveying technologies including its fexible screw and pneumatic
conveyors. Flexicons fexible screw conveyor is able to move bulk material
vertically, horizontally or to any angle over, under or around obstructions.
During operation the fexible screw sel-centres as it rotates, its gentle rolling
action prevents separation o the blend throughout the entire length o the
conveyor. The Flexicon pneumatic conveying system comes into its own where
bulk material needs to be moved over longer distances, and is capable o
transporting material rom single or multiple sources such as storage vessels,
process equipment, trucks, etc., to multiple destinations.
As a manuacturer o conveying, bag dischargers and bag llers incorporating
load-cell weighing when required, Flexicon is able to deliver individual bulkhandling equipment or build combination systems designed to a specic brie,
and implement ull trials on customer material at its Kent based test laboratory to
demonstrate the viability o the solution.
Hussmann is a leader in manuacturing, selling,
installing, and servicing merchandising equipment
and rerigeration systems or customers in the retail
ood industry. The company is growth oriented andcontinually developing new products and solutions
in ood retailing or its customers.
aPrioris Product Cost Management sotware
platorm enables design engineers to quickly and
precisely determine the cost o a new part or
product design by automatically pulling geometric
and eature inormation rom a computer-aided
design (CAD) model. The sotware leverages
intelligent cost models based on the manuacturing
process, materials and the plant where a product or
part will be produced. Using this new level o cost
knowledge, manuacturers are able to make moreinormed new product design decisions and reduce
new product costs without impacting product
quality.
With aPriori, Hussmanns design engineers can
nd the optimal balance between unctionality,
perormance, quality and cost, said Stephanie
Feraday, president and CEO o aPriori. They can
also explore more design alternatives aster, which
Hussmann Corporation selects aPrioris Product Cost
Management Platorm
drives out cost earlier and results in ewer changes
later in development when making changes is
incrementally more expensive. It enables greater
innovation and protability at the same time.
aPriori (www.apriori.com), a provider o product cost management
soware solutions, has announced that Hussmann Corporation,
a manuacturer o rerigerated and rozen ood merchandising
equipment, has selected aPrioris soware platorm to help identiy
product cost savings and eliminate unnecessary costs earlier in the
product development liecycle.
aPriori www.apriori.com
Tel: +44 (0) 1932 503 300
Jacobs have 350 vacancies across all sectors o the business including; Piping
& Mechanical, Project Controls and Project Management.
Don Atkinson the ECITBs Regional Account Manager or the North East
said: There are 2.58 million unemployed people in the UK but we are seeing
unprecedented growth and investment in the engineering construction industry
- the government recently announced a guaranteed 40 billion in 500 projects
or the nations inrastructure. Now the government has taken this step more
and more engineering construction companies will be recruiting, it is an exciting
time or the industry.
Projections show that the UK will need 40,000 more skilled people by 2020. Its
our role to work with organisations like Jacobs to attract, develop and qualiy
people or a career in the engineering construction industry. The ECITB invests
about 20 million each year supporting apprentices, graduates and up-skilling
the existing workorce.
For more inormation about the ECITB go to: www.ecitb.org.uk
For more inormation about Jacobs Engineering, please go to: jacobs.com/
careers
Available or interviews:
Don Atkinson, Regional Account Manager or the North East, don.
[email protected] 01642 777 719
Wanted 350 senior engineers!350 senior engineer vacancies were up or grabs at a recruitment
event supported by the Engineering Construction Industry
Training Board (ECITB) held by the global engineering rm Jacobs
Engineering Group inc. at Middlesbrough F.C Riverside stadium
yesterday.
7/31/2019 EMS Aug 2012 Full Low2
9/52
9Engineering Maintenance Solutions
Maintenance Best Practise
Justication O Planners
Christer Idhammaris a world-renowned and
multiple award winning
Reliability and Maintenance
Consultant and Guru. He
is the Founder and CEO o
IDCON, INC in Raleigh
NC, USA; A reliability and
maintenance training and
consulting company to the
Pulp and Paper Industry
worldwide since 1972.
www.idcon.com
Scheduling is here dened as thework done to decide: When to do the
work and Who will do it.
Planning shall be done beore you
schedule work.
You can say that all work is always
planned beore you do the work. That
is a act. The question is how ecient
can this be done?
I have worked with many plants where
they have no planners because the
maintenance organization was unable
to justiy a planner(s) position. Here
I like to oer some ideas on how we
successully have helped maintenance
organizations justiy more ecient
planning with planners.
With or without planners
somebody always does
planning o work otherwise
the work could not be done.
In an organization without
planners the ollowing is a typical
situation:
(Working hours 07:00 15:30)
07:00 07:30 Crew arrives and
meet with supervisor.
07:30 All have been assigned
what to do today.
E.g. Pump 20-439 does not
pump
07:30 08:45 Two mechanics
troubleshoot and nd that
bearing, seal and impeller unit
must be changed.
8:45 09:00 get rigging tools.
09:00 09:15 Morning break.
09:15 10:30 Finding parts.
10:30 11:30 Arrange rigging.
11:30 12:00 Lunch break.
12:00 14:00 Disassemble
bearing, seal and impeller unit.
14:00 15:30 Impeller too big.
Machine down to right diameter.
15:30 17:00 Install, test and
start pump.
In summary the scope o work had to
be decided by the mechanics, tools,
parts, rigging etc. had also to bedecided by mechanics, adjustment
o impeller was also decided by
mechanics. All o this is PLANNING.
The ineciency in this example
lies in that planning was done ater
scheduling and it must be done the
other way around to be ecient.
The other scenario is that the problem
with the pump was discovered during
an established inspection route a
couple o weeks beore the problem
must be corrected. A planner could
then plan the job eciently. It would
take the planner about two hours to
prepare all needed or work, arrange
or pump impeller to be adjusted etc.
Planning is here dened as dened as the work done to
decide: What work to do, How it will be done and Howlong time it will take.
In this example the maintenance
organization is very reactive and crats
people are put in a situation where
they have to plan to get the work
done. The implementation o basic
inspections will change the situation
so that a planner can plan beorework is scheduled by a supervisor and
executed by crats people. The target
is to get down to about 10% urgent
work where the situation described
in the scenario above would still be
repeated. That would ree up 190
hours/day rom crats peoples time.
To be ecient in work management
this organization would need about
three to our planners (24 32 hours/
day). This would enable crats people
to ree up 158 166 hours/day. The
number o planners is very dependent
on disciplined priorities o work,
access to an updated and accurate
bill o materials and close cooperation
with operations.
Number o
Crats people
60
% o time they
plan
50
Total planning
hours/day
240
Target
Hours/day
50
Freed up
Time. Hours/day
190
The mechanics would then do the
work in an organized way in about ve
maintenance hours instead o about
20 hours including overtime as in the
example above.
We have done hundreds o
evaluations o maintenance
organizations all over the world
and ound that without organizedinspections and planning ollowed
by scheduling o work crats people
spend 40 60 % o their time on
planning activities as given in the
example above.
7/31/2019 EMS Aug 2012 Full Low2
10/52
10 Engineering Maintenance Solutions
7/31/2019 EMS Aug 2012 Full Low2
11/52
11Engineering Maintenance Solutions
Pipe Measurement
GRTgaz operates and marketsnatural gas to the Public
Distribution Systems in France
and to consumers (industrial
customers). GRTgaz operates more
than 32,000km o steel pipelines
and 26 compressor stations and is
currently implementing the Artere
des Hauts de France II project,
which involves the installation o
pipelines linking an LNG terminal
at Dunkerque to the existing gas
distribution network in France.
