march/april 2001

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

ISSUE 10

MAR/APR 2009

BUYERS GUIDELEANMAINTENANCECONDITIONMONITORING

w w w . e n g i n e e r i n g m a i n t e n a n c e . i n f o

INDUSTRY NEWS

MAINTEC 2009 REVIEW

SPOTLIGHT ON ATEX

BOILERS

TOP TEN TIPSfor preventive maintenance

TURN TO PAGE 11 FOR THE FULL STORY

+44 (0)1732 221245www.flir.comfrom £3995

For more information quote EMS Enquiry No. 101 on IBC

15PAGE

37PAGE

21PAGE

19PAGE

6PAGE

3PAGE

EMS, MSL Group, Cobalt House, Centre CourtSir Thomas Longley Road, Rochester, Kent ME2 4BQ+44 (0)1634 731646

www.engineeringmaintenance.info


INDUSTRY NEWS

BASICS OFlean and reliability based spareparts and materials management

EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer IdhammarAlan France, Mark [email protected]

ADVERTISEMENT SALES: Michael Dominguez (Publisher)[email protected] [email protected] [email protected]

WEB MANAGER: Oliver [email protected]

DATABASE MANAGER: Steve Hill

TECHNICAL MANAGER: Igor Seke

CREATIVE:Ric [email protected]

ARTWORK PRODUCTION:Elaine [email protected]


Published six times per year by EMS

Annual subscription: UK FOC Rest of World £90 © 2009 EMSArticles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every effort ismade to ensure the accuracy of information published. No legal responsibility will be accepted by the publishers forloss arising from articles/information contained and published. All rights reserved. No part of this publication may bereproduced or stored in a retrieval system or transmitted in any form without the written consent of the publishers.

In about 50% of organisations spare parts and materials stores reports to themaintenance organisation. In about 50 % of organisations spare parts andmaterials stores is part of the purchasing function.

One of the areas that are first attacked when an organisation wants to becomelean is the materials and spare parts areas. Through reducing the value of spareparts and material kept in storage you can of course reduce costs. It is true thatthere are often big opportunities to lower the value in many stores, but it canalso become very expensive if it is not done correctly. One of the most commonmistakes is to discard parts that haven’t been used in, for example, the past fiveyears or more. To discard these parts based on the fact that they have not beenused for a long time is way too simplified and risky and I am surprised everytime I see that this tactic is still being used in many plants. These incorrect andexpensive cutbacks happen as a result of the people in charge having the goal ofreducing the store value, while the consequences of not having the right part instorage when the parts are needed, is a problem for those responsible foroperations and maintenance.

To read the full story, please turn to page 3.

We are pleased to announce the launch of HES (Hazardous Engineering Solutions)magazine. The first edition is bound into this copy of EMS. HES aims to examinethe latest engineering, technologies and trends associated with hazardousenvironments. There will be particular focus to ATEX equipment and legislation.

PUBLISHER’S COMMENT


LEAN MAINTENANCE

INDUSTRY NEWSLatest trends, news and technology

EUROMAINTENANCE

OEE

CONDITIONMONITORING

LEAN MAINTENANCE

Basics of lean and reliability basedspare parts and materials management

INDUSTRIAL PROTECTIVE COATINGS

CONDITIONMONITORING

New condition monitoring regime met with approval

EUROMAINTENANCE

Rendez-vous in Verona in 2010


A polymer solution to in-servicedeterioration of heat exchangers

OEEThe financial justification

Call the Hire Department to discuss your project:

Tel: 01535 665225EEmail:: [email protected] Web:: www.byworth.co.uk

TEMPORARY BOILERSYOU’LL WANT TO KEEP!

TEMPORARY BOILERSYOU’LL WANT TO KEEP!

