+ All Categories
Home > Documents > EMS_DEC-full_d2_med

EMS_DEC-full_d2_med

Date post: 28-Apr-2015
Category:
Upload: michael3511
View: 30 times
Download: 2 times
Share this document with a friend
52
Electricity Company Practices What It Preaches Page 16 5 - 7 12-19 24-27 Maintenance Best Practice Condition Monitoring Feature Boilers & Burners Feature December 2012 $6.80 £4.16 5.00
Transcript
Page 1: EMS_DEC-full_d2_med

Electricity Company Practices What It Preaches Page 16

5 - 7

12-19

24-27

Maintenance Best Practice

Condition Monitoring Feature

Boilers & Burners Feature

December 2012$6.80

£4.16

€5.00

Page 2: EMS_DEC-full_d2_med

Based in Manchester, we supply GRP grating non slip flooring constructed from fibreglass, as an ideal and cost effective alternative to traditional grating materials like wood, mild steel and stainless steel. Our fibreglass grating is exceptionally slip resistant and the gritted and concave anti-slip grating offers excellent traction in wet and icy conditions.

GRP Grating Systems fibreglass grating can also be supplied in various resin finishes to allow for many and varied applications such as offshore where fire resistance and low smoke are critical or environments where highly corrosive chemicals are present.

Fibreglass grating is formed using continuous interwoven glass fibres as reinforcement material and resin as the matrix with continuous solidification through a mould system. The uniform construction provides excellent bi-directional mechanical properties. It is beneficial to all industries whether it be chemical, pharmaceutical, offshore or leisure to name just a few with many applications like platforms, floorings, walkways, trench covers, ramps and cable trough covers.

We like to think of ourselves as a unique one stop shop facility offering customers outstanding service and quality products. We now offer the following.

• Full in house supporting steelwork design and fabrication.• Full in house GRP Grating and walkway design and

fabrication.• Design, drafting and detailing services.• On site installation, assembly and erection services.• Project Management and support.

Page 3: EMS_DEC-full_d2_med

34-39Industrial Cooling feature - Cooling Tower Safety & Maintenance

P:5-7 Maintenance Best Practice

P:12-19 Condition Monitoring Feature

P:20-23 Product Spotlight

P:24-27 Boilers & Burners Feature

P:47-50 Buyers Guide

Maintec preview ( Extra print run )

CMMS

Compressed air

Seals & Bearing / Lubrication

Pumps / Values

Health & safety

Training.

Contacts

Publisher

Michael Dominguez

Editorial

editors/contributing: Jon Barret, Christer

Idhammar

Advertising

Paul Clappison

Paul Miles

Brian Simpson

Steve Aslett

Production

Tom Britten

Email

[email protected]

Website

www.engineeringmaintenance.info

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

Page 4: EMS_DEC-full_d2_med
Page 5: EMS_DEC-full_d2_med

5Engineering Maintenance Solutions

Maintenance Best Practice

First I like to tell you about myself and from what

perspective I write this series of articles. My world is

process industries such as Iron, Steel, Pulp, Power

and Wood based industries such as Oriented Strand

Board (OSB), medium Density Fiber (MDF), Chemical,

Oil and Gas, Food and Beverage etc. In short all

industries where a break down of critical equipment

assets results in risk for environmental damage,

personal injury, lost quality and volume in throughput

or high costs for maintenance. I lose some of my

important arguments if reliability is not important

because then the maintenance organization has no

“revenue”. If reliability is not important the sense of

urgency and importance in the work we do, as a

maintenance organization is not there.

When I was a very young man I signed on a big

oil tanker as an apprentice in the engine room.

After nine years of maintaining and operating huge

powerful diesel engines that were 33 feet (10 meters

tall), pumps, compressors, lubrication oil and fuel

separators, hydraulic stabilizers, heat exchangers,

fans, sewage systems, boilers etc. I had also

graduated as an engineer.

When I first came to work in a big industrial plant

in 1968 to train people in preventive maintenance

and help set up a computerized maintenance

management system I wondered how I would

manage to do that with my marine background.

My first reaction was that equipment is equipment

and it was not much different than what I had

operated and maintained at sea. The difference was

more that in an industry I could call for help if needed.

Onboard a ship you had no one to call, you operated

and maintained with a very limited crew. Another

difference was that onboard a ship it was a way of

life to constantly inspect equipment and to keep your

area of responsibility very clean and organized. You

also had to get all work planned for execution in next

port.

I realized later in life that this was a very good

background because you managed a crew, operated

equipment, planned work, scheduled work and also

executed work. Reliability was very important to

everybody because it was obvious that you did not

want to have unreliable equipment operating a fully

loaded tanker in a storm or entering through the Suez

Canal and other critical passages.

International PhenomenaToday I work on a worldwide arena and observe the same problems, or improvement opportunities, in all countries and all type of industries. If you have worked as a reliability and maintenance professional in many industries and/or countries you also know that this is true. If you only worked in one plant you believe that you are unique and different than all other plants but that is very seldom the case. The reason why reliability and maintenance management is so similar between different types of industries and facilities lies in a couple of facts.Equipment does not break down, components such as; gears, couplings, control valves, transducers, seals and bearings break down. The whole equipment e.g. a compressor does not break down. These components are the same with some variations in all industrial plants. The environment they operate in is different but if an electric motor is covered by chocolate, saw dust or pulp the consequence is the same: it will overheat and shorten electric life dramatically. Some plants have a more aggressive corrosive atmosphere but again the consequences of corrosion are the same.Reliability and maintenance management is driven by the system and processes people work in, not by the physical assets the organization maintain. There are some differences that make implementation and execution of best reliability and maintenance practices more or less difficult. These are more cultural differences and it is important to know and understand these. They include but are not limited to:Political Systems make a difference in e.g. how profits are calculated.Taxation rules make a difference in how life cycle costs are calculated.Living standards are different between countries. In many countries with high living standard I often find a culture of entitlements and complacency and less of a desire to improve than in other countries where people are eager to learn and improve their

performance.Labor laws, working hours and employee benefits and unionization are very different between countries.Some industrial plants have many short and long shut downs others have no scheduled shut downs. This fact only changes the way you plan and schedule work that requires equipment to be down to do work. If your plant has scheduled shutdowns you must plan work before you schedule work to be efficient. If your plant has no scheduled shut downs, or if it is easy to shut down and start up again, then you should focus more on planning and execute planned work when the opportunity to access physical asset can be done safely and at best opportunity from manufacturing point of view.

But the system, processes and practices used to manage reliability and maintenance are not different. Nor have they changed in the last fifty or more years. What has changed and improved dramatically is technology including much better and more affordable computer systems and tools for condition monitoring. We have much better and more affordable equipment for measurements and analysis of component condition such as:

• Infrared cameras.• Wear Particle Analysis.• Vibration Analysis.• Acoustic Emission• Alignment of components.• Stroboscopes.• Ultrasonic methodologies.• Etc.

All these technologies existed before the 1960s but

they have become much better and more affordable.

The Essential Elements of Reliability and Maintenance Management. – Part 1

Execute them and you will get guaranteed results.

By Christer Idhammar

Founder and Executive Vice President

IDCON INC, Raleigh NC, USA

www.idcon.com

Figure 1.

The System

The market drives the production plan and

all maintenance work requiring shut down

of equipment must be coordinated with the

production plan for best time to be executed.

When maintenance work is planned and then

scheduled you have set the process people

work in right so they can execute work much

safer and more cost effective. To plan work

Page 6: EMS_DEC-full_d2_med
Page 7: EMS_DEC-full_d2_med

7Engineering Maintenance Solutions

Maintenance Best Practice

Do the Basics better and better

My advice is to never forget to improve execution of

the basics of maintenance. This was true 50 years

ago and it is still true. Too often we complicate things

beyond what is necessary. In the field of reliability and

maintenance many tend to give new names on what

in the end anyway comes down to the basics. TPM,

RBM, VDM, QCC, RCM and many other acronyms

lead to confusion in the message you need to send

to your employees in the maintenance organization.

If you mix up where all these tools and concepts fit

in with your strategy your organization will soon start

talking about the “Program of the month” and they

lose faith in you as a leader.

Anyone who have attended any conference, including

conferences covering the subject of Reliability and

Maintenance, have heard several speakers referring

to Albert Einstein’s definition of insanity:

“ To do the same thing over and over and expecting

different results”

This might hold true if you do the wrong thing

over and over. However if you do the right things

better and better over a long period of time you will

generate substantial results.

I know from a very long experience in industry that:

“Guaranteed results will be achieved by executing the

basics of reliability and maintenance (the right things)

better and better forever.”

The basics are perhaps not as glorious to talk about

as many would like them to be but I find them

very interesting and challenging because I am still

interested in people and equipment and the fantastic

results that can be achieved when an organization

execute these well. Results can even be life changing

for some people. Organizations today are spending

way too much time on other more complex initiatives

and therefore forget where the true improvement

potential lies.

The basic elements of reliability and maintenance are:

• Maintenance Prevention

• Inspect

• Prioritize

• Plan work

• Schedule work

• Execute work

If you do not Execute these things very well you

will never have time to do what you know you need

to do to become as reliable and low cost as you

can be. I stress the word Execute because most

organizations know what they need to do but very

few do it. So many strategies and improvement plans

are developed and so little Execution of the very

basic elements of reliability and maintenance occur.

Figure 2.

Within the process called Planning and

Scheduling each step consists of a number

of elements. E.g. best practice within the

work request process is that the request is

not a work order and shall be done using the

Computerized Maintenance Management

System (CMMS), the requested priority shall be

done according to a priority guideline agreed

to between operations and maintenance, The

object identity shall be clearly described verbally

and with equipment number, etc. per figure

2. These elements are what we call the right

things to do.

Figure 3. Many organizations are spending much time to develop and document a reliability and maintenance strategy and not much time to implement and execute this strategy. Many will even change the strategy when a new key manager arrives. This is not uncommon. It is quite obvious that a strategy must be executed otherwise it served no other purpose than to keep people busy developing it. Best organizations execute a well defined, documented and continuously communicated and reinforced strategy and the strategy is long term and does not change when new key managers are employed.

efficiently you must have access to an up

to date technical database including Bills Of

Materials (BOM) and other information. After

work is completed it should be recorded as to

what was completed, parts and material used,

update information to BOM and other valid

information. The recorded information shall

be used to continuously improve using Root

Cause Problem Elimination (RCPE). However,

most organizations do not work in this “Circle

of Continuous Improvement” they work more

in the “Circle of Despair”. This means that they

React, Repair with low quality because of the

reactive mode and therefore will have to Return

to do the work again and the circle Repeat

itself. To get out of this “Circle of Despair” you

must set up the processes for Prevention,

Condition Monitoring, Prioritization, Planning

of work, and Scheduling of work, Execution of

Work, Recording of executed work and how to

do RCPE.

The Processes

An example of a process is Planning and

Scheduling, or the Work Management Process.

It contains several steps and starts with Work

Request then Priority of Request etc. as seen

in figure one.

The ToolsThe tools are used to improve the processes

and enable and enhance how well you can

execute the processes. It is very important

that Processes and Tools are not mixed up.

To be successful you must have a very well

established system including its processes.

Tools are good and very useful when used in

the right environment. Implementation of only a

tool will only result in temporary improvements.

The system and processes must be in place

to support sustainability and continuous

improvement.

The next steps to do to become as good as you can

be include:

• Root Cause Problem Elimination

• Apply Life Cycle Cost when specifying

equipment

• Design for Reliability and Maintainability in early

equipment design

• Use tools such as 5S, Single Minute

Exchange of Dice (SMED), Reliability Centered

Maintenance methodology (RCM), to enhance

performance of work within the processes that

build the whole reliability and maintenance

system

A holistic overview of the reliability and maintenance

management system, processes, elements and tools

can be described in the models per figure 1 and

figure 2.

The structures of system, processes and elements described above are what we call Current Best Practices (CBP) for reliability and maintenance. If you do an audit it is on the level of elements that you evaluate and discover improvement potential and the gap between how good your organization is and how

good it can become. A good advice is to only focus on the right things to do and not discuss how you can do these things. That comes as the next step. The reason for this is that the first step must be to agree on the right things to do. Because the elements are all common sense, we know from a very long experience that your organization will agree. They might not agree on how you are going to implement these elements. As a leader you must show what your beliefs are and give your organization a direction and that is what you do here. Then you bring your organization with you to help execute your strategy. You can say that the well described 245 elements comprises a very well documented reliability and maintenance strategy and if this strategy is not executed you have wasted money and time to develop it. Figure 3 shows what we often find in many organizations.

Page 8: EMS_DEC-full_d2_med

8 Engineering Maintenance Solutions

Pump Excels in Polyurethane ProductionPumping Polyols and Isocyanate.

Isocyanates, when exposed to air, tend to form crystals that generate premature wear

in pumps with dynamic seals while Polyols, especially those containing abrasive fillers,

are equally as destructive to seals and bearings. The Hydra-Cell multi-diaphragm

pump has no dynamic seals and consequently handles abrasive particles with ease,

significantly reducing maintenance costs.

Now with new PTFE diaphragms,

chemical compatibility and service life are

no longer concerns. Hydra-Cell pumps

with these new diaphragms have been

tested extensively and shown to be

able to operate reliably at full flow under

flooded suction conditions.