As part o the preparation or this
project, GRTgaz contracted OMS
to conduct pipe measurement
surveys in two separate locations
in France, Campagne les
Wardrecques and Arques. The
objective o the measurement
surveys was to identiy the
proportion o pipes whose out-
o-roundness tolerance was
greater than 6mm (i.e. out o their
manuacturing specication), whichcould later result in pipe t up
delays and welding issues.
The surveys were carried out in
three separate mobilisations during
November 2011, February 2012
and April 2012. OMS measured a
sample o 450 pipe ends during the
rst survey, 900 during the second,
and 108 pipe ends during the
third survey. Pipe end dimensions
measured included inside diameter,
outside diameter, wall thickness
and out-o-roundness tolerance
(6mm).
For end dimensioning o pipes,
OMS utilised its own automatic
Pipe Checker laser measurement
tool, which is capable o measuring
more than 2,000 IDs and 2,000
ODs. The tool is accurate to
0.05mm and enables just two OMS
sta to measure a minimum o 200
pipe ends in a single shit. This
meant less time on site, minimising
project delays and costs or the
customer and reducing pipe t up
and welding issues.
Dr Richard Gooch, Director o
Technology at OMS commented:
The pipes were stacked outside
in sub-zero temperatures, which
presented our two inspectors
with logistical challenges. Prior
to measurements being taken,
the pipe ends had to be cleared
o snow, ice, dust and debris, as
temperatures dropped as low as
minus 15 degrees Centigrade
during the rst two surveys. We
also had to use mobile access
platorms in order to provide our
inspectors with sae access and
a stable working platorm or
measuring the higher pipes in the
stacks.
OMS inspectors maintained a
paper record o all measurements,
as well as digital measurement
data, which was archived directly to
a laptop computer and led under
the pipe number or traceability. The
measuring tools were calibrated
beore measurements were taken
and then checked or correct
calibration ater measuring. Results
rom all three pipe surveys were
presented to GRTgaz, which
indicated what proportion o pipe
ends were within the 6mm out-o-
roundness tolerance and which
were outside o this specication.
OMS completes pipe end measurementsurveys or GRgaz
Specialist pipe measurement technology company
or the oil and gas industries, Optical MetrologyServices (OMS) Ltd, has successully completed
a series o pipe measurement surveys or GRgaz,
Frances largest natural gas operator.
For more inormation on OMS,
please visit the website at www.
omsmeasure.com or telephone
01279 656038 or email hugh.
7/31/2019 EMS Aug 2012 Full Low2
12/52
12 Engineering Maintenance Solutions
Product Spotlight
Nearly 600 Rockwell Automation employees use FaciliWorks 8i Web-based
CMMS sotware or multi-site asset and calibration management. Mike
Haensgen, Project Engineer, says, Its fexible and easy to use. We looked
at other products, but FaciliWorks gives us the option o incorporating
calibration, so its completely seamless. It was denitely the right choice
or us. Available in Desktop, Server and Hosted versions and a variety o
languages, FaciliWorks CMMS is an all-in-one solution or highly ecient
acility management: track assets, preventative maintenance, work orders,
service requests, inventory, personnel and more. Contact us today or your
Free Trial o FaciliWorks CMMS sotware.
600 Rockwell Automation employees use
FaciliWorks 8i Web-based CMMS sowareIts portability and ease o use, coupled with its ull A, B and
C-Scan capability and optional TOFD capabilities, make the
Pocket UT System (along with available companion scanners
or other compatible
devices) ideal or
on-site inspection
applications. It
quickly assesses
the presence,
depth, shape and
orientation o cracks,
faws, corrosion/erosion,
delamination, and internal
anomalies in a variety o
structures, materials and
suraces.
The Pocket UT can
operate as a conventional
thickness meter (or
spot readings), a basic
faw detector with RF display and alarm gates, or in either active
B-Scan or ull C-Scan modes. The system has a bright, back-lit
LCD colour touchscreen, and an easy-to-use keypad or ast entry
o common commands and data.
MISRAS Pocket U System
MISRAS oers the innovative
Pocket U, a battery-operated, hand-
held, stand-alone, ull C-Scan data
acquisition system.
For urther product ino please visit http://www.pocketut.com/
Worldwide Headquarters
195 Clarksville Road, Princeton Junction, NJ 08550 - USA
Tel: (609) 716-4000 | Fax: (609) 716-0706
Email: [email protected]
Web: www.mistrasgroup.com
Accurate Trough-Coating Metal Tickness InspectionCygnus Instruments, the leading manuacturer o ultrasonic
testing equipment, oers an extensive range o digital thickness
gauges employed the Cygnus-pioneered Multiple Echo
echnique to give accurate, error-checked measurements o
remaining metal thickness through coatings.
The range includes: the ATEX certied Cygnus 1 Intrinsically Sae or use in
potentially explosive environments; the highly versatile Cygnus 4 General
Purpose eaturing a large, bright LCD display and simple menu operation or
all industrial applications; the
small & lightweight Cygnus
2 Hands Free equipped with
a belt/harness clip, a neck
strap and an end-mounted
clear display or hands ree
operations and rope access
inspections.
Email: [email protected]
Tel: +44 (0) 1305 265533
Website: www.cygnus-instruments.com
7/31/2019 EMS Aug 2012 Full Low2
13/52
13Engineering Maintenance Solutions
7/31/2019 EMS Aug 2012 Full Low2
14/52
14 Engineering Maintenance Solutions
Machinery Maintenance
The lietime o machines can be extended by
REWITECs ENHANCEMENT TECHNOLOGY,
even when the rst signs o decay appear.
REWITEC was ound in 2003 with the goalo reducing the problem o wear and tear in
tribological systems.
REWITEC Technology: surace renement with
metal silicates or Tribosystems
Customers report repeatable and highly
avorable results or the use o Rewitec surace
enhancing approach. The method uses the
existing machine lubricant to carry a silicate-
based compound to the rubbing suraces in the
equipment. Rewitec is based on the modication
o machine part suraces that, under riction,
generate a metal-silicate layer. This layer coners
ceramic characteristics to the surace enhancing
the abrasion and wear qualities o the original
metal suraces.
The active ingredient contains various silicates.
The introduced solids produce a chemical
reaction with the lubricated machine element,
such as a gear, engine cylinder and bearing race,
due to high partial pressure and temperatures
during contact. The silicate atoms o the active
ingredient coalesce with metal atoms o the
surace and compose the ceramic-like metal-
silicates layer.
Independent analysis o surace imprints using
topometric imaging suggests appreciable
change in surace roughness on worked
Conditioning And Durable Wear Protection For
All ribological Systems
Te operation and maintenance o machines
and especially o components such as gearboxes,
engines, and bearings can be simplied by
developing appropriate protection strategies.
suraces ollowing treatment. Figures 1 and 2
provide a contrast o surace proles rom a
silicon imprint o the surace o a gear tooth,
contrasting enhancement in the condition
through the coating technology.
Conclusions
The REWITEC surace renement
will prevent wear in all grease and oil
lubricated equipment. Wear processes
can be stopped with it and already
existing damage can be rozen and
made regressive too. Strengthening
the metal suraces o tribological
systems with Rewitec will increase the
lietime o machine components.
Below: Figure 1
Below: Figure 2
7/31/2019 EMS Aug 2012 Full Low2
15/52
15Engineering Maintenance Solutions
Since 1960, S. Himmelstein and Company has
been a leading manuacturer o in-line rotating,
as well as reaction style, torque transducers or
process control and machinery perormance
monitoring applications.