• UK's most reliable and efficient rental boilers

• Modern, fuel efficient boilers with latest technology

• Plant for long term projects can be builtto specification

• Service back up second to none

• Speedy emergency hire service

• Steam boilers from 500 to 16000 kgs/hr

• Hot water boilers from 250 to 5500 kW/hr

• Multiple boilers installed for larger demand

• Full installation, commissioning andtraining available

UK's leading boiler hire service from themanufacturer of the UK's most fuel efficient boilers

• UK's most reliable and efficient rental boilers

• Modern, fuel efficient boilers with latest technology

• Plant for long term projects can be builtto specification

• Service back up second to none

• Speedy emergency hire service

• Steam boilers from 500 to 16000 kgs/hr

• Hot water boilers from 250 to 5500 kW/hr

• Multiple boilers installed for larger demand

• Full installation, commissioning andtraining available

UK's leading boiler hire service from themanufacturer of the UK's most fuel efficient boilers

UK’S LEADING

BOILERMANUFACTURER

UK’S LEADING

BOILERMANUFACTURER


We can show you the way...

Proviso Systems Ltd provide condition monitoring and predictive maintenance productsand services predominantly to the UK market. We utilise techniques including vibrationmonitoring, thermal imaging, oil analysis and integrated plant management philosophies.

Let us light the way to protecting your business...

Tel: +44 (0)1777 817536 Email: [email protected] Web: www.proviso-systems.co.uk

Vibration AnalysisThermographyOil AnalysisHydraulic Circuit TestingRCM

Balance & Laser AlignmentPulley AlignmentElectrical Inspection & TestingMotor Current AnalysisEquipment Criticality Audits


Basics of Lean and Reliability BasedSpare Parts and Materials Management.One of the areas that are first attackedwhen an organization wants to becomelean is the materials and spare parts areas.Through reducing the value of spare partsand material kept in storage you can ofcourse reduce costs. It is true that there areoften big opportunities to lower the value inmany stores, but it can also become veryexpensive if it is not done correctly. One ofthe most common mistakes is to discardparts that haven’t been used in, forexample, the past five years or more. Todiscard these parts based on the fact thatthey have not been used for a long time isway too simplified and risky and I amsurprised every time I see that this tactic isstill being used in many plants. That theseincorrect and expensive cutbacks happen isa result of that the people in charge of the

stores often having the goal of reducing thestore value, while the consequences of nothaving the right part in storage when theparts are needed, is a problem for thoseresponsible for operations and maintenance.

Most stores, especially in plants thatare ten or more years old, can reduce theirvalue by 10 to 20% without negativelyaffecting production reliability. Tosuccessfully, and sustainably, reduce thevalue of parts and material kept in storesyou must focus on measures that drivesdown the cost, not only on reducing thestore value. You should also set up ameasurable goal for this effort. The goalcould for example be “With a service factormaintained at 97 % we will reduce value ofinventory kept in stores”. In this case theservice factor is percent of occasions theright parts/material have been availablewhen needed for a maintenance job.

First you obviously need to know what parts and material you have inyour stores. First do a quick evaluation of how accuratethe inventory list is. Randomly choose 300 to500 articles and compare how correct thebalance is, the location in the stores is etc.We have often found that the inventorycatalogue is 70% accurate while a goodvalue would be 98%+. Even if this accuracyvalue is 100% it does not mean that thestores are cost effective. Do we have theright articles? Do we have too many?

Find out how many articles exist inundocumented storages. If the inventory catalogue and/or the plantregister, including component record andspare parts documented for each piece ofequipment, are not accurate and reliable,then the users will not trust that thearticles they need are going to be available

Lean Maintenance IV

3EMS March/April 2009 www.engineeringmaintenance.info

In about 50% of organizations spare parts and materials stores reports to the

maintenance organization. In about 50 % of organizations spare parts and

materials stores is part of the purchasing function


in the store when they need them. Thisone of the reasons why people startbuilding up their own stores. These storescan become extensive and very expensiveto have. The costs are invisible. Morearticles are purchased before they areneeded and often in greater quantities thannecessary. Moreover the articles are oftenstored in a bad environment where theycan be damaged by corrosion, dirt,vibrations, etc. It is imperative to clean up,sort, organize and document all the articlesin all these storages. The store managerwill most likely not want to take all theseitems back in the central stores, becausethis would increase stores value and takeup costly space.