Meeting the performance standards of API 675, Hydra-Cell pumps are highly

accurate and repeatable, ideal for dosing and injection duties. Being completely

contained, without dynamic seals, they provide no leak paths for potentially harmful

chemicals and their multi diaphragm design ensures low shear, low pulsation delivery.

“The service life of the new PTFE diaphragm is now extended to 240 million cycles;

4000 hrs @1000 rpm,” said Nick Herrington, Marketing and Technical Support

Manager. “This brings diaphragm replacement into line with regular maintenance

cycles.”

Wanner International has introduced a range of Hydra-

Cell multiple diaphragm pumps that it has developed to

meet the specific needs of polyurethane production.Garden Grove, California (30 October

2012) Sensorex’s TX-3000 pH/mV

Transmitter monitors changes in process

fluids, displaying pH or oxidation reduction

potential (ORP, measured in mV), and

temperature for more accurate control

in water, chemical, electronics, food

production, environmental and wastewater applications.

The line-powered TX-3000 can be user programmed on-site to measure

either pH or ORP (Redox). Its dual output design, with an isolated (0)4 – 20mA

output for pH or ORP readings and one for temperature measurement,

eliminates the need for a separate temperature transmitter. A large backlit

LCD screen displays both parameters simultaneously and two adjustable Hi/

Lo relay contacts deliver results to automated process control systems.

With an extended pH measurement range of -2.00 to 16.00, the TX-3000 is

suitable for a full range of applications. The NEMA 4x, IP65 enclosure can be

wall, panel, or pipe-mounted for easy integration in most installations. The TX-

3000 can be easily programmed onsite with its push button interface. The unit

can be password protected for secure installations.

To learn more about the TX-3000 as well as the company’s full range of

sensing products, visit www.sensorex.com, email [email protected],

or phone +1 714-895-4344.

Transmitter Displays and Controls pH and ORP Values for Process Monitoring

TX-3000 pH/mV from Sensorex provides real-time data

MAINTEC, the UK’s only show dedicated to industrial maintenance and asset management, challenged all those working in the industry and taking part in Movember, to share an image of themselves with their ‘Mo’. The images were then put in a special MAINTEC facebook album and assessed by a panel of judges.

Commenting on the judging process Katie Morhen, Marketing Project Manager for MAINTEC 2013 which takes place at the NEC in Birmingham on 5-7 March 2013, said: “We judged the mo’s based on growth, style and general flamboyance - with added ‘mo’ points awarded for photos taken whilst people rocked their mo at work. So as you can imagine, judging was a lot of fun! We had some great entries with, appropriately, lots of mo maintenance skills on show, but Nick was the clear winner.”

As his prize, Nick Pither received £100 from MAINTEC to put towards his Movember fund.

Movember, which takes place throughout November, is responsible for the sprouting of moustaches on thousands of men’s faces in the UK and around the world. The aim of which is to raise vital funds and awareness for men’s health, specifically prostate and testicular cancer.

Visitor registration for MAINTEC 2013 is free. To register visit www.easyfairs.com/maintecuk.

Stand bookings for MAINTEC 2013, which takes place on 5-7 March at the NEC, Birmingham, can be made by contacting Jerry Dawson on +44 (0)20 8843 8823 or email [email protected]. For further information visit www.easyFairs.com/MAINTECUK.

MAINTEC Announces Movember WinnerNick Pither, Technical Engineering Manager at Mixing Solution Ltd has won MAINTEC’s ‘Movember’ competition.

It has become the only manufacturer to offer a comprehensive range of non-hazardous engineering adhesives that cover the lion’s share of applications. Now there is even more choice however as this unique range is complemented by three hazard-label-free cyanoacrylates, more commonly known as instant adhesives.Clean and easy to apply, these adhesives are ideal where aesthetics are important. They are now the Loctite® front-line offering for very fast positioning and fixturing of parts. Classified non-irritant, these new additions provide even more benefits than their hazard-labelled forerunners.Their ability to join a wide variety of dissimilar materials extends to the bonding of porous/acidic substrates such as wood, paper, leather and cork as well as plastics, rubber and metals. The resultant shear and tensile bond strength is excellent even on very small bond faces.These new Health and Safety instant adhesives are colourless with low bloom and low odour. All have a typical fixture time of 5 – 20 seconds dependant on the substrates. As with all Loctite® instant adhesives,

HEALTH AND SAFETY INSTANT ADHESIVESWith successive introductions to its Loctite® Health and Safety range, Henkel has broken new ground.

these three new Health and Safety products are respectively optimised for specific application requirements. The most viscous is Loctite® 403, making it ideal for use where parts are not close fitting or where the product must not run or migrate.Loctite® 408 has very low viscosity and comes into its own where capillary action is required. It can therefore be applied to a joint with an interference fit to create an instant seal. Loctite® 460 has a marginally higher viscosity. All can be integrated into semi- or fully-automated production processes for which Henkel also markets a comprehensive range of dispensing equipment. For applications where special application characteristics are required, Henkel can call on its wider range of instant adhesives. As well as products for difficult to bond rubbers and plastics such as PE, PP, PTFE and silicone, the choices include a new product for gap filling and a new series for high temperature applications.

Web link for enquiries: www.loctite.co.uk

Latest Industry News

Page 9: EMS_DEC-full_d2_med

9Engineering Maintenance Solutions

Both MMA and MMB series cylinders

incorporate features such as removable glands

and separate bodies with detachable heads and

caps to ensure ease of maintenance and low

whole-life operating costs. Steel and aluminium

mills, paper mills and plastic injection moulding

machines are just some of the applications

where the cylinders can be used.

Parker’s mill cylinders are available in a wide

range of bore sizes up to 320mm diameter

and in stroke lengths up to 5 metres. Standard

features include precision ground, hard chrome

plated and polished piston rods, which are

induction hardened as standard on bore sizes

For more information, visit the

company’s web site at:

www.parker.com

Or its investor information web site at:

www.phstock.com

Parker’s ‘Mill’ Cylinders Deliver High Performance Under Harsh Conditions

up to 200mm diameter. Detachable threaded

flanges for head and cap retention simplify

maintenance, while heavy wall steel tubing

honed to a high surface finish ensures a long

seal life. Optional features include adjustable

cushions at both ends for shock suppression

and high speed cycling performance, air bleeds,

gland drains and special modifications for water

service. Where precise control over performance

and positioning is required, feedback devices

and non-contacting position switches can be

specified.

Mill cylinders can be used at operating

temperatures of between -20ºC and +150ºC and

generate up to a massive 2000kN, making them

the ideal choice for high force applications in the

toughest conditions.

Parker’s standard mill cylinders are available in two ranges.

The MMA series is rated at 250 bar working pressure and

conforms to ISO 6022 and DIN 24 333, while the MMB

series of 160 bar cylinders conforms to ISO 6020/1.

Above: MMA Series 250 bar ‘mill’ type hydraulic cylinder

Page 10: EMS_DEC-full_d2_med

10 Engineering Maintenance Solutions

The university is determined to reduce its energy bill while also cutting its contribution to CO2 emissions by targeting energy efficiency improvements across its teaching faculty buildings and other facilities.

David Blackman, Building Services Engineer in the University’s Building Services department says: “The University has a five year target to reduce its carbon emissions and this is one project we had identified as being capable of contributing to that. We worked on the premise that most of the air conditioning plant is overrated and that we could reduce the speed of the fans without affecting the air flow adversely.”

Blackman asked ABB Drives Alliance member Mid Kent Electrical (MKE) to investigate the potential for using variable-speed drives (VSDs) on air handling units (AHUs) in buildings on the Medway, Greenwich and Avery Hill campuses.

Russel Kimpton of MKE says: “Starting on the university’s Medway campus, we looked at the air handling equipment across several buildings and recorded motor and fan data. During our survey of the site we found that many of the fan units have rated speeds and powers less than that of the motors. These were either being run too fast or the speed of the motor is being reduced by the pulley ratios on the belts driving the fans. We were also told that when the original system was set up, airflow was adjusted by setting

dampers on vents at room level.”

MKE looked at air handling installations in the six buildings on the Medway campus – Blake, Hawke, Anson, Nelson, Grenville and Pembroke. Monitoring was carried out on the AHU3 fan motor in Anson. Over the two day test period, while running on normal direct-on-line operation, the 4 kW motor consumed an average of 3.353 kW, for a total annual running cost of £871. Running the motor for two days using an ABB ACH550 HVAC drive consumed an average of 2.087 kW at a total annual cost of £542.

These results were extrapolated to produce estimated savings for the motors in the other buildings, a total of 44 installations with a combined installed power of 127 kW. It was estimated that following the installation of VSDs on these fans, the fan applications would save some £10,472 a year in running costs, as well as reducing carbon emissions by over 57 metric tonnes per annum.

MKE recommended that the applications highlighted in the report should be fitted with ABB VSDs, a project which has now been completed. MKE also recommended conducting further investigations to establish the rooms served by each air handling unit and each extractor fan. This would highlight areas where additional savings may be achieved by further adjustment of both vents and VSDs.

Further investigation of the Greenwich campus revealed the potential to save £883 on the Dreadnought, Queen Mary and Stephen Lawrence buildings, with a corresponding reduction of four metric tonnes of CO2. The King William building on the Greenwich campus could save a further £1,157 a year, cutting CO2 by five metric tonnes a year.

Avery Hill campus could save £2,157 per annum in running costs with a cut in CO2 of 10 metric tonnes a year. Total monetary savings from these additional projects could amount to £4,197, with a total cut in CO2 of 19 metric tonnes.

Says Blackman: “We were looking for payback times on the projects of around five years, yet most were much quicker than that. We are very pleased with the outcome of the project and consider it very worthwhile doing. MKE are a good company to work with and there were no problems throughout the contract.”

ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 145,000 people.

University Of Greenwich Cuts £10,000 From Air Handling BillThe University of Greenwich is set to save £10,000 on its air handling costs across its three campuses following the installation of ABB variable-speed drives at a number of its buildings. Additional savings from further projects could cut running costs by another £4,000.

Latest Industry News

Precision Micro has become a centre of excellence in the design and production of such components using LEEP, a precision chemical machining process that incorporates laser technology.

Plates are profiled and channels generated simultaneously in a single etch process, before being stacked and laminar bonded, or simply held under pressure to form a functional matrix. Precision chemical machining imparts no mechanical or thermal stress on the plate that could compromise its planarity (flatness). Alternative manufacturing methods such as CNC milling, stamping or laser machining, can generate thermal distortion and machining detritus that can compromise stack bonding.

The versatility of the etching process enables designers to vary the sizeand shape of channels and incorporate headers, collectors and port features, knowing that they can be produced economically without the need for extra process steps.

A further benefit of the process is the ability to control the etchant chemistry, which in turn controls the non-directional surface finish within the channels.

As well as achieving a four-fold improvement in pitch accuracy across an 800mm x 600mm sheet of components, the LEEP process guarantees top/bottom side alignment of component features. This enables highly accurate channels to be produced on both sides of the plate, and also simultaneously. In this way high channel densities can be achieved, and by interlacing top and bottom side channels, stack heights can be minimised and thermal transfer improved.

LEEP produced channels enhance fluid management

Functional components that use etched channels to transport liquids are becoming increasingly popular in a variety of fluid management applications, such as diffusion bonded plate heat exchangers, mixers, reactors, heat sinks and fuel cells.

Southern Manufacturing & Electronics 2013

Southern Manufacturing is the UK’s premier marketplace for

industry and manufacturing, covering just about every aspect of

production and maintenance, including tools, consumables, safety

equipment, test & measurement, labelling, storage and many more.

See hundreds of top suppliers in one, easy to get to venue with free

entry and free onsite car parking. See presentations delivered by

an outstanding line-up of experts the show’s free technical seminar

programme; see live demonstrations of the latest equipment.

The UK’s top industrial technology exhibition

returns to FIVE, Farnborough, 13th & 14th of

February 2013.

Entry and seminar registration is free, quick and easy online

at http://www.industrysouth.co.uk You can also catch up

with all the news from the show at http://blog.industrysouth.

co.uk or by following #southmanf on Twitter and LinkedIn

Page 11: EMS_DEC-full_d2_med

11Engineering Maintenance Solutions

Page 12: EMS_DEC-full_d2_med

12 Engineering Maintenance Solutions

Condition Monitoring Feature

In conjunction with local agents AKA Vietnam,

Sensonics supplied transducers and a Sentry

G3 Turbine Monitoring / protection system for

the 110MW Russian built turbine operating at

the PhaLai Power Plant. These were for a wide

range of functions including; shaft position,

high / low pressure cylinder expansion, turbine

block expansion, shaft vibration and eccentricity

speed. The PhaLai site has two power plants,

an older facility with eight boilers and four

110MW turbines, all Russian built and a newer

facility with two boilers and two Japanese

manufactured 300MW turbines.

The ‘retrofit’ project was fairly complex and

included a number of variants which the

Sentry G3 system was required to monitor.

For example, Shaft position measuring and

monitoring, relative to the position between

the turbine shaft with the bearings. The system

also automatically protects the turbine when

the relative position is over the pre-set level.

Specifically, the turbine will be stopped when

the shaft move to the generator side 1.2mm or

when the shaft move to the turbine side 1.7mm

(-1.7mm to + 1,2mm). Other variants include;

high and low pressure cylinder expansion, with

both requiring an alarm signal.