Our laboratory oers ISO 17025 accreditedtorque calibration services or transducers rom
virtually any manuacturer. The scope o our
accreditation covers ranges rom 0.07 Nm to
450,000 Nm.
orque ransducers Save Space,
Simpliy Installation
MCR 86000V Series Bearingless Digital orque ransducers
are characterized by high perormance, short installed lengthand simple installation, or accurate measurement o torque
in rotating applications. Digital and analog outputs connect
directly to users control systems or ast response.
S. Himmelstein and Company
2490 Pembroke Ave, Homan Estates, IL 60169, USA
1-847-843-3300 | www.himmelstein.com | [email protected]
Torque Tranducers
7/31/2019 EMS Aug 2012 Full Low2
16/52
16 Engineering Maintenance Solutions
Product Spotlight
Maintenance engineers are exploiting the signicant cost savings and
operational lie improvements gained rom having components restored
to original equipment condition with the reassurance o NDE Clarke
Pitchlines ISO9001 accreditation and 36 years industry experience.
Trained engineers are able to survey entire applications and produce a
ree, ully itemised inspection report identiying potential cost savings and
liespan increases that can be gained rom driveshat service and repair
without any hidden costs. Re-Balancing o drive shats to certied grade
G16 or G6.3 is completed or shats running over 500rpm along with ull
cleaning, re-greasing and re-painting.
Sudden Rise in Universal Drive Sha Service & RepairCoventry based power transmission specialist
NDE Clarke Pitchline is reporting an inux
o new service and repair orders or universal
drive shas and prop shas rom customers in
industrial sectors.
Free Site Survey: Mr Ivan Luton on 02476 222272
or e-mail [email protected]
Website: www.ndeclarkepitchline.co.uk
Established over 50 years ago
in Yorkshire and now with an
additional 4000 M2 actory inChina, Haliax Fan is indisputably
a global leader in the design and
manuacture o high specication
radial ans. Haliax can supply
identical products, all built
to ISO9001 standards, rom
whichever actory is closest to
the customers site, speeding
delivery and cutting costs. Haliax oers the widest range o standard
impeller designs although the nal design is bespoke engineered
to meet the customers exact requirements by their team o highly
experienced an engineers who will provide ree consultation on the
best an design and materials or the application.
Haliax Fan is indisputably a global leader
in the design and manuacture
t: +44 1484 475123
www.haliax-an.com
O8 a New Approach to theRemoval o Oil Stains
O8, manuactured by Oil echnics Ltd in Scotland, is a
biological oil stain remover that rapidly removes and digests
oil stains rom suraces such as block work, paving stones,
concrete, orecourts, garage oors, driveways and equipment.
OT8 penetrates most porous suraces and
its unique blend o biological enzymes and
bacteria digest oil stains to completion.
Oil Technics Ltd have been providing their
customers worldwide with innovative
cleaning, re protection and spill control
products since 1984, and ensure their
products are always eective, economical
and environmentally riendly.
For urther inormation on OT8 or other products, please contact:
Oil Technics Ltd, Linton Business Park, Gourdon, Aberdeenshire,
Scotland, UK DD10 0NH | Tel: +44 (0) 1561 361515
Fax: +44 (0) 1561 361001 Email:[email protected]
Web: www.oiltechnics.com
7/31/2019 EMS Aug 2012 Full Low2
17/52
7/31/2019 EMS Aug 2012 Full Low2
18/52
18 Engineering Maintenance Solutions
The MC6 contains a ull eldbus
communicator or HART,
FOUNDATION Fieldbus and
Probus PA instruments. The
usability and ease-o-use are what
really makes the MC6 unique.
The large 5.7 color touch-screen
with a multilingual user-interacemakes the MC6 an ideal portable
measurement device or eld use
in various industries.
Te Beamex MC6 Advanced Field Calibrator
and Communicator is a solution to the new
process industry requirements.
Te MC6 is an advanced, high-accuracy eld calibrator
and communicator. It oers calibration capabilities or
pressure, temperature and various electrical signals.
For more details and enquiries please email:
Capable o
providing accurate
measurements up
to 10 T or 5 kV
versions and 20 T
or 10 kV versions
and having acilities
or automatic timed
IR tests and more
advanced diagnostic
tests; PI, DAR, DD, SV
and ramp tests.
Meggers new IRTs are available in three versions. The MIT515 is an
entry-level 5 kV test set which oers insulation resistance (IR), timed
insulation resistance (IR(t)), dielectric absorption ratio (DAR) and
polarisation index (PI) test modes.
Get your MIs on Meggers new insulation testers!
Meggers new high-voltage insulation resistance testers (IRs)
oer exceptional versatility in a compact, rugged and light unit
that weighs little more than hal as much as its predecessors.
The old-up industrial doors, craneway doors and partitions we
manuacture rom standardised components according to customers
specications are extremely dependable and have minimal servicing needs.
All our old-up doors are CE-marked and comply with currently valid
standards. In very large openings, like hangar doors, width and height are
not limited owing to Champion Doors elevating support post solution.
Vertical liing abric old-up doors and partitionsare the best alternative or large-scale door locations
requiring high-quality heat and noise insulation
these include actory sheds, aircra hangars, harbours,
mining and energy storehouses.
Product Spotlight
7/31/2019 EMS Aug 2012 Full Low2
19/52
19Engineering Maintenance Solutions
OEE
Instant OEE or any production line!Analyse OEE. Record Downtime. rack Production. Create
Reports. Drive Action. Te XL Productivity Appliance is a
single system giving you Data Anywhere, Data Everywhere.
The XL Productivity Appliance is a
simple and eective way to improve
manuacturing productivity. The bright
LED display inorms, alerts, and
motivates your plant foor operators, and
the integrated sotware delivers instant
production reports and analytics to
supervisors and managers whereverthey are.
Bolt-on: The XL Appliance is so easy to use it can be sel-deployed in about an
hour to instantly deliver meaningul, accurate, actionable inormation anywhere
in your plant.
Pick a number: Monitoring over 200 KPIs in real time, just pick the numbers
that matter to you. In real time XL will display your numbers on the screen, and
track them or real time reports.
Tried and tested: With over 7000 implementations Worldwide, the XL
Productivity Appliance is a tried-and tested solution that works or applications
just like yours.
Try the system or ree: Vorne and our International Partners encourage you to
try an XL Productivity Appliance in your plant, on your lines. The trial is ree and
available to all qualiying sites.
Worldwide support: Highly trained XL Productivity Appliance Partners are
available across the Americas, Europe, Asia, Southern Arica, and Australasiaproviding local sales and technical support.
Contact our UK Team today: To start your trial or nd a local partner contact
OptimumFX: [email protected] or call us on +44-1926-623356
Are You Driving Perormance, Or Is Downtime Driving You?
Short Interval Control (SIC) uses regular reviews o perormance data during the
shit to enable mid-course corrections and immediate xes that signicantly improve
perormance. It bridges the gap between reactive and proactive and it delivers
results ast!
The core principle behind Short Interval Control is very simple: we cannot change the
past; however, we can learn rom it to improve the uture. At a practical level, SIC is
implemented as a series o short (ve to ten minute) and ocused reviews carried out
every two to our hours by ront-line engineering and operations teams. The teams
review losses and carry out actions that will improve perormance during the shit.
Most plants nd it extremely challenging to move rom a world o
constantly reghting unplanned breakdowns to a world o proactively
managing perormance. Would you benet rom a more proactive and less
reactive approach to downtime?