I sometimes call these undocumentedstores emotional stores. If you have madeefforts to document all these stores and thentake away all parts in these stores from thepeople who have them, and put the parts incentral stores, then you will understand whyI call them emotional stores.

Decide what you are going to have in storage.In addition to known and traditionalmethods and data used to decide whatshould be kept in storage such as deliverytimes, economic purchasing quantities,consumption statistics etc. it is notuncommon that information such as; riskfor breakdown of a component, cost if anarticle is not in storage when it is needed,condition monitoring based storage,number of identical parts used in the plantequipment etc. are missing. Then onlyguesses are made as to what should andshould not be kept in storage.

It is important that an analysis hasbeen done on what production equipmentis critical and which components withineach piece of critical equipment couldcause a breakdown. The breakdown costcompared to the cost of keeping parts instore is an important piece of informationthat should be taken into considerationwhen storage levels are decided.

With good condition monitoring you canoften avoid keeping parts in storage if theso-called failure developing period is longerthan the delivery time of the parts you aremonitoring. A practical example is chainsand sprockets made of steel. They weardown over a longer time period, they areeasy to inspect with objective methods andthe delivery time of replacement sprocketsand chains are often short. If you monitorwear of sprockets and chains you can orderthem when you need them instead ofkeeping them in store.

With an accurate inventory catalogueand/or the plant register, includingcomponent record and spare partsdocumented for each piece of equipmentyou will know how many identical articlesare included in the production equipment.This is necessary and important informationto have when doing evaluations ofsuppliers’ recommendations and decisionson what to keep in stores. The absence ofthis documentation will lead to that youkeep wrong parts and in the wrongquantities in your stores.

Standardization can also reduce storagesubstantially. If you have a production linewith 22 or so different and critical,electrical motors you might decide to keep

one of each of the 22 motors in thestorage. You can often standardize by aboutfive different motors or even just one type.Then only five or maybe just one motor iskept in storage.

What good looks likeA good storage does not only have a costeffective store volume. The store is closedand delivers parts where and when theyare needed. The picture shows the deliveryof parts and special tools for a shut downthat is going to start in three days. In theworst organizations there is a line outsidethe store in the morning of the shut down.

Store item maintenance. You need to keep parts you store in theright environment, free of dust, othercontaminations and vibrations. Shafts ofrotating items such as electric motors andpumps shall have their shafts orientedtowards the isles in the store so they caneasily be rotated to avoid sagging of shaftsand damages of bearings. V-belts and otherbelts made of rubber and similar materialshall be kept away from day light,preferably in a dark location. Bearingsshould be stored laying flat and turned on aregular basis.

� www.idcon.com

� Reader Reply Number: 300

Christer Idhammar is a world renownedexpert in Reliability and MaintenanceManagement best practices. He started theIdhammar group of companies in Sweden in1972 and IDCON, INC in USA 1985. In 2002 he received the Euromaintenance IncentiveAward for outstanding internationalcontributions to improve Reliability andMaintenance in industries world wide. In May 2008 he received the Salvetti Foundationreward for best speaker among 154 speakersat Euromaintenance 2008 in Brussels. He canbe reached at [email protected]

Christer Idhammar,president IDCON INC

LEAN MAINTENANCE IV


LATEST NEWS AND PRODUCTS


Merlin Power Management has added the valuable diagnostics tool, ThermalImaging, to its growing portfolio of productsto further enhance its status as a TotalSolutions Company.