Also, turbine block expansion to measure the

expansion of the turbine block relative to the

floor, specifically temperature from 55 to 65°C,

pressure from 15 to 20 kg sq/cm, vibration from

18 to 20 um and also oil vapour detection. For

shaft vibration and eccentricity, the sensor was

required to monitor speeds from 3 to 300rpm

when the turbine was started, with a unit of

measuring um (10-6 m). Finally, a speed sensor

covering the range of 0-4000 rpm (turbine rated

speed of 3000rpm) was required with 2 alarms

for over-speed of 10% and 16% in comparison

with the rated speed. Following the installation

of the Sensonics system on the older Russian

built turbine, engineers at the PhaLai plant have

been very satisfied with the performance and

as a result have asked Sensonics to quote on

additional monitoring systems for their Japanese

manufactured turbine.

The completion of the installation at the PhaLai

Thermal Power Plant in Vietnam project is

another example of continued success for

Sensonics in the Far East and underlines their

commitment to developing the most effective

solutions for vibration, position and speed

monitoring for critical machine condition

monitoring applications around the world.

Continued Success For Sensonics In The Far EastCondition monitoring specialists SENSONICS are enjoying

continued success in the Far East with new contracts for their

innovative Sentry G3, high performance sensor conditioning

and monitoring system. In addition to a number of successful

installations at power plants in China is another project in

Vietnam at the PhaLai Thermal Power Plant.

Further details are available from:

Russell King, Sensonics Ltd,

Berkhamsted, Hertfordshire, UK.

Tel: +44 (0) 1442 876833.

Fax: +44 (0) 1442 876477

Email: [email protected]

Web: www.sensonics.co.uk

Page 13: EMS_DEC-full_d2_med

13Engineering Maintenance Solutions

The IML lock uses an operating key to

lock the actuator in an open or closed

position so that the valve cannot

turn -- no matter what. No custom

brackets are required; any valve or

actuator with ISO standard mountings

is compatible with the IML lock.

In normal operations, actuated valves respond to process commands

in a pre-determined way. But during maintenance, the command

architecture may need to be stopped. Ensuring that the valves are

set in their failsafe position enables work to be done safely. The IML

intermediate lock is available as a key-operated system from the

control room or as a standalone lock-out system. Lock Boxes are

available with base tags that match up to each lock-out key for ease

of identification.

The IML lock is made of sturdy 3/16” stainless steel built for harsh

environments. All ISO 5211 patterns –F05, F07, F10, F12, F14, and

F16 – are covered by the IML’s six models.

Easy Mounting IML Lock eases Maintenance of Valves and Actuators

Smith Flow Control (SFC) has introduced its ISO-pattern IML intermediate lock with universal mounting.

For more information, please visit the company’s website at:

www.smithflowcontrol.com or call +44 (0) 1376 517901

Page 14: EMS_DEC-full_d2_med

14 Engineering Maintenance Solutions

Condition Monitoring Feature

In May 2012, FOR installed five FAG WiPro s

condition monitoring systems from Schaeffler on

five wind turbines at the Crystal Rig wind farm in

Scotland. These systems continuously monitor

the condition of the main rotor bearings, gearbox

and generators, with Schaeffler UK also providing

remote monitoring services on a 24/7 basis.

Crystal Rig wind farm is located on the Lammermuir

Hills, approximately 40km east of Edinburgh in

the Scottish Borders. When Crystal Rig wind farm

commenced operations in October 2003, it was the

largest onshore wind farm in Scotland, with a rated

output of 50MW. The hub heights of the Phase 1

wind turbines are 60m with a rotor diameter of 80m.

In phase 2, a further five wind turbines were

installed at Crystal Rig, bringing the total number

of turbines to 25, generating a total capacity of

62.5MW from May 2007.

Stuart Naylor, Operations Manager at Fred.Olsen

Renewables UK commented: “We are delighted

with the condition monitoring systems and remote

monitoring services provided by Schaeffler and we

look forward to continuing and further developing

this working relationship in the future. Back in

September 2011, when we were looking for a

suitable UK-based supplier, we found Schaeffler

to be extremely professional and competitive, as

well as demonstrating confidence that their system

could provide us with the most suitable condition

monitoring system. Additionally, Schaeffler offered

flexible training, remote monitoring and reporting

services to meet our requirement.”

Schaeffler’s FAG WiPro s is an online condition

monitoring system that is suitable for the permanent

monitoring of wind turbines. The system is

extremely compact, with the monitoring unit and

multiplexer integrated in a single unit, which offers a

high degree of flexibility for end users.

The system combines all control modules into

a single compact housing, which measures just

260 x 150 x 90mm, enabling easy installation in

control cabinets. The integrated multiplexer enables

the recording of signals from up to eight different

sensors.

FAG WiPro s monitors vibration conditions, which

if left undetected, can cause costly unplanned

shutdowns of wind turbines. These conditions

include damage to bearings and gears, as well as

shaft misalignments. If a specified threshold value

or alarm limit is exceeded, the system triggers

an alarm. The vibration monitoring data can be

analysed directly on site at the central control

station or this data can be retrieved via a TCP/IP

communications link and analysed by either the

end user or by Schaeffler. Integration of oil quality

(particles) as part of the monitoring is also possible.

“On each of the five wind turbines being monitored

at Crystal Rig wind farm, we’ve installed six vibration

acceleration sensors,” stated Dr Steve Lacey,

Engineering Manager at Schaeffler UK. “One of

these sensors is a special, low frequency vibration

sensor that monitors the main rotor bearing and

there is also a low frequency vibration sensor on the

input shaft to the gearbox. Two additional standard

vibration acceleration sensors are installed on the

power train gearbox, with a further two vibration

sensors on the generators. These sensors provide

us with 24/7 vibration data – including both time-

based and frequency-based vibration data – which

enables us to look for faults or to detect problems

early.”

“Since the condition monitoring systems were

installed in May, we’ve picked up a couple of

faults in the generator bearings and identified early

problems with some gears on a planetary gearbox.

These faults were confirmed by Fred.Olsen by using

fibre optic cameras [endoscopes] to look inside the

gearbox,” he added.

Schaeffler Provides Online Condition Monitoring Of Turbines At Crystal Rig Wind Farm

Bearings and condition monitoring specialist Schaeffler (UK)

Ltd has supplied five online condition monitoring systems to

wind farm developer and operator Fred.Olsen Renewables (FOR).

A further 20 condition monitoring systems from Schaeffler are

expected to be installed later this year on the remaining turbines.

For more information on Schaeffler’s

condition monitoring systems for wind

turbines, please call Schaeffler UK’s

Marketing Department on 0121 313 5870.

Alternatively, email [email protected]

Page 15: EMS_DEC-full_d2_med

15Engineering Maintenance Solutions

Page 16: EMS_DEC-full_d2_med

16 Engineering Maintenance Solutions

Condition Monitoring Feature

Quite simply, a more powerful camera allows an

image to be seen in far greater detail over distance.

And this is vital for the safe thermal inspection of

high voltage lines and substations.

For this reason the Electricity Supply Board (ESB),

Ireland’s premier electricity utility, uses FLIR P-Series

cameras. These state-of-the-art cameras were

supplied by FLIR Systems’ Irish distributor, Butler

Technologies in Maynooth. They have the highest

resolution detector in the predictive maintenance

market, thermal sensitivity of up to 30mk and come

with a wide range of built in features for efficient

thermal imaging and advanced analysis.

All four of ESB’s FLIR P-Series models have

interchangeable optics, so in addition to the

standard 24° or 45° lens supplied, each camera

was also ordered with a 7° lens. This provides

almost 3.5 x magnification by comparison with

the 24° lens and is therefore ideal for inspecting

overhead power lines.

There are of course many other applications

involved in maintaining the efficient running of a

substation that lend themselves perfectly to thermal

inspection. Some of these do not present any

arcing risk and can therefore be conducted safely

within a shorter range. It was for this purpose that

ESB sought a camera model that would provide the

same level of image detail as the FLIR P-Series at a

closer distance from the target.

“I conducted a trial on site with one of ESB’s senior

engineers whereby we compared the temperature

measured by his FLIR P660 camera with that

captured by a top-of-the-range FLIR i-Series

camera which I operated over a much shorter

distance,” explained David Doyle from Butler

Technology. “The results were the same. So

this camera was also approved for use, allowing

more ESB engineers to take advantage of thermal

imaging without the company needing to rely solely

on its FLIR P-Series cameras. It was a highly cost

effective solution.”

With the introduction of the new FLIR E-Series, ESB

has since been able to obtain even better camera

performance for its wider engineering community.

The original FLIR i-Series cameras have now been

replaced with the FLIR E50 and E60 models.

Standard features and high resolution belie the

entry-level status of these cameras.

Both have an integral 3.1 Megapixels visible light

camera, thermal fusion for merging visual and

infrared images for easier analysis and scalable

picture-in-picture that allows the user to clearly

identify areas of interest. A laser pointer is provided

as standard as is Wifi for the wireless transmission

of images to a smart phone or similar mobile device.

These models are also MeterLink enabled which

means they can receive measurement data from a

similarly equipped clamp meter.

Another significant benefit of this upgrade for

ESB is the ability of the FLIR E50 and E60 to

accept different optics. Whilst the 7° lens is only

suitable for use with the FLIR

P-Series, the E-Series can

be fitted with the 45° wide

angle lens or a telescopic 15°

lens, considerably broadening

application potential.

Electricity Company Practices What It PreachesWhen it comes to high voltage electrical inspection a

high end thermal imaging camera is undoubtedly the

best choice.

Making thermal imaging available to more ESB

engineers was certainly the driving force behind the

company’s second wave of thermal imaging camera

investment but it has now been able to extend this

privilege to its entire workforce.

The FLIR i-Series cameras supplied by Butler

Technologies are also the lynchpin in a brand

new award winning initiative introduced by ESB’s

Sustainability Team. Through this scheme, ESB

staff can borrow a FLIR thermal imaging camera

to learn how efficiently their homes use heat. A

phenomenal level of interest has been shown, with

over 320 staff registering within the first two weeks

of operation, necessitating the purchase of another

FLIR E-Series camera to meet demand.

The success of the scheme has been

acknowledged by Green Workplaces established

to provide a resource for likeminded companies

to share ideas on safeguarding the environment

and promote best practice. The organisation runs

its annual Challenge competition to recognise

excellence in endorsing environment efficiency and

this year it judged the ESB scheme a worthy winner.

Founder and Chief Executive of Green Workplaces,

Siobhan Hamilton said: “The ESB scheme provides

employees with a tool that assists them in their

personal space. And one of the best ways for

organisations to engage employees in workplace

sustainability initiatives is to show them how

they can make cost savings at home. This is a

scheme that could be adapted to work in other

organisations and community groups.”

FLIR Systems Ltd.

Tel: +44(0)1732 220011.

Fax: +44(0)1732 843707.

Email: [email protected]

Web Site: www.flir.com

Page 17: EMS_DEC-full_d2_med

17Engineering Maintenance Solutions

Condition Monitoring Feature

Today, test tools using Herschel’s infrared

discovery enable professionals in many

fields—security, healthcare, maintenance,

HVAC, automation, building inspection and

energy management—detect and fix problems

otherwise invisible.

Now a new innovation, the Fluke VT02 Visual

Thermometer—developed with British innovator

Infrared Integrated Systems Ltd, (Irisys)—is

bringing affordable infrared testing to technicians

who once had to choose between limited IR

thermometers and costly thermal imagers.

“The VT02 is genuinely a new category of

product,” said Tim Wheatley, Chief Technical

Officer for Irisys. “I don’t think it’s right to

compare it to either a spot radiometer or a

thermal imager. It’s neither of those things. It’s

very much a completely new style of product.”

Early infrared sensors detected infrared radiation

using single element detectors, and created

line images. The military learned to use these

infrared images to see targets, even in darkness

or smoke. But these early infrared sensors were

costly, and some types had to be actively cooled

to function.

A new type of uncooled sensor, the

microbolometer, was developed in the late

1980s. Now thermal imagers could be built

small enough to be hand held, at a cost more

users could afford. Today thermography is

widely used. Firefighters use it to see through

smoke. Installation and maintenance technicians

use thermography to detect faults in electrical,

mechanical and steam systems. Building

analysts detect air leaks and insulation faults.

Fluke and Irisys: a Legacy of Infrared Innovation

In the second quarter of 2012, Fluke

Corporation, a world leader in calibration and

hand-held test instruments, acquired the

privately-held British firm Infrared Integrated

Systems Ltd, (Irisys), to enhance the company’s

R&D capabilities in thermography. Founded

in 1996, award-winning Irisys is based near

Northampton in the UK. The company invests

a double digit percentage of revenues in R&D

and holds more than 70 patents. One in six

employees and one in three on the R&D team

has a PhD.

Both firms have a long record of innovation

in thermography. Fluke, world famous for the

durability of its test tools, offers both tough

infrared thermometers and a line of thermal

imagers designed for extreme field use.

Irisys used its expertise with infrared sensors

and software to create the field of ‘queue

management’, using heat sensors to count

gathering customers and software to predict

their likely behaviour. Irisys systems signal

retailers and service firms to add service staff

when queues grow long, or reassign staff to

other tasks when lines are short. The result:

greater productivity and happier customers.