During each review the SIC team completes a series o short and simple steps:
Assess Previous Actions (evaluate completion and eectiveness o actions agreed in
previous SIC against targets set and whether ollow-on actions are required)
Identiy Greatest Losses over SIC Period (evaluate the top losses or potential
countermeasures)
Identiy Risks (identiy upcoming conditions and changes that may adversely aect
perormance, such as changeovers or material changes)
Decide Actions (determine one or two actions to be completed to improve
perormance during the next interval, including setting targets and accountability)
The actions decided upon during the SIC review are then carried out by the team to
maximize production during their shit. The power o this process is that it unites the
engineering and operations teams to review perormance, agree an action area, and
to implement change on a regular and periodic basis.
Getting started is easy you just need to know your losses, and manually calculating
OEE is a great way to start. It can be done with pen and paper or with a simple
spreadsheet, and only ve pieces o data are needed (Planned Production Time,
Down Time, Ideal Cycle Time, Total Pieces, and Good Pieces). Perorming manual
OEE calculations helps reinorce the underlying concepts and provides a deeper
understanding o OEE. However, there are also very strong benets to quickly moving
to automated OEE data collection with a simple monitoring system:
Downtime: The accuracy o manual down time tracking is 40 to 60% at best (based
on real-world experience across many companies). With automatic Run/Down
detection, this accuracy can approach 100%, plus real-time and trended data letsyou know as it happens, what the loss is and whether it is an on-going issue.
Small Stops and Slow Cycles: For most equipment it is impossible to manually
track small stops and slow cycles. This means that a great deal o potentially useul
inormation, such as time-based and
event-based loss patterns, is not
available.
Engineer Focus: With automated data
collection the operator spends more
time ocused directly on the equipment
(versus spending time on paperwork).
Real-Time Results: Automated data
collection provides results in real-time,
enabling improvement techniques such
as SIC (Short Interval Control).
Implementing SIC lits teams rom living
in a reactive world to ruling a proactive
world. By working with a stream o real-
time data, teams prioritize their precious
time to proactively identiy and x issues
beore they turn into signicant losses.
I youd like to chat urther about SIC.
call me at +44 1926 623300
or drop me an email at samir.
Samir Shah is the Principal
Consultant at OptimumFX.
Samir and his team are experts
at helping manuacturing
companies use data to drive
perormance improvement.
Working in blue-chip
manuacturing organizations
across Europe, OptimumFX
work within teams to
implement sustainable and
practical processes that drive
equipment perormance up,
and stamp downtime out.
www.optimumx.com
7/31/2019 EMS Aug 2012 Full Low2
20/52
20 Engineering Maintenance Solutions
Product Spotlight
Metrics include RMSacceleration, peak
velocity and peak-peak
displacement. Plots include
orbits, orders, spectra and
spectral maps.
Balancing is standard.
Data can be acquired
and analysed in real-time whilst simultaneously recording raw data or
subsequent post-processing.
Hardware options are available to optimise portability, channel counts and
sampling rates. Standalone hardware can even acquire data independent
o a host computer or long periods o time, continuing data acquisition
automatically ater any interruptions including power ailure.
Vibration Analysis Portable, Versatile, Intuitive
m+ps renowned SO Analy zer is equipped with all the
unctionality required or condition monitoring o rotating
machinery, constant and variable speed.
Tel: 01420 521222,
email : [email protected].
Nondestructive Inspection O Steel Wire Ropes
Wire rope tester INTROS is designed or nondestructive inspection
o wire ropes on-site, such as cranes, elevators, mines, cableways,
bridges, chimney res, etc. or during production run. The battery
powered instrument operates MFL principle, and comprises basic
unit and magnetic heads or ropes with diameter rom 6 to 150 mm.
INTROS detects outer and inner broken wires, measures loss o
metallic area due to corrosion and abrasion. Inspection data are
shown on the display o basic unit, available on-line on computer,
and can be downloaded or detailed analysis. Explosive-proo
INTROS version is available.
For more inormation please visit www.intron-plus.com.
7/31/2019 EMS Aug 2012 Full Low2
21/52
7/31/2019 EMS Aug 2012 Full Low2
22/52
22 Engineering Maintenance Solutions
The range consists o three models: the fagship
HDS 6/12 C 240v which eatures adjustable
water fow and pressure and a steam unction;
the 110v HDS 6/10 C; and entry-level HDS 5/12
C 240v.
All models in the new range eature Krchers
eco!eciency mode, which reduces uel
consumption by 20% compared to previous
models, saving on diesel costs and reducing the
amount o time needed or reuelling but without
compromising cleaning results. HDS Compact
models are also backed by a 3-year burner coil
warranty.
The new range showcases a contemporary
chassis design with a number o details that
combine to make a class-leading machine;
including large wheels, tilting aid and new handle
design or easy manoeuvring; clear, intuitive
controls or quick amiliarisation and start-up;
on-board accessory storage; accurate detergent
dosing that reduces waste; easy-pour detergent
and diesel tanks to reduce risk o spillages; and
proven, high quality materials.
Krchers Product Manager Je Hilton is excited
about the new range: The HDS 601 C has
been our best-selling hot water machine or over
seven years, but we are delighted with the new
HDS 6/12 C. It does everything the 601 did well,
but with simple improvements to make it easier
to use, easier to service and above all cheaper
Krcher Sets New Standard For Compact Hot WaterPressure Washers
Krcher, the worlds leading manuacturer o cleaning machines, has launched a
new compact hot water pressure washer range that oers a number o key cost-
saving and time-saving benets including 20% reduced uel consumption.
to run, without losing any o the appeal o the
old machine. The Compact range really sets a
new benchmark or compact hot water pressure
washers.
For urther inormation on how the
new HDS Compact range can make a
dierence to your business visit www.
hdscompact.co.uk, call 01295 752142
or email [email protected].
Chilled water is a undamental part o scores
o industrial processes, rom ood processing
to plastics moulding, printing manuacture
to chemical production temperature control,
through medical imaging and mechanical or
laser welding and cutting. There are many ways
to create chilled water, but Parker Domnick
Hunter Hyperchill water chillers are gaining
increased popularity or three main reasons:
These chillers are precision-designed to supply
water at the exact temperature requested. They
operate in a closed circuit, avoiding any costly
water wastage. Because o this they help meet
increasingly stringent quality & health directive
standards - and prevent the discharge o impure
water into the environment.
Parker Domnick Hunter Hyperchill has over 30
years experience o industrial chiller design and
production, dedicated to ensuring optimum
industrial application perormance. Hyperchill
models are adaptable to a broad range o
individual output requirements and can handle
both diering water temperatures and fuctuating
water fows.
Its easy to get ast and expert advice on
any aspect o chilled water processing: The
Thorite Water Chiller Specialist Team can be
contacted ree on 0800 034 2511 or emailed at
[email protected] The Hyperchill Water
Chillers brochure can be downloaded rom the
Thorite website, or customers can contact any
o Thorites nine regional branches.
Alternatively, why not request a visit rom a
member o Thorites Capital Equipment Team.
Theyll not only explain all the Hyperchill water
chillers advantages and answer all queries, but
also supply a quote or the most suitable model
or your individual requirements.
Worried about Cold Water Processing Needs? Chill Out with ToriteMany industrial processing applications rely on a supply o low temperature water
to achieve optimum results. Torite, the UKs biggest pneumatic products and
process systems distributor, can now provide the means to satisy this requirement
in the elegant orm o a water chiller rom the market-leading Parker Domnick
Hunter Hyperchill range.
Further Inormation: Ross Gowler
Thorite Marketing and Engineering
Services Director
Tel: 01274 663471.