By using a thermal imaging camera it ispossible to identify the transfer of Infraredheat radiation from an object and displayan image of the temperature distribution.The camera quickly detects temperaturedifferences often invisible to the nakedeye, thereby allowing corrective action tobe taken before costly system failuresoccur. A single survey could identify faulty

cabling, a defective motor bearing, poorinsulation a defective circuit breaker etc.

Thermography also enables inspections to beperformed while electrical systems are underload. Faults in electrical cables, switches,fuses, motors, batteries, etc. can be detectedwithout time consuming, disruptivemaintenance necessitating the switching offof circuits. Engineers quickly scan a piece ofequipment from a safe distance withoutputting themselves in harms way.

� 08700 623349 � www.shentongroup.co.uk � Reader Reply Number: 301

Thermal imaging is added toMerlin’s portfolio of products

JG Speedfit, the Push-Fit Solution for Plumbing, Heating and Underfloor Heatingsystems has just launched an update to its underfloor heating literature.

The new 22-page brochure combines the Main Voltage Electrical Controls, the LowVoltage Network Control Products and the Energy Saver Plus Manifold System.

The new brochure gives both installer and end user one point of reference forthe three ranges and provides easy to follow installation advice.

� +44 (0)1895 449233 � www.johnguest.com � Reader Reply Number: 304

Merlin has added ThermalImaging to its growing

portfolio of products to furtherenhance it’s status as a Total

Solutions Company

Merlin has added ThermalImaging to its growing

portfolio of products to furtherenhance it’s status as a Total

Solutions Company

The entry level Formula range comprises fourstrong and durable steel cabinets that areideal for light industrial applications,maintenance operations or when blasting isrequired on an intermittent basis.

Guyson Formula blast equipment provides afaster alternative to labour intensiveoperations such as: scraping and wirebrushing, sanding, grinding and manyothers. It is the ideal solution formaintenance departments, restorationworkshops and reconditioners andremanufacturers seeking to replace theseslower and more labour intensive methods.

The range starts with the F1200 bench topmodel, which has trigger operation for theblast gun and this is perfect for smallworkshops, laboratories, studios and evenDIY applications. If larger components needto be blasted there are the F1400 and F1600cabinets, which have a foot operated blast

gun. Thelargestcabinet in therange is theF2000 which hasa flip-top lid,allowing forloading of lightbut bulky orawkwardly shapedparts into its spacious interior.

All use the industrial quality Guyson model400 blast gun, which can be tailored to suitair supplies of between 8 and 16 CFM whenblasting at 80 PSI. Standard electrical supplyis single phase 220 volt, 50 Hz. All cabinetsare supplied with a highly efficient dustcollector as standard.

� +44 (0)1756 799911 � www.guyson.co.uk � Reader Reply Number: 303

Medway Maritime Hospital has shaved 2to 3% off its main boiler house energybill with the installation of twoautomated systems for boiler blowdownfrom Spirax Sarco. The automatic TDS(total dissolved solids) systems monitorthe build up of contamination in theboilers and initiate a boiler blowdownwhen the level of contaminants reaches apreset threshold. Before the installation ofthe Spirax Sarco systems, staff at theKent-based hospital carried out periodicblowdown operations on the two boilersby hand. “With manual blowdown we

didn’t know exactly howoften to blow down so wehad to err on the side ofcaution,” says thehospital’s TechnicalEngineer - Environmental,Phil Belton. This meant

that the hospital was discarding more hotwater than necessary. “We identified theblowdown operations as one of the areasin the boiler house that could play a partin our carbon reduction operations. Afterall, we were spending an average ofaround £40,000 every month on boilerfuel,” says Mr. Belton. “We’re extremelypleased with the results.” The two SpiraxSarco TDS systems have now beenoperating for over a year and haveproved very reliable. “They’ve given usno problems whatsoever,” says Mr Belton

� +44 (0)1242 521361 � www.spiraxsarco.com/uk � Reader Reply Number: 302

Medway MaritimeHospital saves energy

NEW update to underfloor heating literature

FORMULA FORmaintenance blast cleaning

ABB offers the expertise and support you need to address

every aspect of your plant, encompassing automation

and control through to power distribution. ABB’s service

teams transform your plant through a comprehensive

range of lifecycle services that focus on achieving optimum plant performance.