“No-one asked us to invent queue

management,” said Irisys Technical Director

Lindsay Galloway. “We came up with

the concept because we developed the

technologies and saw a new way to use them.

Then we asked our customers, if we could do

this for you, would you buy it?” The answer was

yes, and Irisys still dominates the international

queue management industry.

Today Irisys continues developing new ways

to use thermography, with innovations in

security, healthcare applications and industrial

diagnostics. With the new Fluke VT02 visual

thermometer, the two firms have created a

thermography tool that sets a new standard in

performance per dollar, and puts thermography

in the hands of a broad new group of

technicians.

Your Time or Your Money

Until now, infrared testers were divided into two

categories: infrared thermometers and thermal

imagers. The low-cost (<£75) answer was the

infrared “point and shoot” thermometer, which

measures the average surface temperature of

a “spot” that varies in size depending on the

specification of the thermometer and its distance

from the target. Like other infrared testers, these

deliver the advantage of safety (taking readings

from a safe distance). They require little or no

training to master, and they are inexpensive

enough to provide one to nearly every

technician. But there are disadvantages.

Taking a detailed temperature profile of a system

requires the technician to see and write down

multiple temperature readings and record where

they were made. In addition, it’s hard to know

exactly how large an area or “spot” the sensor is

“seeing” and measuring.

Thermal imagers provide far more detail and

sophistication—at a price. A single image can

provide hundreds or thousands of individual

temperature readings, one for every pixel in view.

These pixels display a “heat map” that makes for

rapid identification of hot spot problems. Some

imagers make it possible to blend thermal and

visible light images, making it easier to locate a

problem. These images can be recorded, and

processed for viewing using software. But it

takes considerable training to get the most from

New Fluke Visual Thermometer Makes Infrared Imaging Affordable

Just over 200 years ago, the famed British composer and astronomer

Sir William Herschel discovered infrared radiation.

Page 18: EMS_DEC-full_d2_med

18 Engineering Maintenance Solutions

Condition Monitoring Feature

a thermal imager, and its cost (>£1500) means

most shops will have only one.

In some industry segments, such as heating,

ventilation, air conditioning and refrigeration, the

cost and training requirements have prevented

many from adding a thermal imager to their

portfolio. Shops that face the impending

departure of many senior technicians may resist

investing in thermography training for their

replacements.

Yet the value of infrared testing is unquestioned.

The answer: a new kind of infrared tester, the

visual thermometer.

The Head of a New Class of Infrared Testers

To fill the space between the two infrared

technologies, Fluke set out to design a product

to provide quick, easy temperature readings in a

visual context—one affordable enough that every

technician on a team could have one with him at

all times.

Traditional thermal imaging technology was not

the answer. Thermal imaging is based on the

microbolometer, which requires vacuum sealing

and very precise manufacturing that makes

it too expensive for this type of application.

Meeting the goals of affordability and ease of

use was going to require a new technology and

manufacturing approach. Enter Irisys.

“The approach that Irisys has used to develop

our infrared sensors is fundamentally different

from the standard bolometer technology,” said

Wheatley. “Basically, the microbolometer works

by having a resistance that changes when it’s

heated. That variable resistance is then read

out. The method that we use actually uses

a pyroelectric ceramic sensitive to changes

in surface temperature. It creates a charge

proportional to the change in temperature on the

surface of the device. It’s the charge, effectively,

that we read out.”

Pyroelectric technology costs much less to

manufacture than a microbolometer, but getting

it to form a thermal image was a challenge. The

most common use of pyroelectric technology is

in motion sensors, like those used in Irisys queue

management systems. But rather than creating

a thermal image, Wheatley said, signals from

queue management sensors detect changes

in temperature, and drive sophisticated artificial

intelligence algorithms that help merchants

respond to customer activity.

For the Fluke VT02, Irisys developed a unique

hyper-thin film on which it can manufacture an

array of elements dense enough to create an

image. This is the engine that drives the Fluke

VT02 Visual Infrared Thermometer.

Its multiple pyroelectric sensors enable the

Fluke VT02 to deliver far more than a single

temperature reading. The user sees a thermal

map of the test area that shows exactly where

the hot and/or cold areas are. The tester shows

the temperature at the centre crosshairs, and

the hottest and coldest spots in the image are

marked.

In addition, the Fluke VT02 can record a visible

light image of the test area. By combining the

thermal and visual views, the technician can

make it clear exactly where the thermal image

is recorded—and where any maintenance issue

can be found.

“Visible gives you a certain level of information

that you can’t get from thermal,” Wheatley said.

“If you scan something that’s got writing on it,

for example, you can’t see that with a thermal

imager—so the visual overlay helps you do that.

But traditionally it does tend to be more of a

high-end imaging function.”

It’s essential to see the problem, but may

be even more important to document your

discovery and report the solution to your boss or

your customer. That’s where Fluke SmartView®

Thermal Imaging Analysis and Reporting

Software proves so valuable. The Fluke VT02 is

shipped with SmartView software, a proven suite

of tools to view, optimise, annotate and analyse

thermal images. With SmartView the technician

can generate fully customised, professional

reports in a few easy steps. It’s easy to use for

customers with basic needs, yet delivers the

performance that advanced users demand. All

future software upgrades are included.

More Images, More Data for More Users

The new Fluke VT02 Visual Thermometer makes

a powerful set of capabilities available to many

who thought such sophisticated infrared testing

was out of reach.

Many technicians have known about

thermography and wanted a thermal imager,

but just could not justify the capital investment

required, or spare the time for the training

needed to get maximum value from an imager. If

such a tool were available, it was likely reserved

for use by a trained plant engineer.

With the Fluke VT02, those limitations are

history. Now the HVAC installation and repair

technician, the smaller industrial user, and the

general facilities maintenance technician can

afford this rugged, highly capable tool—to

carry on a regular basis or add to the shop tool

inventory. There’s no need for time-consuming

training to make the most of this tool.

“This is really placing the ability to do thermal

analysis into the hands of tradesmen,” said

Wheatley. For professionals like these it’s a new

day for infrared testing. That day dawns with the

Fluke VT02.

Page 19: EMS_DEC-full_d2_med

19Engineering Maintenance Solutions

Condition Monitoring Feature

This heavy-duty yet sophisticated instrument brings

powerful analysis and troubleshooting capabilities to

your condition monitoring program, offering unique

productivity and efficiency.

Condition monitoring the SPM way is uniquely easy

to learn and utilize. Highly advanced measuring

techniques, optimized for a minimal and smooth

learning curve, quickly brings your maintenance

department up to speed, providing organised

management for large numbers of routine

measurements. Immediate, on the spot condition

evaluation is also a trademark of all SPM measuring

devices.

Building on the successful Leonova platform,

Leonova Diamond® features state-of-the-art digital

technology and a robust, rugged design. Leonova

Diamond® is the first portable instrument offering

the recently patented and award-winning SPM

HD® measuring technique for condition monitoring

of rolling element bearings. Capable to reliably

measure machine condition in the 1-20.000 RPM

range, the method has broadened the potential

scope of condition monitoring to include more

machinery than ever before. SPM HD® brings to

light machine problems which are impossible to

monitor with traditional vibration measurement

techniques.

Alongside SPM HD®, Leonova Diamond® also

offers highly sophisticated vibration analysis

capabilities. The instrument boasts an excellent

signal-to-noise ratio and provides razor-sharp

spectrums even where signals are weak and low

in energy content. The wide frequency range,

covering from 0 to 40 KHz, enables measurement

where absolute position is vital. For machinery

with journal bearings, Leonova Diamond® reliably

measures dynamic and centerline movement of

the shaft. Multi-channel measurement enables the

use of triaxial transducers and multi-axes vibration

monitoring while cutting long measuring routes

down to a minimum of time. Providing maximum

value, performance and control, Leonova®

Diamond is the perfect tool for the beginner as well

as the advanced vibration analyst.

Leonova Diamond® incorporates highly advanced

and innovative order tracking functionality. The

powerful HD Order Tracking, applicable in an RPM

range from just a few to thousands of revolutions

per minute, enables more precise measurements

and more detailed spectrums than ever before.

On machinery operating under variable speed,

vibration analysis with HD Order Tracking provides

reliable data and crystal clear measuring results

also under large RPM variations. Corrective

maintenance techniques such as run up-coast

down measurement, shaft alignment and dynamic

balancing can be added to the instrument as

optional modules.

The powerful Condmaster® Ruby software

fully supports the Leonova Diamond® features,

providing setup of personalized default settings for

the instrument and all the expert knowledge needed

to evaluate

machine

condition.

Condmaster® Ruby

is modular and system

functionality can be tailored to

specific customer needs.

Leonova Diamond is engineered for performance.

It is a dependable and highly capable analysis

tool, addressing all condition monitoring needs.

The instrument offers a full range of sophisticated

measuring techniques as well as all the supporting

diagnostic and troubleshooting capabilities.

Designed for heavy industry, the look and feel of

the instrument reflects its intended use. For use

in hazardous areas and hostile environments,

an intrinsically safe version of the instrument is

available.

Stan Jackson, Managing Director of SPM

Instrument UK, comments on the launch of the

instrument: “Leonova Diamond® is the latest

proof of our commitment to developing first class

condition monitoring products for more profitable

maintenance. In a direct response to feedback

from SPM customers worldwide, we developed

a durable, high-performance instrument that will

deliver long working life under the toughest, most

demanding circumstances.Leonova Diamond®

puts portable intelligence and productivity in the

palm of your hand.”

SPM Instrument Announces The Release Of Leonova Diamond®

SPM Instrument, announces the launch of its

next generation of handheld measuring devices,

the Leonova Diamond®; a portable instrument

for condition measurement in rough industrial

surroundings.

www.spminstrument.co.uk

email [email protected]

For technical details, please visit:

http://www.leonovabyspm.com/

www.spmhd.com

Page 20: EMS_DEC-full_d2_med

20 Engineering Maintenance Solutions

This stringent standard requires that organisations storing or distributing

liquids have adequate precautions to deal with accidental spills and leaks.

Blue Diamond offers a market

leading range of spill control

products available directly

from stock.

Spill control kits are ready

for immediate use, typically

comprising absorbent pads,

socks and pillows, protective

wear (goggles, gloves and coverall suit) and disposal bags. The contents

can also be custom designed to meet individual requirements.

Biozyme Spill Control Products To Meet ISO 14001

Blue Diamond offers a complete range of spill control kits meeting the requirements of the ISO 14001 standard for Environmental Management.

Blue Diamond Technologies Limited, Rolwey House, School

Close, Eastleigh, Hampshire SO53 4BY

Tel: (023) 8025 8966 Fax: (023) 8025 8989

Email: [email protected]

Website: www.blue-diamond.co.uk

The FP-PS24 Series is a range of three PSU models offering the

following specifications.

• 24W/1A (Input: 100-240Vac, Output: 2 x 24Vdc/1A)

• 60W/2.5A (Input: 100-240Vac, Output: 2 x 24Vdc/2.5A)

• 120W/5A (Input: 100-240Vac, Output: 2 x 24Vdc/5A)

The compact design of the series has

been optimised for cooling, allowing

them to operate in temperatures up to

+70ºC without the need to derate.

Each model offers over voltage, over

current and short circuit protection

and complies with international

approvals (IEC60950, UL60950, CSA22.2-60950, EN60950) for

global use.

For further information on FP-PS24 Series of Power Supplies or any

other Panasonic Factory Automation products please contact:

www.panasonic-electric-works.co.uk | [email protected]

New 24VDC Power Supplies from Panasonic Electric Works

A new range of 24VDC Power Supplies is now available from Panasonic Electric Works to compliment their range of Factory Automation products that include PLCs, HMIs, Photo Electric Sensors and Automation Components.

Welded Plate Heat Exchangers

The PLATULAR® is of a robust construction manufactured from

either stainless steel or higher alloys. To enable it to be broadly

used with all different types of media, an independant and generous

spacing can be provided between the heat transfer plates, whilst

removable access covers and optional wash systems simplify routine

cleaning and maintenance.

More information are directly available on our website at the address:

http://www.barriquand.com

The Company Barriquand is specialized in the design

and the supply of Easy to Clean All Welded Plate

Heat Exchangers called PLATULAR® and patented

by our company since many years.

New Gas-Pro Confined Space Gas Detector from Crowcon

The Gas-Pro has a number of special

features specific to confined space

entry (CSE) work.

The Gas-Pro is therefore ideally

suited for CSE work. Personnel

entering these spaces can now focus

on their core activities, safe in the

knowledge that their gas detector is

focused on its core activity.

Crowcon’s new Gas-Pro portable gas detector is designed

with just one purpose – ensuring safety in confined spaces.

It is robust, reliable and simple to use with a bright, easy to

read display and long battery life.

Crowcon company contact and reader enquiries:

Louise Early

Tel: +44 (0)1235 557700, Fax: +44 (0)1235 557718

E-mail: [email protected] | Website: www.crowcon.com

Product Spotlight

Page 21: EMS_DEC-full_d2_med

21Engineering Maintenance Solutions

Product Spotlight

The MC6 contains a full fieldbus

communicator for HART,

FOUNDATION Fieldbus and

Profibus PA instruments. The

usability and ease-of-use are what

really makes the MC6 unique.

The large 5.7” color touch-screen

with a multilingual user-interface

makes the MC6 an ideal portable

measurement device for field use

in various industries.