Email: [email protected]
Web: www.thorite.co.uk
Industrial Cleaning
Process Systems
7/31/2019 EMS Aug 2012 Full Low2
23/52
7/31/2019 EMS Aug 2012 Full Low2
24/52
7/31/2019 EMS Aug 2012 Full Low2
25/52
25Engineering Maintenance Solutions
Compressed Air
A number o dierent brands o dryer have been
tried and tested on site with limited success.
Some dryers actually ailed in less than 6
months.
BEKO TECHNOLOGIES looked at the PH
value o the condensate and the acidic ambient
conditions. From this a tailor-made DRYPOINT
RA 600 solution was oered, where all the
internal copper piping and condensate discharge
points o the dryer were coated with a special
anti-corrosion treatment. The rst RA dryer sold
to KP Foods has been installed on site now or
nearly 4 years without a single ailure. This was a
major actor in the choice or the new dryers or
the Hoops compressor room location.
Pressure drop was also a major actor as well as
pipe work distribution. With this in mind BEKO
were invited to tender or the whole turnkey
project which included removing all the old
equipment, supply and installation o new dryers,
lters and pipework. BEKO successully won
the order or the complete turnkey project and
in conjunction with Direct Air and Pipework o
Coventry the whole installation was carried out
in less than 48 hours. The installation included
a complete new 6 maniold, 4 drops into the
2 x DRYPOINT RA 600 dryers and 2 x Flanged
lters. Timing was essential as the compressed
air went o at 2pm on a Saturday and had to be
installed and running by 8pm on a Sunday.
The installation was successully carried out on
Beko echnologies solves KP Foods drying problems.
KP Foods, a part o the United Biscuits group have had issues in
recent years with rerigeration dryers ailing because o the acidic
conditions on site due to ingredients such as acetic acid aectingthe internal copper tubing o rerigeration dryers.
time. KP Foods are now reaping the rewards in
energy reduction o very low pressure drop and
a constant dewpoint throughout their actory
with the added reliability o the BEKO DRYPOINT
RA range.
BEKO Technologies Limited
Tel: 01527 575778.
E-mail: [email protected]
Website: www.beko-technologies.co.uk
7/31/2019 EMS Aug 2012 Full Low2
26/52
26 Engineering Maintenance Solutions
Ventilation
7/31/2019 EMS Aug 2012 Full Low2
27/52
27Engineering Maintenance Solutions
At the plant steel plate up to 12m x 3m is cut
using a large ESAB plasma-cutting machine.
Western Air Ducts installation extracts the
umes and dust through slots in the machine
bed, into an under-foor duct rom where they
are carried outside the building, where the air
is ltered and cleaned beore being emitted to
the outside air via a chimney.
The plasma process generates sparks. In
order to avoid these reaching the air lters
(which are themselves re-retardant) Western
Air Ducts installed its unique Flashback Box
between the extract duct and the lters.
The lters are replaced annually, but during
the intervening time they are rereshed by
a reverse pulse mechanism. One o the
eects o this process is that the airfow varies
as air is extracted more rapidly through the
cleaned lters. Western Air Ducts thereore
incorporated an in-line device to measure the
fow rate, together with a system o dampers,
which can be opened and closed to exactly
Western Air Ducts - Breath o Fresh Air or ArcelorMittal
Extracting the dust, umes and sparks generated by
plasma cutting poses specic problems, and it was these
that Bob Kilby, Head o Health and Saety/Quality and
Environment at ArcelorMittals plant in Birkenhead,
sought the expertise o Western Air Ducts to solve.
regulate the airfow. As Bob explains; Being
able to regulate airfow enables us to ne-tune
the system to operate at optimal eciency.
Above: ESAB Suprarex installation similar
to that at ArcelorMittal
For urther inormation please visit
www.wadlev.co.uk
and
www.wad.co.uk
Dust & Fume
Unique Bidirectional
Hydrodynamic Drive (BHD)
patented design provides
minimum discharge o
water less than 1% o
total system fow during
cleaning while maximizing
lter screen cleaning
eciency. The only
automatic lter oering
a no leak body design; 316 Stainless body and screen construction
provides superior component longevity. Virtually limitless fow rates and
various degrees o ltration are available rom 1500 to 10-micron. Made in
USA.
VAF Filtration SystemsVAF specializes in the Engineering & Manuacture o automatic
sel-cleaning individual, modular and skid mounted ltration
systems that include integrated controls and valves or
Cooling owers, Pre-RO, Desalination, Water & Waste Water
applications.
VAF Filtration Systems ~ www.vausa.com ~ +1 303 425 4242
7/31/2019 EMS Aug 2012 Full Low2
28/52
28 Engineering Maintenance Solutions
Thermal Imaging
Fluke Oers Entry Level Termal Imager At Reduced PriceIdeal or electrical applications- only 1650
Fluke, the global leader in handheld electronic test
and measurement equipment, is oering its entry-level
Fluke i9 Termal Imager, targeted at electricians and
industrial maintenance technicians, at a reduced price or
orders placed beore 30th o September - 1650 instead
o 2090. Rated to IP54, the rugged Fluke i9 is ideal
or electrical applications, being extremely robust and
optimised or work in harsh environments.
This amazing special oer price also
includes the Fluke SmartView sotware
or generation o proessional reports.
The Fluke Ti9 Thermal Imager,
with 160 x 120 pixel resolution,
delivers clear, crisp images to
nd problems ast, revealingthe smallest details with the
widescreen ormat colour LCD
display. Featuring an intuitive
three-button menu, users simply
point the instrument rom a sae
distance and pull the trigger to
capture the ull image.
That saves valuable time and greatly
increases the speed o inspecting,
repairing and veriying electrical and
electromechanical equipment. Over
1200 ull radiometric images can be
captured on its removable SD memory
card.
The Fluke Ti9 helps extend equipment
lietime, avoid electrical res, and validate
installation, repair and maintenance
procedures. It can detect problems in
a wide range o equipment including
The Fluke Ti9 can be purchased
rom Fluke authorised distributors.
For more inormation about all Fluke
products, or to order the Fluke 72 page
booklet Introduction to Thermography
Principles visit www.fuke.co.uk
switchgear, motor control centres and
lighting systems. Even small temperature
dierences are visible in components like
transormers, panels, controls, uses,
receptacles and bus bars. Hot spots
regularly indicate an imminent problem or
equipment ailure in electrical equipment.
Inrared thermometer measurements show
only a single hot spot at a time, which is
not enough or an accurate evaluation.
Thermal imagers show the ull picture
instantly, with dierent colours representing
dierent temperatures.
The Fluke Ti9 incorporates a thermal
imager lens with adjustable ocus
and detects a wide -20C to +250C
temperature range. There is a 23 x
17 viewing angle and a minimum ocus
distance o 15cm. Small details are visible
in a perectly ocused image. The IP54-
rated Fluke Ti9 resists dust and water, andwithstands a drop test o 2 metres.
Fluke SmartView sotware, eaturing
3D imaging capability and options or
optimising and organising thermal images
and creating proessional reports, is
included with the product as well as a 2GB
SD memory card, a rugged hard carry
case, a sot transport bag, an adjustable
hand strap (or right- or let-handed use),
a rechargeable internal battery, AC power
supply/battery charger (including mains
adapters)
7/31/2019 EMS Aug 2012 Full Low2
29/52
29Engineering Maintenance Solutions
Thermal Imaging
A FLIR T425 thermal imaging camera supplied
by Bedord-based Thermascan has taken time
out rom its usual predictive maintenance and
condition monitoring duties to provide artistic
images o British elite athletes.