Our transformation goal is simple: to maximise the return on your investment today,

tomorrow and forever.

To find out more, call 01480 488080 ref. ‘Transformation’

or visit www.abb.com/service

ABB LimitedHoward Road

Eaton Socon

St Neots

Cambridgeshire

PE19 8EU

Tel: 01480 488080

Fax: 01480 470787

© Copyright 2009 ABB.

...the way you manage your plant

Totally transforming...

Power and productivityfor a better world TM


www.elcomponent.co.ukt 01279 503173 f 01279 654441 e [email protected]

Unit 5, Southmill Trading Centre, Bishop’s Stortford, Hertfordshire CM23 3DY

aM&T Sub-Metering SystemsFlexible cost-effective metering for all utilities and every type of business. We have the hardware, software, networking and installation skills to supply the package you need, on time and on budget.

alarm signalling

Power Quality AnalysersHigh performance instruments for the most demanding energy and powerquality analysis applications designed and built to the highest quality standards.Supplied complete with the latest windows software.

Energy Data LoggersEasy to use portable data loggers forelectricity and general utility monitoring.Safe, non-invasive.

(3 phase analysers)

Power Factor Correction

fast payback and real savings.



T: 01767 691812 • F: 01767 691802

• www.easi-dec.co.uk

per month buys you thisEasi-Dec Roofline System

- interest paid!Now you can turn your hire costs into profit!By using wasted money to buy your first Roofline System.The benefits are outstanding.

• Huge time savings on site

• Leaves your customer’s

garden untouched

• Very professional image

• Over conservatory access

• Dormer access

• Corner access

• Full training included

• Delivery included

and more!

…call us for a demo

£195 +VAT

Field Sales vacancy for North West area

Dust and fume extraction hoses from Masterflex

� Temperature range -260°C to +1100°C

� Size range 38 mm to 900 mm

� Very flexible, small bend radius

� Long service life, low operating costs

� Suitable installation and connecting systems

Masterflex Technical Hoses Ltd

GB-Oldham OL1 4ER

Tel: 0161 626 8066

www.masterflex-uk.com

TUBE PROTECTIONPU / FABRIC HOSES CONNECTIONS


An integrated stepper motorand drive has been introducedby motion control specialistsAstrosyn InternationalTechnology. The STM23 can besupplied with an encoder fittedto its rear shaft.

In this arrangement, the motoroperates in closed loop modeand can outperform servo motorsfor speeds up to 1500 rpm. Italso provides better acceleration,especially for short distanceapplications. The combined unitis more compact than anequivalent servo motor, as wellas being considerably less

expensive. Other advantages arelong life and high reliability.These benefits combine to makethe STM23 an attractivealternative to servo motors in awide range of applications.

The size 23 motor and drive arecontained in a compactaluminium heatsink housing.Designed from the outset as anintegrated package, the STM23reduces cabling requirementsand saves space and costs. It alsohas excellent EMC properties.

The high resolution drive isprogrammable using richinstruction set software, via

built in RS232 and RS485interfaces. Coding can bedownloaded to the drive forstandalone operation, or theunit can be controlled usingserial commands from anattached PC, PLC or other host controller.

Two versions are available from Astrosyn, with single ordouble stacks. Power supply is12-80Vdc and output current0.2-5A peak.

� +44 (0)1634 815175

� www.astrosyn.com





As someone involved in themaintenance of a company’sassets, which may includeplant machinery, vehicles, longterm hire equipment, stockand spares; you will be awareof the bewildering amount ofguidance on the subject.