The Beamex MC6 Advanced Field Calibrator and Communicator is a solution to the new process industry requirements.

The MC6 is an advanced, high-accuracy field calibrator

and communicator. It offers calibration capabilities for

pressure, temperature and various electrical signals.

For more details and enquiries please email:

[email protected]

Industry-Leading Induction

Heating Solutions from Ambrell

Ambrell is a leading manufacturer

of induction heating solutions.

With systems ranging from

1kW to 800kW, its solutions

can tackle heat treating tasks

such as annealing, tempering,

through and case hardening.

Other common applications

include brazing, shrink fitting and curing. Ambrell has installed over

10,000 systems in more than 50 countries. With a free half-day of

applications lab testing available, you can be sure your system will

meet your requirements prior to placing an order.

Ambrell’s systems are manufactured in an ISO-certified facility in

the United States, and Ambrell has local offices around the world,

including in the United Kingdom, Netherlands and France. Visit www.

ambrell.com for more information.

Ambrell Is A Leading Manufacturer Of Induction

Heating Solutions.

Ambrell Ltd, Phoenix Works, Saxon Way, Cheltenham, Gloucestershire, GL52 6RU+44 (0) 1242 [email protected]

Creative Pultrusions pultrudes an array of decking, flooring, grating and

panel products that are used extensively around the world where corrosion

resistance, lightweight, ADA compliant, low maintenance solutions are

sought. Our customers want to eliminate future replacement costs and

maintenance associated with traditional materials of construction. Our

pultruded products will not rot, rust spall or corrode. Typical applications

include, cooling tower decks, mass transit decks, industrial walkways,

highway bridge decking, pedestrian walkways and docks and piers.

Our Customers Want To Eliminate Future Replacement Costs And Maintenance Associated With Traditional Materials Of Construction.

Visit our web site at www.creativepultrusions.com to see first

hand our products and solutions.

Page 22: EMS_DEC-full_d2_med

22 Engineering Maintenance Solutions

Easy installation - just clamp a small sensor

to the outside of a pipe and immediately get

a reliable, repeatable flow measurement.

Virtually no installation costs,

no interruption to service,

clean and simple.

Flow Pulse – A Major Advance In Non-Invasive Flow MeasurementFlow Pulse from Pulsar Process Measurement is a compact,

cost-effective pipe flow monitor that promises exceptional

repeatability and simple installation with no down time,

perfect for monitoring flow rates in fluid distribution

systems, for pump efficiency, in process plant or sewage

pumping stations.

Ultrasound is fired through the pipe wall then

reflected from bubbles, particles and vortices

in all directions and at a wide range of

frequencies, the reflections

received back into Flow Pulse.

Flow Pulse’s Refracted Spread Spectrum

Analysis (RSSA) digital signal processing

analyzes and integrates received signals over a

wide frequency range, then slices them for real-

time analysis and flow rate calculation.

Flow Pulse operates in a flow range from 0.3m/

sec through to 4m/sec, with minimum particle

size of 100 microns and concentration of

200ppm or above.

Pipe material can be rigid plastic, stainless steel,

mild steel or cast iron. Corrugated pipe is not an

issue and even light corrosion will give a good

result. Flow Pulse provides repeatability and

accuracy of around ±5% (up to 14in pipe dia).

For more details go to:

www.pulsar-pm.com

Product Spotlight

The motors are also classed as intrinsically-safe

in hazardous environments, which reduces

the possibility of explosion from the ignition of

flammable gases.

The air motors can be used in a variety of

industrial and manufacturing sectors such as

food and beverage; medical, healthcare and

laboratory; and environmental, with typical

applications including mixing equipment; pump

and conveyor drives; food and pharmaceutical

packaging; and hoists and winches.

Gast’s non-lubricated air motors are available in

four basic models from 0.13 to 1.86 kW (0.18

to 2.5 HP), with motor speeds up to 4,000

RPM. Oil-lubricated versions are available in

seven basic models from 0.33 to 7.1 kW (0.45

to 9.5 HP) with motor speeds variable from

300 to 10,000 RPM. A range of recommended

accessories is also available and bespoke

versions can be manufactured to special order

for OEM quantities.

Air motors can be mounted in almost any

position and users can choose from hub,

foot, face, NEMA C-Flange or Metric D

Series interface mountings, and clockwise,

counterclockwise or reversible rotations. Four

vane models are available as standard, with

eight vane models available for smoother running

and better control for short-run applications

including winches, hoists and hose reels.

GAST Group Air Motors Full Range Now Available With ATEX Approval

Known industry-wide for their rugged construction

and reliability, the Gast Group’s range of compact,

lightweight air motors are now available with II 2 GDc

T4 +1ºC < Ta < +40ºC ATEX approval, which means

they will work in ambient temperatures up to 40ºC.

For further information on the Gast

Group’s range of ATEX-approved air

motors, call +44 (0)1527 504040,

email [email protected]

or visit www.gastmfg.com.

Page 23: EMS_DEC-full_d2_med

23Engineering Maintenance Solutions

Product Spotlight

For years the accepted practice has been to

change oil in equipment on a predetermined

scheduled basis regardless of whether the oil

is spent. Mostly, used oil is simply loaded with

contaminants such as dirt particles, wear metals,

water and gases, while the oil remains within

specifications and suitable for continued use. If

the contaminants can be adequately removed

without affecting the additives, there is no reason

why oils cannot remain in service.

LUBEMASTER is innovative & very cost effective

and enables oil life to be extended many fold,

resulting in cost savings of more than 50%.

Cleanliness levels achieved by LUBEMASTER

are much higher than other systems &

particularly pore membrane filters which allow

the small particles to remain in circulation and for

the filter to block once a particle larger than the

pore size is caught in the element.

As well as lubricating oil, LUBEMASTER can

be utilised for :

• Cleaning contaminated diesel fuel

• Cleaning and restoring transformer oils

• Effectively cleaning heat circulating systems

• Cleaning waste oil suitable for use as a

diesel substitute to burn off in diesel engine

fuel

Advantages of LUBEMASTER include:

• Easy to operate & low energy requirement

• Cleans oil while host machine continues

operating

• Has few moving parts thus minimal wear

• Expensive filters not normally required

• Cleans all grades of oil at full flow rate

• Removes particles to sub-micron size

• Removes all types of water (free, emulsified

& homogenized)

• Cleans system to cleaner levels than oil

change.

The CLEAN OIL AlternativeClean Oil Services offers a range of LUBEMASTER Oil Cleaning Equipment for cleaning fuels and all grades of lubricating oil – designed to keep lubricating oil in perfect operating condition and extend machine life.

For more information please visit our

website: www.cleanoilservices.com

Or contact: Bob Smith

Email: [email protected]

[email protected]

Fuel cleaning with the low cost Fuel Klenze

Filter will ensure optimum fuel quality, keep

fuel injectors, filters and tanks clean, minimise

maintenance and downtime and provide

optimal engine efficiency and performance.

Most filters rely on paper, which needs

regular replacement and generates waste.

It’s far better to eliminate contaminants

before they enter the engine, as it will operate

more efficiently, have an increased lifespan,

benefit from improved fuel consumption and

generate fewer harmful emissions.

Low Cost Fuel Klenze Filter Means Clean Fuel and Efficient Engines

In the quest for engine performance, efficiency and environmental

benefits, technologies are emerging at an impressive rate.

But modern engines are increasingly sensitive to fuel

contamination, which can cause engine wear and damage to

components.

Using an entirely new and unique filter design,

the low cost Fuel Klenze Filter fundamentally

delivers cleaner fuel - virtually eliminating filter

volume and saving time and money on repairs.

The system uses a long-life filter element; an

osmotic process separates fuel from 99.9%

of visible water - including emulsified water -

allowing only pure fuel to pass through.

A 30 micron stainless steel mesh removes 95%

of solid contaminants, further purifying the fuel.

Separated water, sediments and sludge are

drained using the valve at the bottom of the unit.

No replacement of filter element or cartridge is

required. The reusable long-life filter element is

easily washed in clean fuel should it become

blocked, and reinstalling this requires no tools.

Various models are available to suit engines of all

sizes, from 150 up to 1200 horse power.

Page 24: EMS_DEC-full_d2_med

24 Engineering Maintenance Solutions

Boilers & Burners Feature

Twenty years ago industrial boiler design was

driven mainly by the demands of equipment

buyers and specifiers for boilers which produced

maximum output at minimum purchase price.

While fuel was relatively cheap and emissions

not high on the agenda, purchase price probably

was the most important factor to consider.

Many boilers therefore were designed to be small

in size with the least steel, tube and insulation

possible without greatly affecting reliability and

output. This resulted in mediocre efficiency, with

higher fuel and power consumption and NOx

emissions.

How things have changed. Now, with the

exception of those organisations lucky enough

to have a ready source of cheap fuel, there

cannot be any boiler project which doesn’t

prioritise running costs and reliability over

purchase price.

Design

Leading boiler manufacturers have responded

quickly to this need, with new boiler designs

shifting the emphasis from low purchase prices

to low running costs and emissions.

Boiler shells and furnaces should both now be

generously sized, not minimized to save on steel

costs. A steam space which is too small causes

priming and “carry over” of water in the steam

system resulting in wet steam, dissolved solids in

the process, scaling and water hammer.

In order to reduce NOx emissions, the furnace

length to diameter ratio should ideally be 3.5

to 1: the lower volumetric heat release rate in

the furnace reduces the flame temperature and

less thermal NOx is formed. For sites which

require “ultra-low” NOx levels, Byworth will

design bespoke furnaces to match the particular

requirements of the preferred burner supplier.

Pre-heating Combustion Air

The latest development in steam boiler

technology has seen the introduction of the

pre-heated combustion air boiler. This recovers

otherwise wasted heat from the exhaust gases

using a recuperator. When combined with X-ID

tubes tests have shown efficiency gains of up

to 7% when benchmarked against Byworth’s

already efficient Yorkshireman 3-pass boiler.

Advantages of pre-heated combustion air are

that it is completely synchronous with the burner

operation and that it maintains a high efficiency

gain with turndown, 5% at one third firing rate.

RAISING THE BAR FOR BOILER EFFICIENCYTony Green, Sales & Marketing Director of

Byworth Boilers, looks at recent developments in

boiler technology.

Byworth’s pre-heat boiler showing the

flue gas economiser and air-to-air heat

exchanger.

Flue Gas Economisers

Flue gas economisers are a proven concept and

can improve boiler efficiency by up to 5%. The

heat in flue gases, which would otherwise be

lost up the stack, is utilised in an air to water

heat exchanger to pre-heat the feed water to the

boiler. The economiser seen here in the photo

is a drawer type for ease of maintenance and

located above the rear smoke box.

not be required. The recuperator does not

contain any moving parts and its robust Even

after the flue gases have passed through the

economiser there is still usable heat and they

can be combined with a recuperator to pre-

heat the combustion air. The air-to-air heat

exchanger shown here above the economiser

is of the drawer type to minimise its footprint. A

bypass is incorporated into the ducting should

pre-heat design ensures a long life.

Add-on Technology

To support the increased efficiency of the

boilers themselves there have been significant

technological advances in burners and boiler

controls. Burners with electronic air and fuel

control give better efficiency right across the turn

down range and also reduce NOx emissions.

Variable speed drives on burners and feed water

pumps will greatly reduce electrical consumption

whilst automatic blowdown and TDS control

systems also increase efficiency and reduce

risks associated sludge build up and foaming.

Byworth Yorkshireman2 waste heat

combination boiler

Page 25: EMS_DEC-full_d2_med

25Engineering Maintenance Solutions

Page 26: EMS_DEC-full_d2_med

26 Engineering Maintenance Solutions

The site, located in Somerset, was contaminated

with toluene over many years and developers

were looking to extract the flammable solvent

so the land could safely be used for housing.

In what is believed to be the first project of its

kind, Provectus decided to dig out the soil and

treat it above ground using an extensive system

of steam heating coils. The contractor brought

in Spirax Sarco to design a steam distribution

system to do the job.

The conventional approach for toluene

decontamination is to inject live steam into the

ground to vaporise the volatile solvent. But the

local geology meant there was a risk that the

toluene would migrate into the surrounding

ground, rather than rising to the surface.

Provectus also judged that the 24-hectare site

was too big to install an effective underground

barrier around the operation to prevent such

leaks escaping.

The company therefore decided to treat the soil

ex-situ, where it could control the process more

effectively. “It meant we could homogenise the

material better and improve the transmissivity,”

says Provectus Director Steve Langford. “It

also prevented any contaminated vapour from

migrating into the surrounding area through the

fractured geology.”

In addition, using heating coils rather than direct

steam injection was more efficient in terms of

energy and water. Spirax Sarco advised using

steam as the heating medium in the coils rather

than hot water, because it would remain at a

constant temperature, rather than cooling down

as it passed through the system.

Spirax Sarco engineers devised a series of

trombone-shaped coils, laid flat across one of

the old concrete factory floors. Several thousand

metres of pipework were needed to provide a

big enough heating area to treat the batches

of soil that were piled on top. It was tricky to

calculate the necessary heat transfer area,

because the ability of the soil to conduct heat

changed as the material nearest the heating coils

dried, making it more difficult for the heat to flow

through to the remaining soil.