The thermographer in this instance is Penny
Crots, a talented artist whose work was recently
shown at the Expo Fine Art Gallery at Heathrow
Terminal 5. Over the last year Penny has met
several athletes at the top o their game to
create a body o artwork that orms a legacy or
Britains sporting endeavours and achievements
during 2012.
Penny Crots trained at the prestigious art
school, Central St. Martins. It was her previous
training as a nurse however that red her interest
in the artistic representation o the human body.
She ound that thermography has given her a
unique way o expressing this interest and her
Gold Medal TermographyWe all know the application scope or thermal
imaging is expanding all the time but here is a newaddition that is particularly topical.
subjects incredible athletic commitment.
The paintings are acrylic on canvas and based
on thermal images o rowers, Mark Hunter MBE
and Steve Williams OBE, the tri-athlete Nick
Beer and the GB sailing team.
FLIR Systems Ltd., 2 Kings Hill
Avenue, Kings Hill, West Malling, Kent
ME19 4AQ
Tel: +44(0)1732 220011.
Fax: +44(0)1732 843707.
Email: [email protected]
7/31/2019 EMS Aug 2012 Full Low2
30/52
30 Engineering Maintenance Solutions
Thermal Imaging
ransmission Values: What o Look For...In Order o Look Trough!
By Joe DeMonte
ASN/PdM Termal Inrared Level III
Purpose:
The purpose o this paper is to educate on the subjects o:
1. Transmission values or inrared windows: Does a high value equal more
accuracy? Or, is knowing the percentage o transmission more important?
2. Transmission values or inrared windows: How does a grill eect
transmission? Will it make quantitative thermography null and void?
ested Components:One electrical lug and one hot plate heated to steady state conditions. One
polymer inrared window with a mesh style saety guard and one crystal calcium
fuoride (CaFl) inrared window. One generic plastic garbage bag. One stainless
steel cup lled with water and heated to steady state conditions.
Tools Used During the Test: FLIR E50 thermal imager, thermometer
Denitions:
Transmission, transmissivity: The ability o light in the specied wavelength to
pass through an object. Example: visible light through a pane o glass, LW
inrared light through a polymer inrared window.
Thermography: is a technology that creates and analyzes images by detecting
the heat radiating rom an object.
Quantitative Thermography: Analyzing thermal images by acquiring temperature
values. Qualitative Thermography: Analyzing thermal images without acquiring
temperature values.
Steady State Conditions (Heat Transer): When heat transer is occurring while
the temperature o the objects involved do not change.
LW/Long Wave/8-12um: The waveband o most modern inrared maintenance
cameras. The metric unit micrometer/micron/um is used to measure the
wavelength.
Non-Gray/Selective Radiator: Most substances and materials will not keep
the same value o transmission, refection, and emission throughout the light
spectrum. This may result in dierent thermography cameras obtaining dierent
results when measuring the same material.
Introduction:
As an active thermographer and instructor or Inrared courses, Ive always
considered inrared windows as an exciting technology. In the 90s, there
werent many choices when talking about IR windows. Nowadays, we haveseveral. I will cover two major materials used in modern inrared windows:
polymers and fuoride crystals. Both have value or the particular band width
(reerred to as LW/Long Wave/8-12um) o inrared cameras that 99% o the
thermographers use during condition based monitoring.
Recently, I have been made aware o a rumor that polymer windows axed with
a mesh style saety guard cannot be used or accurate quantiable temperature
measurements. I had not considered this as an issue during my role as a
thermographer or heard o it as an issue rom the 100s o electricians that ran
our inrared program or TEGG Corporation around the globe. I decided that I
had better double check our methods and see or mysel i I had been doing
things incorrectly or years.
est Parameters
In order to measure transmission through a material, I will propose two
procedures. We have to remember that the results o the tests may not apply
to other cameras even with the same wavelength lters. This is primarily due to
inconsistencies o detector response curves across the waveband being used
and the non-gray selective radiator eects o most materials in that waveband.
Our transmissivity procedures:
How to Measure Transmittance with a radiometric (temperature measuring)
thermal imager:
Set your thermal imager up to measure apparent temperatures with e = 1.00
and distance (i you have that setting) to 0. Also, external window optics should
be o or 100%.
Heat up a metal target with a high emissivity target (electrical tape will work)
axed to it to a steady state condition. I would recommend at least 30C aboverefected temperatures.
Measure and set refected apparent temperature.
Measure target without the IR window. Note the temperature.
Measure target with window in place.
6. Adjust emissivity to set the camera temperature equal to the original temp
without the window. This is NOT the emissivity measurement o your window.
We are using the cameras emissivity as a loss calculation and calculating
the losses through the window. The emissivity value you arrive at to reach the
original directly viewed target temperature equates to the transmission o the IR
window.
OR
For cameras that have EXTERNAL OPTICS TRANSMISSION, this procedure is
a little bit more accurate. Heat up a metal target with a known emissivity target
axed to it. About 30C or more above refected temperature is desirable.
Measure the actual temperature o the target. Example: with electrical tape,
set e = 0.95 and measure and set Refected Apparent Temperature. Note the
temperature.
Measure target with window in place.
Adjust external window optics temperature to the temperature o the window
(the window is best kept at room temperature).
Adjust external window optics transmission until you reach the actual
temperature o the target as measured without the window in place. The value
o transmissivity that you arrive at to achieve the original temperature is the
transmissivity o the IR window.
7/31/2019 EMS Aug 2012 Full Low2
31/52
31Engineering Maintenance Solutions
Thermal Imaging
Question 1:Does a high value equal more accuracy? Or, is knowing the
percentage o transmission more important?
I will compare the results o a household garbage bag to a industrial strength
polymer inrared window and a crystal window. The polymer window should
have a lower transmission value due to the thickness/type o polymer and the
reinorcing saety grill. The garbage bag should be relatively high. The crystal will
be lower than the garbage bag.
Here are the results:
From the tests above, the 3 round polymer inrared window with a saety grid
has a transmissivity o 0.46. Applying that result to an entirely dierent target
and checking that result to a contact thermometer, we nd the ollowing:
My initial ndings were that it appears we can use the known transmission
value, even though it is only 46%, and continue to perorm quantitative
thermography. Will this be the transmissivity value that all inrared cameras
measure through this style IR window? Absolutely not! Perhaps this was the act
that led to some o the conusion in the industry.
On to the plastic garbage bag....
The test on the single ply garbage bag with the 90C target shows a
transmission measurement o 0.83 or 83%. We will change out the target to a
metal cup with heated water and check the results with our same thermometer
or accuracy.
It appears that the original value o 0.83 transmission or the garbage bag holds
ater looking at a dierent temperature object. It is a high value o transmission,
but doesnt give us any more accuracy when perorming thermography over the
lower value (0.46) o the polymer/mesh window. In other words, know the value
o your window with regards to your thermal imager and dont worry about how
high the value is.
Continues on page 32
7/31/2019 EMS Aug 2012 Full Low2
32/52
32 Engineering Maintenance Solutions
Thermal Imaging
I will now test the crystal window. It has a viewing diameter o 68mm with a
thickness o 2mm. Using the same two heated targets, here are the results:
The crystal window has a transmission percentage o 0.43 or 43%. A little lower
than the polymer stacked with the mesh on this temperature target. I will now
look at the cooler target, the hot water in the stainless steel cup with electrical
tape axed to it.
At a transmission o 0.45 or 45%, we do obtain a slightly dierent value o
transmission in order to match the directly viewed result.
Fluoride crystals are very non-gray to the majority o thermal inrared cameras
used by thermographers (a concept that has been documented in many
papers). This means that the temperature o the viewed object will cause
the perceived transmission through the crystal to change when using long
wave inrared cameras. When we are trying to measure the temperature o an
unknown object, such as ound inside electrical cabinets, we cannot know the
exact transmission value to use in the camera. Because the actual value o
transmission, not how high the value is, controls our quantitative thermographic
accuracy, we normally cannot achieve accurate measurements or accurate
dierentials between two objects through that type o material.
I will show one more example o a high temperature target and the polymer and
crystal to urther the experiment on transmissivity values.
I I dial in the original 46% transmission value or the polymer/mesh window, I
get the correct temperature (within the IR camera manuacturer specication).
The crystal is a bit o and will continue to be urther away rom the actual
temperature as the objects temperature changes.
Question Number 2:
How does a grill/mesh aect transmissivity? Can I get accurate
results through an IR window that has a saety grill/mesh
installed?
So ar, our experiment has used a polymer window with a grill/mesh. When the
inrared camera is place up close to the mesh, the camera can ocus beyond
the mesh and was able to obtain consistency. I personally use the area max
measurement unction when viewing targets through IR windows and directly
viewed targets to keep consistency. Some instances dictate that I use a single
point temperature spot, and I preer inrared cameras that can do both or
fexibility.
To perorm this experiment, lets start by considering the grill. In my experience
looking through inrared windows installed in electrical cabinets, I nd that the
best/widest eld o view is when the inrared camera is close to the window.
The mesh, when installed, will be out o ocus and not look like a mesh on
the image. It will aect transmissivity values by lowering them, but again, we
are not so much concerned with a lower value. Even when using a non-mesh
window such as a crystal, normal operation will have the inrared camera closer
7/31/2019 EMS Aug 2012 Full Low2
33/52
33Engineering Maintenance Solutions
Thermal Imaging
to the window or a wider eld o view into the cabinet (see the ollowing visual
example). There is no need to have dierent procedures between the two types
o windows (mesh or non-mesh) based on this consideration.
I also want to document the eects
o viewing angle on transmission
when regarding mesh and non- mesh
windows.
My simple setup contains an electrical
component heated on a hot plate
or steady state purposes. The IR
polymer window with the saety grill/
mesh is installed into the side o a
box. It is approximately 8 away rom
the electrical component (outside the
minimum sae distance o 4 or 5kv
cabinets).
The same concept using a crystal window without a saety mesh/grill:
It appears that we have near identical eects rom both the polymer with mesh/
grill and crystal windows. It may be the oreshortening o the angle to the grill or
the polymer window, and it may be due to the increased thickness o the crystal
being viewed through or the crystal window. Another possibility is that the
overall Emittance o the target will change with angle and or the electrical tape,
it will lower as you approach 45 and beyond towards parallel with the surace.
Summary:
In the eld, a thermographer is always going to move the
camera slightly to obtain the best picture. I would always
recommend this regardless o whether you are looking
through a transmissive material or directly at the target.
Consider your inrared window materials careully and
check your sources. I have personally heard seasoned
thermographers make statements that a grill or mesh will
not allow or accurate temperatures. Or that the higher
the transmission, the better the window. In our study, we
have determined that both o the tested material windows
have similar transmission values or our specic inrared
camera (2011 FLIR E50). Te crystal window will vary
the transmission as the temperature o the object changes.
I a thermographer decides to back the camera away
rom the inrared window in his/her surveys, the mesh
may not aect the transmission that the camera sees
through the window. Te transmission values will be
much higher (again, knowing the value is important, not
how high the value is), but are still measureable as long as
the openings o the mesh are not smaller than the overall
IFOVmeasureable (also known as Spot Size Ratio) o
your specic camera. I would not recommend this only
because o the much smaller overall eld o view you will
have during your inspections versus being close to the
inrared window.
7/31/2019 EMS Aug 2012 Full Low2
34/52
34 Engineering Maintenance Solutions
Dew Point Hygrometer
It is the smallest and among the lightest instruments
on the market which is capable o measuring dry dew
points precisely to -90C (0.1ppmv) with no need or
additional, external cooling equipment. Combined with
its 0.1C accuracy this also makes it the most cost-
eective as well as convenient hygrometer in its class.
Chilled mirror hygrometers have excellent accuracy and
repeatability because they base their measurements
on the actual ormation o condensed water or rost
on a mirror surace. This is a primary characteristic o
moisture so will not drit over time, as can occur with
calculated or inerred variables.
The S8000 RS has a sophisticated new optical system
that detects very small changes in moisture condensed
on the mirror surace. This guarantees high sensitivity
and ast response when measuring low-dew points. As
with all Michell chilled mirror hygrometers, the S8000
RS is available with UKAS accredited calibration
traceable to NIST.
With a high-contrast LCD touch-screen, the S8000 RS
is easy to operate and interrogate. USB or Ethernet
connections are supplied as standard to enable remote
operation and data logging via a PC or network.
The robust overall design and practical eatures like
alarms make the S8000 RS Reerence hygrometer a
multi-purpose tool or a wide range o applications in an
industrial environment as well as or calibration acilities.
Michell supplies precision hygrometers and is the
largest dew point sensors manuacturer in Europe.
Their reerence chilled mirror hygrometers, such as
the S8000 RS, are constantly in use within their own
actory or dew-point sensor manuacturing, and their
24/7 calibration acility and service. Michells customers
benet rom the robustness and 40 years o expertise
built into each chilled mirror hygrometer design.
Key applications or the S8000 RS include:
Reerence instrument or calibration laboratory.
Compact, light and needing no additional
cooling it is ideal or small in-house calibration
laboratories.
Veriying the purity o industrial gases. Its ast
response and high sensitivity enables quick
measurements to be taken.
Ensuring the dryness o controlled industrial
environments.
New Fast and Easy to Use Chilled Mirror Hygrometer or Low
Dew Point Reerence Measurements in the Lab and Industry
Michells new S8000 RS has been designed to provide undamental, dependable
measurements in a range o industrial applications where highest precision o the
dry gas measurement is critical and the ease o use is essential.
The TopTherm range o packaged chillers, which
is suitable or a cooling medium o water, are
intended or internal applications and include
wall-mounted, roo-mounted or foor-standing
and modular variants.
Rittals TopTherm wall-mounted chiller, which
may be installed directly to an enclosure, has
a cooling capacity o up to 4kW, whereas
the roo-mounted or foor-standing variant is
available with a slightly larger cooling output o
up to 6kW. Finally, the modular chiller, which is
capable o removing up to 40kW o heat, utilisesthe renowned TS 8 rame so that it can be
seamlessly integrated into a suite o enclosures.
The unique construction o the TopTherm
modular chiller allows the simple replacement o
rerigerant and hydraulic modules. In the event
o ailure, modules o the same type can be
exchanged quickly. Those o dierent capacities
can be substituted should a greater amount o
cooling be required, eectively making it possible
to upgrade the chiller in situ rather than replace
it in its entirety.
Packaged chillers rom the Rittal foor-standing
enclosure range are suitable or internal or
external applications and or a cooling medium
o either water or oil. The robust, yet highlyadaptable platorm ensures that there is a
solution rom this range that can satisy most
project specic requirements.
Rittal Chillers For Te Industrial MarketRenowned more or their enclosure cooling equipment
in the eld o climate control, Rittal also supply chillers
to the industrial market.
Rittal chillers can be used to supply chilled
water not only to the cold plates, wall-mounted
and roo-mounted ranges o air/water heat
exchangers available rom Rittal, but also to
the multitude o industrial processes or which
cooling is essential. All Rittal TopTherm chillers
are able to accept either a 50Hz or 60Hz supply,
resulting in global applicability.