Bristol-based contractor Engineering Services

assembled the necessary pipework according to

the Spirax Sarco design, complete with steam

traps and associated controls to ensure that

the system worked smoothly. The company

also provided a 1250kW containerised boiler to

generate the steam.

“It was quite a complex arrangement, but the

biggest challenge for us was the physical site

conditions,” says Bob Clark, managing director

of Engineering Services. “We were working

exposed to the weather for the whole time.

The process ran over the four weeks, heating

around 4,000m3 of material and collecting

the resulting vapour in plastic sheeting. From

there the solvent passed through a system of

activated carbon beds, which absorbed the

toluene before discharging clean air to the

atmosphere.

“We’d never seen a project like this and neither

had the Environment Agency personnel who

inspected the operation,” says Mr Langford.

“We’d cleaned up the first batch of soil within

two weeks and the site is now suitable for even

the most sensitive developments – residential

housing with gardens.”

“I’m more than happy with the support we

got from Spirax Sarco, which helped us to

complete the project so quickly and efficiently.

The solution prevented us from having to send

the contaminated soil off to landfill and bring in

replacement material.”

“We’ve worked on projects with Spirax Sarco for

over 20 years,” adds Mr Clark. “This was the first

time anyone had attempted to do a clean-up this

way and the results were outstanding.”

Spirax Sarco’s Expertise Helps Provectus With Rare Decontamination Project

When contaminated land specialist Provectus

decided to take a novel approach to cleaning up

the soil from an old printing works, Spirax Sarco

provided the steam system expertise to help turn

the concept into reality.

Boilers & Burners Feature

Page 27: EMS_DEC-full_d2_med

27Engineering Maintenance Solutions

Simultaneous firing of fuels

can usually be achieved using

conventional products but waste and

bio-fuels are often characterised by

variable availability and inconsistent

calorific values. To overcome this

an algorithm within the controller

software enables safe and efficient combustion to be achieved; an external signal is

used to indicate the proportion of waste fuel that should be used across the firing

range. Oxygen trim ensures that any variability in either the fuel calorific value or

external atmospheric conditions does not compromise combustion efficiency.

The ETC6008 caters for liquid and gaseous fuels to be fired either independently or

simultaneously. A second new model the ETC6009, is designed to allow a gaseous

base fuel to be mixed with a gaseous bio or waste fuel and includes the provision for

valve proving on two separate gas trains. The ETC6009 can be further enhanced to

facilitate the firing of a back-up liquid fuel. The full range of ETC peripherals including

a 10.4” touchscreen, CANbus servo motors, and temperature and pressure sensors

are all fully compatible will all the new models.

ETC Launches Combustion Controls for Waste Fuel Firing

Energy Technology & Control Ltd, a UK manufacturer of electronic

Burner Management Systems, has expanded its range of combustion

controllers to allow waste and bio-fuels to be fired either independently or

simultaneously with a conventional gaseous or liquid base fuel.

Contact for enquiries for ETC products

[email protected]

Tel: 01273 480667

One such company has been Billerud Beetham Ltd, a world leader in the manufacture of speciality papers for health care and food packaging markets. Seeking to replace three of their aging boilers, they searched the market for a company that offered a one-stop solution, designing, manufacturing and managing the whole process. Cochran Ltd was best placed to meet those requirements, and to provide the long term service support that Billerud needed.

Cochran designed and built a new energy centre comprised of two Thermax steam boilers complete with flue gas economisers. These high pressure boilers have a rating of 10210 kg/hr, and were fitted with matched Cochran Equinox pressure jet combustion systems providing electronic combustion control, variable speed FD fans and exhaust gas analysis equipment to optimise the boiler output and performance. As well as installation, Cochran undertook the replacement of the existing steam manifold system and integration of the boiler into a new balanced steam header arrangement. The remaining Cochran boilers at the site are over 35 years old but are still in good condition. These are currently being updated with the latest combustion and control equipment as part of Cochran’s continued service contract.

As a result of the modernisation of their steam generation and distribution system, Billerud have reduced their fuel bills by up 13% per annum. Tony Halhead, Engineering Manager at Billerud said: “The support we received from the Cochran site team and their head office engineering teams was first class. The project went as well as could be expected and was delivered on time and on schedule.”

Cochran complete Turnkey Installation at Cumbrian Specialist Paper Mill

Cochran Ltd are the largest manufacturer of industrial boilers in the UK, and have over 130 years of history providing energy solutions. Our customers have come to depend on our quality engineering and service, and our boilers are in use the world over.

The entire space heating requirement is met by two 90kW R-Series dual fuel boilers – B100 bio-diesel and natural gas. The R Series is a year-round high efficiency condensing boiler which bridges the gap between gas condensing boilers and bio-mass boilers by providing combustion which burns traditional fuels and also ‘green fuel’.

Liquid bio-fuel boilers are at an advantage to other ‘green boilers’ such a bio-mass boilers for several reasons. Liquid bio-fuel is easier than bio-mass to store and feed to the boiler and produces 37 megajoules of heat per kilogram against 17 megajoules of heat per kilogram for good standard biomass. In addition, the UK has a surplus of waste and home-grown vegetable oils which the developing liquid bio-fuel boilers are ready to burn with efficiency and minimum noxious emissions.

The boilers were specified by BSD of Corby and installed by Mitchell & Hewitt of Derby.For more information see www.atlanticboilers.com

East Midlands Enterprise Centre harnesses bio-fuel technology

Atlantic Boilers of Oldham have installed dual-fuel boilers at the new Corby Enterprise Centre in Northamptonshire. The £8.3m centre is home to 15 workshops, 38 offices and a café area.

Kings involvement did not end there however. Being Europe’s largest

stockist of re-conditioned boilers, Kings had an almost identical 35,000lb/

hr steam boiler in stock at their Mildenhall branch. King’s Director,

David King, offered the unit to Addenbrookes, who promptly decided to

purchase. The boiler was fully re-furnished and delivered to the hospital six

weeks later.

Engineers at Addenbrookes were delighted to have sourced an almost

identical boiler locally and with such rapid delivery, and also benefit from

the large financial saving over buying a new boiler unit.

“We are delighted that both King’s Boiler Hire and Sales departments were

able to assist Addenbrookes in such a timely manner” said David King.

“We are proud to have developed an excellent working relationship with

the trust”.

HOSPITAL MAKE EMERGENCY CALL TO KINGS BOILER HIRE

When Addenbrookes Hospital Cambridge recently had a major failure on one of their main 35,000lb/hr steam boilers they contacted Kings Boiler Hire Ltd. Kings, whose Mildenhall branch is close to Cambridge, were asked to urgently provide a temporary boiler to help cover the hospitals steam demand. The emergency unit was delivered and on line with the minimum of loss to the hospital.

Boilers & Burners Feature

Page 28: EMS_DEC-full_d2_med

28 Engineering Maintenance Solutions

Product Spotlight

The weatherproof J+J actuator offers multi-

voltage connectivity via supplied external Din

plugs, eliminating the need to remove the

actuator’s cover to connect electrically, saving

time and money on installation. With selectable

manual override the J+J actuator can be

operated manually during commissioning, and

automatically resets any actuators over-travelled

whilst in manual mode, when switched back into

‘Auto’.

End of travel confirmation via volt free contacts

for remote position indication, and an external

local visual indicator lets operators see the

actuator’s position at a glance. A top mounted

LED gives continuous visual indication of the

actuator’s operational status, a constantly lit

LED advises all is well, whereas a blinking LED

indicates non-operational status, either due to

manual mode being selected, or the electronic

torque limiter has detected a valve problem.

Modulating functionality via the J+J digital

positioning system (DPS) provides either 0-10V

or 4-20mA input and corresponding output,

standard or reverse acting, and the J+J battery

failsafe system (BSR) provides an alternate,

constantly trickle charged power supply in the

event of external power interruption. The BSR

can be configured normally open or normally

closed. Installing both conversion kits gives

failsafe modulating functionality.

The J+J electric valve actuator is known as the

Smart Red Box for a reason.

J+J Motorised Valves using the original Smart Red BoxThe EU designed and manufactured J+J electric valve actuator

distributed by J+J Automation in Worcestershire continues to see

healthy growth due to its impressive array of standard features,

and its unique ability to have its function changed from on-off to

modulating or failsafe using the J+J plug and play conversion kits.

Contact J+J Automation UK Ltd on 01386

552254, visit www.jjautomation.com, or email

[email protected] for more details.

These products have been specified for the

synchronised lifting and handling of an 18.3/4”

15,000psi BOP unit before and after drilling

operations. Two hoists are each mounted on

twin parallel overhead rails, with each hoist

providing 50 tonne load and 20 metre lift

capacities for between deck operations. With

the two sets of hoists operating together, a

combined lift capacity of 200 tonnes is made

available.

Synchronised operation of all linear movement

and lifting operations is provided with the F

type multi-function pendant controllers also

supplied by JDN. These tough, ergonomically

designed controllers are suitable for the outdoor,

heavy-duty operations that can be experienced

offshore. A main air emergency stop together

with load monitoring device is incorporated

in the controllers. A complete offshore

documentation package was supplied together

with all hoists having JDN’s full protection kit for

offshore corrosion protection.

The hoists provided are part of a range of

well-proven JDN monorail hoists with individual

lift capacities from 10 to 115 tonnes. All these

products are fully ATEX rated providing reliable,

robust and efficient performance. They are

ideally suited for working in hazardous areas

and the drives are hermetically sealed-off from

the environment. They incorporate integrated

overload protection with a fully enclosed, robust

gear motors and extremely low noise emissions

and with optional air or hydraulic hoist operation.

JDN HOISTS PROVIDE 200 TONNE HANDLING CAPACITY ON OFFSHORE RIG

Four J D Neuhaus type EH50 air operated monorail hoists have

been supplied and mounted by Westcon Løfteteknikk AS of Bergen

to the Maersk offshore rig Guardian.

Further information is available on request to:

J D Neuhaus GmbH & Co. KG, 58449,

Witten-Heven, Germany

Telephone: +49 2302 208-219

Fax: +49 2302 208-286

e-mail: [email protected]

www.jdngroup.com

Page 29: EMS_DEC-full_d2_med

29Engineering Maintenance Solutions

Page 30: EMS_DEC-full_d2_med
Page 31: EMS_DEC-full_d2_med

31Engineering Maintenance Solutions

Product Spotlight

Fully user programmable, with an

embedded PC controller and colour

touch screen interface, it satisfies

the stringent demands of Quality and

Compliance regulations. HygroGen2

has the capability to calibrate

instruments from any manufacturer

over their full working temperature

and humidity ranges; it is embraced

throughout industry as the leading calibrator in its class.

HygroGen2 is now optionally available with AutoCal - fully automated

calibration, with adjustment of up to six probes. PDF calibration

certificates are generated, with set-points and pre- and post

adjustment values as required.

Contact Rotronic for a technical datasheet and to arrange a

demonstration.

Tel: 01293 571000 Email: [email protected]

Web: www.rotronic.co.uk

The ROTRONIC HygroGen2The ROTRONIC HygroGen2 has become the benchmark for transportable humidity and temperature calibrators due to unsurpassed chamber stability, speed to reach set-point equilibrium, and extended operational ranges 2…99 %rh and -5…60 °C.

The cameras feature

a 640x480 image

resolution and 17μm pitch

microbolometer detector.

The novel and compact

platform meets the demand

of reduced weight, size and

power consumption for machine vision applications. It detects very

small temperature differences down to 0.05 oC and delivers thermal

images at 50 Hz.

The Gobi-640-GigE is the first official certified LWIR camera with

MVTec’s HALCON imaging software. More vision software such as

Cognex VisionPro is supported as well.

Smallest thermal GigE cameraXenics’ Gobi-640 uncooled thermal camera with GigE-Vision interface and Power over Ethernet (PoE) is now also introduced with a CameraLink version.

Xenics headquarters Ambachtenlaan 44 BE-3001 Leuven, Belgium

Tel +32 16 38 99 00 [email protected] www.xenics.com

Early detection enables you to take

immediate action, preventing the

situation escalating to anything from

business disruption to a full scale

disaster.

BTI monitoring systems have

become a valuable asset to many organisations large and small, and is an

essential part of any Business Continuity Plan.

Protect your IT Investment……. Don’t Wait Until It’s Too Late!

BTI provide monitoring systems for IT and their environments that will alert you wherever you are day or night, weekday or weekend of potential problems within your computer room whether it be High Temperature, UPS on Load, Water Detected or Critical Server Failure.

BTI Computer Systems (UK) Ltd.

t: +44 (0) 1527 598500

w: www.bticomputer.com

The HS-630 Series Vibration/Temperature Meter Kit

The kit comes complete with a mains or in-car

charger and rechargeable battery, while a

sensor/cable fault indicator provides warning

against error. The HS-630 Series can provide

measurements in either imperial or metric and

conforms to ISO 10816-3. The temperature

measurement function of the HS-630

differentiates this unit from the HS-620 Series Vibration Meter Kit, which

otherwise offers the same reliable performance and range of features as

the HS-630.

The HS-630 Series Vibration/Temperature Meter Kit

provides all of the key tools required for monitoring

velocity and bearing condition and temperature

measurement in a convenient, protective, portable case.

For more information on the extensive range of Hansford Sensors

products, please visit: www.hansfordsensors.com.