Industrial Cooling
7/31/2019 EMS Aug 2012 Full Low2
35/52
7/31/2019 EMS Aug 2012 Full Low2
36/52
36 Engineering Maintenance Solutions
Shows & Exhibitions
2012 set to be largest ever
UK composites event
Ian Stone, Managing Director o show
organisers UK Tech Events comments:
Year on year we are seeing very strong
growth in both the volume o speciality
exhibitors rom the UK and overseas
as well as expanding and more diverse
industry attendee groups. With the show
seeing major growth in both its ootprint
and the number o exhibitors, the 2012
composites show foor is already attracting
a major infux o new international and
domestic exhibitor names, including,Azelis Composites, AIM Composites,
LAMILUX-Heinrich Strunz, PECOLIT
Composites, Matrix Composite Materials,
Axson Technologies, Ipeco Composites,
Zoteoams, Natural Perormance Materials,
Cygnet Integrated Solutions, Mirka
(UK), Cutwel, Permabond Engineering
Adhesives, Hydromar, Engis UK, Intrinsys
to name but a ew.
With an increase in international exhibitors
signalling a growing desire to reach the
UKs developing composites market, plus
a high proportion o repeat exhibitors
increasing stand space or larger displays,
it is likely that the show will see total
composites exhibitor numbers reach 200+,
representing an impressive 35% growth.
Stone continues: The demand across
product design and development
teams or lightweight, high perormance
composite materials solutions is growing
at an unstoppable rate and the show is,
uniquely and importantly, positioned to
showcase the diversity o composites
materials, design, processing and
abrication capability as well as supporting
inrastructure available to harness or
the successul execution and delivery o
current and uture composites engineering
programmes
Growing strategic input rom
CompositesUK
Refecting the growing importance o the
show as the UK composite industrys
biggest networking and technology transer
opportunity, CompositesUK, headline
industry partner or the event, will in
2012 host their annual Composites UK
awards alongside the event on the rst
evening, acknowledging key advances and
innovation made by UK companies over
the past 12 months. Supporting the 2012
nominated awards, the show foor is to
eature a showcase o award nominated
composites engineering excellence with
supporting project insight presentations,
as part o the two day open orum
programme. Furthermore, CompositesUK
are again committed to hosting a
selection o on the show foor open
technology sessions, drawing on expert
contributions rom across the industry in
CompositesUK o Host Session On NonDestructive esting O Composites At
Te NEC Tis NovemberBuilding on the success o last Novembers
(2011) Composites Engineering show,
held at NEC Birmingham, the 2012 event
promises urther signicant growth and
to again bring together all sides rom this
rapidly expanding technology sector, around
the event which will this year be moving to
Hall 1 at the NEC on 7-8 November, 2012.
7/31/2019 EMS Aug 2012 Full Low2
37/52
37Engineering Maintenance Solutions
Shows & Exhibitions
processing innovations, new technology
and developing applications not least
in addressing the latest processes and
capability related to non destructive testing
o composite materials.
In parallel will again be the CompositesUK
hosted daily UK composites industry
overview sessions highlighting advances in
and priorities or UK composites capability,
crucial by sector market outlooks,
skills outlook and latest developments
in the UKs composites industry support
structure including the launch o the
UK Composites Hub, the UKs integrated
inrastructure support harnessing the
collective resources o the National
Composites Centre (NCC), Composites
Skills Alliance , and CompositesUK. Dr
Sue Halliwell, Secretary or CompositesUK
observes: Over the past ew years,
Composites UK has worked closely with
Composites Engineering to promote and
raise the prole o the UK Composites
industry and ensure the show continues
to develop and grow to refect our
homegrown capability and expertise.
The 2012 show promises to be bigger
and better than ever and sends a clear
statement that the UK composites industry
is open or business.
Part o the growing Advanced
Engineering UK group o
events, including new UK
Automotive Engineering show
As part o Advanced Engineering UK
group o events, one o the astest
growing B2B industry events in the UK,
the 2012 Composites Engineering Show
will again co-locate alongside the UK
Aero Engineering show, providing perect
synergy, given the enormous importance
o the aerospace composites market in
the UK. This was refected in 2011 with
excellent numbers o attendees rom
major players including Airbus, GKN, BAE
Systems, Bombardier, EADS Astrium, GE
Aviation, Rolls Royce, Honeywell and many
more.
Furthermore 2012 sees the introduction
o the UK Automotive Engineering Show
into the Advanced Engineering UK group
o events. This addition will support
a urther exciting synergy, driving an
exponential rise in the numbers o volume,
niche and motorsport engineering teams
attending the show and building on the
already impressive 2011 CompositesShow automotive and motorsport
sector attendance. With an attendance
approaching 7,000 in the 2011 group
o events, and an anticipated 9,000+
attendees or 2012, the Composites
Engineering Show is bracing itsel or
another record turnout and to consolidate
its credentials as THE meeting point or all
sides o the UK composites industries.
est Measurement &
Inspection Focus
Another key growth area at this years
Advanced Engineering UK group o events
has been testing, measurement and
inspection - so much so that there are now80+ exhibitors involved in this area on the
show foor, together with a dedicated seam
o related technical presentations over the
2 days o the event, aimed at all parts o
the testing liecycle, including Maintenance/
atermarket, and MRO teams. The Test,
Measurement and Inspection Focus spans
all 4 co locating events and is supported
by BiNDT, Chartered Quality Institute, Mira,
and QMT magazine
For more inormation on the
Advanced Engineering UK group
o events held this November
7-8 in Hall 1 o the NEC,
Birmingham - visit http://www.
advancedengineeringuk.com
7/31/2019 EMS Aug 2012 Full Low2
38/52
38 Engineering Maintenance Solutions
7/31/2019 EMS Aug 2012 Full Low2
39/52
39Engineering Maintenance Solutions
Energy Management
Wigan Inrmary is a redeveloped and modern
District General Hospital situated in Wigan. The
hospital, part o the Wrightington, Wigan and
Leigh NHS Foundation Trust, provides a base
or emergency and acute work. Steam is used
by the hospital or a wide range o services
including the various plant rooms heating & hot
water heat exchangers, space heating, AHU
batteries and humidication.
Prior to the installation o the GEM steam traps,
the hospital ound that a percentage o its steam
traps were ailing each year. Thermal Energy
International conducted a survey o the hospitals
steam traps using an inrared thermometer. It
ound that two percent o the traps had ailed
to open, allowing large amounts o expensive
steam to be wasted, one percent had ailed and
was partially open allowing smaller amounts
o steam to pass and a urther two percent
had ailed and closed which was causing the
condensate to back-up and create wet steam,
corrosion problems and water hammer. It was
calculated that Wigan Inrmary was losing a total
o over 200,000 kWh per year rom steam loss
alone.
Wigan Inrmary Expected o Save Over 48,000
A Year Following Installation O Gem Steam raps
Te Royal Albert Edward Inrmary in Wigan, better known as
Wigan Inrmary, anticipates it will avoid spending 48,847 per
annum in uel and maintenance costs ollowing the installation o
Termal Energy Internationals GEM venturi orice steam traps.
A total o 157 GEM steam traps have been installed throughout
Wigan Inrmarys site providing the hospital with a projected
payback in just under two years on steam savings, increased
efciency, ailed traps, maintenance and Carbon Oset Value costs.
According to research carried out by Queens
University, Belast, GEM steam traps have
been proven to be the most ecient desi