Page 32: EMS_DEC-full_d2_med

32 Engineering Maintenance Solutions

CMMS Software

Managed correctly, CMMS Software enables

organisations to optimise the reliability and

efficiency of assets, property and equipment

to reduce costs and improve service. It

automates and manages scheduling activities,

such as testing, inspections or health and

safety; can determine elements that affect the

reliability, servicing and repair of an asset; whilst

supporting the creation of unique and flexible

maintenance regimes.

For any company seeking to invest in, or update

existing CMMS software, it is important to

cost justify the investment by identifying how

the new system will produce cost savings,

so that the project is self-financing. Current

business processes should be reviewed and

where appropriate, procedural improvements

considered, in order to determine the scale and

scope of benefits that a CMMS software system

could potentially deliver.

The first step for any business when reviewing

CMMS software is to consider the benefits

offered by the software and align these to

requirements within the business. On average, a

business should aim for a return on investment

within two to three years. Initial costs that

should be taken into account are the CMMS

software licences, professional services such as

consultancy, data manipulation, training, ongoing

maintenance and internal costs associated with

the project.

The development of an effective and realistic

implementation plan is a very important step

in ensuring that the timely delivery of the new

software solution meets the needs of a business.

It is crucial to develop and agree a formal project

plan with all stakeholders to enable resource

demands to be met and clearly defined project

milestones to be achieved.

Whilst developing the implementation plan,

it is also useful to put in place some key

performance indicators (KPIs) against which the

success of the project can be measured. These

should include key project milestone dates that

must be achieved in order for the supplier to

claim progress payments.

Once the initial development and implementation

is complete, it is vital to have excellent support

from the CMMS software supplier to ensure

the long-term success of the system. It is

important to understand what is included in any

maintenance fees, i.e. access to future upgrades

of the software and the scope of the support

offering (telephone, remote and/or on-site).

In summary, if properly implemented and

maintained correctly a good CMMS Software

application can ensure that an organisation

optimises operational efficiency whilst reducing

costs.

CMMS Software – Good Practice for FM Implementation

With organisations looking to manage

their budgets more tightly given the current

economic climate, utilising the capabilities of

a comprehensive CMMS (Computer Aided

Maintenance Management Software) application

can have a number of positive operational

benefits to any organisation.

To receive a

complimentary

copy of Service

Works white paper

‘Best Practices for Successful CMMS

Implementation’,

please call: 0208 877 4080

or email [email protected]

Page 33: EMS_DEC-full_d2_med

33Engineering Maintenance Solutions

Page 34: EMS_DEC-full_d2_med

34 Engineering Maintenance Solutions

Industrial Cooling

In recent years a major worldwide auto

manufacturer experienced a tragedy when

four of its maintenance workers became

ill with pneumonia-like symptoms that

ultimately claimed the lives of two. The cause

- Legionnaires Disease due to Legionella

bacteria found in one of the manufacturers

cooling towers. The company quickly moved

to conduct a “cause analysis” by inspecting its

cooling towers and boiler systems worldwide

to identify how systems were being maintained

and to identify best maintenance practices. This

ultimately led to the establishment of a world

class maintenance and monitoring system that

ensures such a tragedy will never be repeated.

How a Legionella Outbreak Can Occur

When someone becomes ill from an unsafe

cooling tower it most often isn’t the result of the

company’s blatant negligence; rather, it’s typically

the result of not having a clear understanding of

the need for the water treatment program to be

in alignment with effective debris management.

It is well known that cooling towers are highly

efficient air scrubbers; airborne debris drifting

past one is likely to get caught in its draft and

be sucked-in. When organic debris such as

pollen, cottonwood seed, leaves, insects, grass,

birds etc. get into the water and decompose,

the warm temperatures create a nutrient rich

environment for bacterial growth including

Legionella. Further, if the volume of decomposing

debris exceeds the chemical dosage’s ability

to provide control, then the “tipping point” has

been reached and the cooling tower will silently

grow dangerous even while chemical dosing

continues. The fact of the matter is that it’s

easy for companies to develop a false sense of

security that their cooling towers are safe when

they are chemically treating the water; however,

if organic debris management isn’t in alignment

with water treatment dosage levels, there is an

increased probability of the tower becoming a

health and safety hazard. It doesn’t matter how

large or small a company and its cooling tower

is; bacteria doesn’t discriminate - it will thrive in

any poorly managed cooling tower!

An Obvious Question

“What is the appropriate ratio of water treatment

chemicals to the debris load inside the cooling

tower to ensure cooling tower safety?” Although

the question is obvious, the answer isn’t.

Organic debris is drawn into cooling towers

in different concentrations depending upon

location and time of year. Every type of debris

places a different demand upon the biocides

and scale inhibitors being dosed into the water;

therefore, there is no known ratio that will hold

constant for every cooling tower. However, it

is safe to say that if you don’t deploy diligent

maintenance procedures that include debris

Cooling Tower Safety and Maintenance The Importance of Aligning Debris Management With Water Treatment Procedures By Randy Simmons

The following is an important reminder of the need for

all companies and institutions utilizing cooling towers, to

adopt diligent maintenance and water treatment programs;

Why? - Because what’s at stake is worker health & safety,

operational efficiency and the company’s reputation.

Cooling Tower Basin With

High Organic Debris Content

This photo shows serious maintenance

neglect. Tower has high organic content and

heavy scaling. This tower is a health and

safety hazard.

Page 35: EMS_DEC-full_d2_med

35Engineering Maintenance Solutions

Industrial Cooling

management, more water treatment chemicals

will be required to keep it safe. Some may say,

“Load the tower up with chemicals to ensure

safety”, however, local environmental guidelines

typically place restrictions on the amount and

type of chemicals that can be used, therefore

the use of chemical treatment alone is not the

solution. Furthermore, adding chemicals to offset

poor maintenance practices is a shortcut that

will do little to prevent fouling and clogging of

the fill, strainers, blow down valves, chiller and

heat exchangers and could eventually lead to

health and safety problems and a reduction in

equipment performance.

Although the answer to the chemical ratio to

debris question isn’t apparent, the answer to

keeping a safe cooling tower is crystal clear and

can be simply stated - “Keep the cooling tower

free of debris and deploy a good water treatment

program and your cooling tower will operate

safely and efficiently.”

How to Keep a Safe Cooling Tower

In recent years The Chartered Institution

of Building Services Engineers in Europe

(CIBSE) and the American Society of Heating,

Refrigerating & Air-Conditioning Engineers

(ASHRAE) in the US have provided excellent

recommendations and guidelines for

cooling tower maintenance. In addition to

recommending maintenance activities, they

also call for establishing procedures that are

measurable. Although the suggested guidelines

are excellent, companies must ultimately

weigh the operational and economic realities

of any maintenance program they deploy. If

maintenance procedures are too frequent,

cumbersome or complex, they commonly results

in more downtime, lost productivity and higher

maintenance costs. Conversely, if the intervals

between maintenance are too long, it may be

more cost effective, but the condition of the

cooling tower at each maintenance interval may

be less than desirable and potentially place

maintenance workers, employees, tenants and

the public at risk. So the answer largely lies

somewhere in the middle where water treatment

Legionella as found in cooling towers and boiler systems

Photo Compliments of Centers for Disease Control

and managing debris in the tower come

together.

Today, companies have many options available

for managing debris; they include a variety

of water based filtration technologies and air

intake filtration. Water filtration can help manage

waterborne and other debris after it gets into

the cooling water while Air intake filtration

technology is highly effective at stopping

airborne debris from getting into the tower by

filtering the air as it enters the system. When

determining what maintenance and debris

management technology to use, it is important

to first determine what the source of the debris

is. If the source of debris is waterborne (e.g.;

sediment, algae from pond or river, or water with

a high dissolved solids content), water filtration

in combination with a good water treatment

program is typically the best solution and will

help protect the tower and its piping from scaling

and fouling. However, if the source of debris is

airborne related then Air Intake Filters are the

best solution because debris is stopped at its

point of entry while water filtration can only help

manage the airborne debris once it gets into the

water basin. In combination with a good water

treatment program, Air Intake Filtration is highly

effective at stopping the kind of debris that clogs

strainers, blow down valves, fill, chillers and

heat exchangers. In extreme cases where both

waterborne and airborne debris is problematic,

both air intake filtration and water filtration

in combination with a good water treatment

program may be required in order to keep the

cooling tower safe and operating efficiently.

Personal Safety

No matter what cooling tower maintenance

procedures are adopted, personal safety

precautions must be integral to the maintenance

Page 36: EMS_DEC-full_d2_med

36 Engineering Maintenance Solutions

Industrial Cooling

procedures. Best practices require workers to

wear respirators, gloves and protective clothing

to help prevent exposure to water treatment

chemicals and bacteria, especially Legionella.

Important Note: cooling water doesn’t have to

look dirty to be dangerous - just because the

water is clear doesn’t mean it’s clean or free

of bacteria - Every cooling tower can harbor

bacteria. Always take precautions because

unless the water is routinely tested for Legionella

and other bacteria, the bacteria will never

announce its presence until it’s too late.

Consider The Cost Of A Sick Tower

Companies that don’t insist upon diligent cooling

tower maintenance procedures put not only

their employee’s health and safety at risk, but

also their business and reputation. Consider the

cost of a single cooling tower related Legionella

incident:

• Reduced employee moral and productivity

due to an unsafe work environment.

• Negative customer perceptions and their

willingness to buy goods & services should

a Legionella outbreak become public.

(Especially risky for food and related

processors).

• Loss of income to families when a loved

one becomes ill or dies from Legionnaires

Disease.

• High cost of litigation which usually follows.

• Higher company insurance costs when

claims due to job related sickness or death

occur.

In comparison to the cost of a proactive

maintenance initiative, the incidents listed above

when considered individually or collectively carry

staggering cost.

Follow A Leader

So, you may be wondering exactly how the

major automotive company mentioned at the

beginning took a tragic situation and turned it

into a world-class maintenance program. They

formed an oversight committee sponsored by

executive management that is charged with

the responsibility of working with consultants,

water treatment professionals, maintenance

employees and contractors to establish a global

water management program that encompasses

specific maintenance tasks, procedures,

schedules, management accountabilities

and reporting guidelines at the facility level. A

representative at each facility is accountable to

a regional representative who reports activities

and results to the oversight committee. The

establishment of the oversight committee and its

global management network ensures uniformity

of their program plus, gives the company a

vehicle to quickly implement changes and

enhancements that provide continuous

improvement to their global water management

program.

It Doesn’t Take Rocket Science

It simply requires that companies using cooling

towers “step-up” and initiate proactive and

on-going maintenance procedures that align

effective debris management technology with

effective water testing and treatment techniques

because when these elements are in alignment,

the result is a safe, healthy and efficient

operation.

Legionella Bacteria multiplying inside of cultured human lung tissue.

Photo Compliments of centers for Disease Control

Randy Simmons, is President of

The Newway Company dba / Air

Solution Company manufacturer

of Intake Filter Screens for cooling

towers and condenser coil based

cooling systems. For questions or

information, he can be reached at

Tel 513-860-9784

in the US or, visit their website at:

www.airsolutioncompany.com

For availability in the UK, please

contact ECEX on 01635 244 100 or

visit their website at www.ecex.co.uk

Page 37: EMS_DEC-full_d2_med
Page 38: EMS_DEC-full_d2_med

38 Engineering Maintenance Solutions

Industrial Cooling

Requirement...ICS Temperature Control were requested to

investigate the most energy efficient solution that

would have minimal disruption of the production site

during installation, and that needed little input from

the customer. An after care support package was

also requested to maintain the efficiency and life

expectancy of the new equipment.

ICS Temperature Control were pleased to be able

to utilise their wealth of knowledge and experience

in delivering streamlined, turnkey solutions and offer

the customer a number of options for consideration.

In the first instance an energy analysis was carried

out which determined the most energy efficient

solution for the application. One option considered

was partial or full heat recovery, which is the

reutilisation of heat energy from a cooling system

which would otherwise be lost.

The energy analysis estimated that by using

heat recovery on a new chiller at an operating

temperature of 10°C, the savings on energy costs

could reach 45%. If the discharge temperature were

to be 5 degrees warmer, the savings could increase

to 50%, which is significant. From this savings

potential the customer would be seeing a payback

in approximately 2 years with savings on energy

continuing each year after.

To explain the savings figures; In cooling only

mode, the existing chiller consumes 47% more

power than the proposed unit when running

at a full load capacity of 705kw. The two units

consume 2,196,329kWh (existing) & 1,158,746kWh

(proposed). When operating the chillers in heat

recovery mode the existing chiller will provide

852kW of recovered heat for a total power input of

219.2kW & the proposed unit provides 801kW of

recovered energy for 171kW of total power input.

The existing chiller has a Global efficiency ratio

of 6.94 versus the proposed unit having a Global

efficiency ratio of 8.4

Solution...With continuous improvements in technology and

design, new equipment proves to be much more

efficient than running old equipment for years.

Frequent review of equipment is vital to ensure your

process is working at maximum efficiency.

A turnkey solution was provided and had little

impact on the facility during installation thanks to

the experienced ICS Temperature Control Project

Manager. An air-cooled chiller with full heat recovery

using a heat exchanger was installed and the

results were fantastic, as estimated. ICS’s Service

packages come in standard and bespoke form to

best meet their customers’ requirements. For this

project, a 3 year extended warranty package was

chosen, giving the customer complete peace of

mind that their new equipment would be maintained

and that ICS would be there 24hr a day to support

with servicing.

A Complete Solutions Provider of Equipment & Maintenance Support ICS are specialists in providing cooling and

temperature heating and controlling solutions.

Working with a wide range of industries including

food, chemical, plastics and healthcare, ICS offer

standard and bespoke packages to best suit their

customers’ requirements.

With Nationwide Service Support, ICS have a

team of experienced engineers to visit sites on

either the same or next day to review the business

requirements, recommending the most resilient and

economic solution.

Heat Recovery Helps Metal Treatment Company Reduce Energy Costs

A Midlands based metal treatment company contacted ICS

Temperature Control regarding a solution to replace their ageing,

inefficient cooling system which provided chilled fluid at 10°C to a

number of anodising tanks.

Industrial Cooling Systems

ICS House, Stephenson Road, Calmore

Industrial Estate, Totton, Southampton,

SO40 3RY

t: 023 8052 7300

f: 023 8042 8366

e: [email protected]

ICS’ energy efficient air cooled chiller

Heat recovery process

Page 39: EMS_DEC-full_d2_med
Page 40: EMS_DEC-full_d2_med

40 Engineering Maintenance Solutions

This closed cell, fibre-free material offers low

thermal conductivity values to limit heat and

energy losses whilst preventing moisture ingress,

an important feature for controlling condensation

on cold air ductwork. The flexible material

also features in-built Microban® anti-bacterial

protection to minimise the potential for surface

microbial growth which can contribute to the

symptoms of sick building syndrome. In addition,

Armaflex Duct has good noise absorption

properties, helping to reduce breakout noise and

decreasing the transmission of air and structure-

borne sounds within commercial buildings.

Armaflex Duct insulation is available in rolls of

both 1 and 1.5 metre widths, and in a range

of insulation thicknesses from 9 to 40mm.

The product is also available with or without a

self-adhesive mounting surface and can also be

supplied with or without a protective aluminium

facing on one surface. This dust and fibre-free

material is highly flexible for easy installation on

rectangular or circular ducting surfaces. The self-

adhesive version in particular reduces installation

times, while the aluminium faced option has

an easy-clean external surface. This aluminium

surface also provides protection against

mechanical impact for the underlying Armaflex

insulation layer.

NEW ARMAFLEX DUCT INSULATION COVERS ENVIRONMENTAL REQUIREMENTS

The range of specialised insulation materials manufactured by

Armacell now includes Armaflex Duct, a purpose developed solution

for the fast and effective outer cladding of ductwork systems in

commercial air conditioning systems.

Further information is available on request to:

Armacell UK Ltd, Mars Street, Oldham,

Lancashire OL9 6LY

Telephone: 0161 287 7015

Fax: 0161 633 2685

e-mail: [email protected]

www.armacell.com/uk

They incorporate a level control which ensures

zero air loss during the condensate discharge

process which is via a diaphragm valve.

Contaminants contained in the airline

condensate (including oil, water, rust and other

accumulated debris) can be highly detrimental

to production processes, including in-line

equipment as well as production batches.

Condensate drains are designed to remove this

damaging material from pressurised air systems

at minimum expense and in the safest manner.

The ZLD series zero-loss products incorporate a

large cross-section diaphragm valve to flush out

the condensate under the fault-free operation

of the valve. At the same time, the condensate

is prevented from forming an emulsion which

would incur expensive condensate treatment.

A volt-free alarm contact is also incorporated

in the ZLD products to monitor the condensate

drainage process.

Four models are available in the range, suitable

for operation with airline pressures up to 16 bar,

within a temperature range of 1 - 60°C. They are

designed typically for operation with compressor

aftercoolers, refrigeration dryers and airline

filter units, covering throughput capacities from

180m3/h up to 95000m3/h.

LOSS-FREE CONDENSATE DISCHARGE WITH HI-LINE ZLD DRAINS

The ZLD series of condensate drains now available

from Hi-line Industries Ltd are designed to eliminate

accumulated contaminants from pressurised air systems.

Further information is available from: Hi-line Industries Ltd,5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PGTelephone: 01283 533377Fax: 01283 533367 e-mail: [email protected] www.hilineindustries.com

Product Spotlight

Page 41: EMS_DEC-full_d2_med

41Engineering Maintenance Solutions

In the same way that you get your car serviced at regular intervals to ensure reliability, having your door serviced at regular intervals, will prolong the life of the asset and greatly reduce unwanted and potential costly breakdowns.

While most companies view the maintenance of machinery on their production lines as vital, many overlook the maintenance of their industrial doors, failing to appreciate that the production line could come to a standstill if a goods-in or goods-out door were to jam shut for example, resulting in costly down time and lost production. Furthermore, as with any other piece of machinery a door that is not regularly serviced is more likely to breakdown incurring high repair costs. All industrial doors and associated access equipment should be serviced periodically, since routine checks and visual inspections help identify problems before they escalate and become costly.

The frequency of servicing per year will depend on the usage of the asset and the environment in which it operates. An industrial door that is in a high usage area, i.e. a goods in and out loading bay in a 24 hour operating distribution centre, would be ideal to have at least 2 services a year. Compared to an industrial door that is designed for security purposes. Therefore an annual inspection would be sufficient.

When companies are putting in place provisions for having a regular programme of maintenance, they should give due consideration on how they would proceed with implementing the programme. Either having in-house competent personnel, (A trained and qualified engineer) which can dedicate time to carry out visual inspections/checks and can carry out vital repairs, while keeping accurate records. Or for peace of mind, employing an external industrial door company that can carry out this work at a nominal cost. Thus enabling on-site maintenance personnel to carry out their day-to-day duties.

Having a service and maintenance programme or an agreement in place with BID Group a competent industrial door maintenance specialist, provides assurance that companies are meeting their obligations under the various health and safety regulations; Fire Precautions (Workplace) Regulation, Provision and Use of Work Equipment Regulation and Workplace (Health and Safety and Welfare) Regulation.

At BID every service agreement is tailored to each individual site’s requirements; the number of doors and associated assets, the usage and the working environment. We take all the hassle away from the company by carrying out the service and inspection. Providing peace of mind that not only are companies complying with the current regulations but also their doors, which are an integral part of the day-to-day operations, are fit for purpose and remain that way.

In addition to on-site engineers, BID Group also has an extensive technical department that can diagnose that vast majority of faults and in some circumstances can advise companies’ own maintenance staff how to rectify the problem without having to place a call-out.

Tips:

General maintenance and periodically visual inspections will- Prolong the operational life of the door- Keep the doors in a safe and efficient condition- Help prevent potential downtime- Keep it legal

‘Tips And Things To Think Of ’ When Ensuring That Industrial Doors Are Well Maintained

Servicing of industrial doors, gates, loading bay equipment and other goods in and out associated equipment is seen by leading industrial door companies, such as BID Group, to be the most beneficial and cost effective measure of ensuring continually safe and reliable operation.

Page 42: EMS_DEC-full_d2_med

42 Engineering Maintenance Solutions

Fully supported worldwide via our offices in USA, Australia and

Malaysia with Qualified Agents in UK, Canada, South Africa,

and Latin America. On-Site and remote training available.

Contact [email protected]

www.cworkssystems.com

CMMS Solutions from CWorks Systems Inc

We provide innovative, flexible, easy to use,

affordable solutions to your maintenance needs.

CWPlus, affordably priced MSAccess

solution, over 500 installations world wide.

CWSQL for larger and multi-site application.

Also includes remote site solutions.

CareWorks/Easy, web-based, no upfront

costs, provided as SaaS via a modest monthly fee.

All solutions include Handheld device options for remote updating of Work

Orders, Spare Parts and Meter Readings.

Olivo portable insulated containers have been manufactured for

over fifty years and are the market leaders in the distribution of

temperature-sensitive food products. In the dry ice sector, Olivo

containers are used by many leading names- Air Liquide, Messer,

Linde, BOC, Praxair, Coljet, Yara, etc. The combination of high

quality insulation and robust plastic construction with steel fittings

ensures that the containers have a very long life. The ease of

movement on casters or feet makes the containers very easy to

handle so that the dry ice pellets for blast cleaning can be taken

direct to the point of use and still at exactly the right temperature.

Olivo Contain Dry Ice Pellets

Page 43: EMS_DEC-full_d2_med

43Engineering Maintenance Solutions

Page 44: EMS_DEC-full_d2_med

44 Engineering Maintenance Solutions

Doors

Door closers are regarded as a commodity

product, with very little thought given to their

performance other than the initial purchase

price. By the time anything goes wrong, the

subcontractor who originally fitted them can be

difficult to contact, leaving the end user to inherit

the problem and its associated costs.

The problem with a purchase price approach to

specification is that mechanical door closers are

often subject to very heavy usage, particularly

when fitted in high traffic areas in public

buildings. A large department store entrance

for example will have around 5,000 openings

per day which equates to 1.5 million annually.

A school entrance door will have circa 1,250

openings per day or 225,000 annually and a

hospital ward door will typically be opened

350 times a day which equates to 128,000

openings annually. With door closers, as in

many other walks of life, you get what you pay

for and a cheaper product will often be unable to

withstand this volume of use.

However, the problems don’t stop with the

mere opening and closing of doors. Real world

conditions impose strains on mechanical

door closers which do not come to light in

manufacturer test bed conditions.

For example, forced openings and door

misalignment lead to sagging doors and frames

and bent arms, amongst other problems. In turn,

this causes damage to the internal workings of

the door closer and can ultimately lead to the

door closer failing to perform as it should.

At this stage, bigger problems start to

occur. There will be a loss of door control,

with unreliable closing and associated safety

and security risks. Inevitably, this will lead

to increased costs for door replacement,

maintenance and door frame repairs.

What Is The True Cost Of A Door Closer?Mechanical door closers are frequently specified on the basis of

initial purchase cost, but all too often the low purchase price masks

on-going maintenance and performance issues which can lead to

costs spiralling out of control, says Paul Barrows of Ingersoll Rand

Security Technologies.

For more information about Ingersoll

Rand Security please visit

www.ingersollrand.co.uk.

Page 45: EMS_DEC-full_d2_med
Page 46: EMS_DEC-full_d2_med

46 Engineering Maintenance Solutions

Capable of

providing accurate

measurements up

to 10 TΩ for 5 kV

versions and 20 TΩ

for 10 kV versions

and having facilities

for automatic timed

IR tests and more

advanced diagnostic

tests; PI, DAR, DD, SV

and ramp tests.

Megger’s new IRTs are available in three versions. The MIT515 is an

entry-level 5 kV test set which offers insulation resistance (IR), timed

insulation resistance (IR(t)), dielectric absorption ratio (DAR) and

polarisation index (PI) test modes.

Get your MITs on Megger’s new insulation testers!

Megger’s new high-voltage insulation resistance testers (IRTs)

offer exceptional versatility in a compact, rugged and light unit

that weighs little more than half as much as its predecessors.

It is an extremely versatile, expandable data logging and alarm system,

ideal for real-time monitoring of a wide range of parameters such as

temperature, humidity , energy use and can also be used with third party

sensors. It can take measurements over large areas such as warehouses,

greenhouses, cold rooms and factories. EnviroMon is made up of a

number of different modules including sensors, converters, alarms and a

logger. You can network up to 15 mixed converters to a logger, and add

alarm options if required.

AlphaTemp Technology are exclusive distributors to the

EnviroMon product range developed by Pico Technology.

These accurate and versatile

sensors will automatically

transmit air temperature and

humidity data without disturbing

the environment in which they

are placed. Temperature data is

then wirelessly streamed live to

your PC. No need for cables.

The free software enables the

user to customise high and low alarms plus data transmission times. An

audible alarm warning will indicate as soon as temperatures reach above

or below the selected settings. The received data can be immediately

displayed in graph format or transferred into other applications.

NEW WiFi Temperature Monitoring Sensors

With audible alarm indicators and WiFi capabilities, the

EL-WiFi range are the ideal ultra compact temperature and

humidity monitoring device.

www.corintech.com

01425 655655

The MSR165 is capable of

making 1600 shock and vibration

measurements/s in all three axes

for up to 6 months. It can also

measure temperature, humidity,

pressure, light and record 4

analogue input signals. Boasting a memory capacity of over 2 million

measurement parameters, the MSR165 monitors shock up to ±15

g, 32 measurement values are recorded even before the event

takes place. Using a microSD card, the memory capacity can also

be significantly increased which is particularly useful for recording

vibration measurements.

MSR165: data logger records shock for up to six months

Swiss Technology Company MSR Electronics GmbH

launched its MSR165 data logger, complete with a built-in

three-axis digital accelerometer.

MSR Electronics GmbH

Tel. +41 52 316 25 55 | Fax +41 52 316 35 21

[email protected] | www.msr.ch

Data Loggers

Page 47: EMS_DEC-full_d2_med

47Engineering Maintenance Solutions

Buyers Guide

Page 48: EMS_DEC-full_d2_med

48 Engineering Maintenance Solutions

Buyers Guide

Page 49: EMS_DEC-full_d2_med

49Engineering Maintenance Solutions

Buyers Guide

Page 50: EMS_DEC-full_d2_med

50 Engineering Maintenance Solutions

Buyers Guide

Page 51: EMS_DEC-full_d2_med
Page 52: EMS_DEC-full_d2_med