You may well be new to thesubject having just beendelegated to look at yourcompany’s asset portfolio, orgiven this task in addition toother operations work.

But what ever the situationthis short check guide fromMCP will help you look at themacro questions which effectcorrect maintenance activityand asset management.

1. Are all the assets yourcomputerised maintenancemanagement system identifiedregistered, and recorded, andhow many are not being used?

2. Do you know which assetspresent the greatest risk toyour business in terms of:

Business continuity? Health & Safety? Environment? Lost production output?

3. Do you know the conditionof all the assets and do youknow the level of reliability?

4. Do you have an effectivepreventive maintenanceprogramme which aims forzero failures?

5. Do you know the utilisationand efficiency levels of yourmaintenance technicians?

6. Is the level of engineeringdowntime less than 2%?

7. Do you know the scope forenergy savings in your business?

8. Are you proactively lookingat ways to reduce the amountyou spend on spare parts?

9. Is the total cost of maintenanceexpenditure less than 5 % ofyour operating costs?

10. Is your maintenanceexpenditure decreasing year on year?

THE TEN QUESTIONS YOU SHOULD ASK ABOUT your maintenance activity and physical assets

The STM23 integrated

stepper motor with encoder

from Astrosyn can outperform servo

motors for speeds up to 1500 rpm

INTEGRATED STEPPER MOTOR with encoder outperforms servo motors

If you answered no to morethan two of the above question you are missing anopportunity to reduce yourmaintenance costs and improveyour plant performance, whichtypically results in lower cost of goods sold.

� +44 (0)121 506 9034 � www.mcpeurope.com � Reader Reply Number: 306



NEW COMPRESSED AIR DRYERS

Metal component and assembly provider,Stevens & Carlotti has invested in two fullyenclosed spray rooms and one gas fired boxoven, designed, installed and commissioned

Ciba takes Lean Engineering seriously andnowhere more so than at its Bradfordfactory where it manufacturers its worldleading range of chemicals for watertreatment and paper industries. Ciba’spolicy of continuous improvement andwaste minimisation led them to invest inan ELGA Process Water reverse osmosissystem. Ciba wanted to maximise theutilisation of the borehole water supply,so they discussed with ELGA ProcessWater about pre-treating it so that theycould feed it to the deioniser. Thetreatment system supplied by ELGAProcess Water included sand filters,organic scavengers and a MegaRO.� +44 (0)1628 897000 � www.elgaprocesswater.co.uk � Reader Reply Number: 308

by surface coatings specialist, HI-TEC SPRAY(HSL). The enclosures are constructed fromgalvanised, mild steel panels. The smaller hasextraction at one end with filtered airreplacement introduced via hinged roofpanels. The larger booth has double sideextraction combined with the central roofinput, which creates a semi downdraft sprayenvironment. This affords good all-roundspray application, particularly when coatinglarge products without compromising extractefficiency in a large spray area environment.Both environmentally friendly booths operateon a forced shop air replacement system.

� +44 (0)1622 356590 � www.hitecspray.co.uk � Reader Reply Number: 307

GOOD ALL-ROUND SPRAY

uses only 6.75m2/h, therefore saving8.25m2/h. Depending on the compressor’stype and condition, this is equivalent to apower consumption of 1kW. At a full-costprice of 0.02 €/m3 of generated compressedair and 8000 operating hrs/yr, this gives anannual saving of about 1,320€. UltrapacClassic dryers are available in three ranges,for volume flows from 5-1000m3/h. Withtheir compact design and economicaloperation, these heatless adsorption dryersare a proven “all-in-one” treatment system,suitable for a wide variety of applications.

� +00 49 2129 5690

� www.emea.donaldson.com � Reader Reply Number: 310

The introduction of the new Ultrapac Rangefrom Donaldson, means users of heatlessadsorption dryers can now benefit fromreduced energy (using Donaldson’sUltraconomy control) and maintenancecosts as the dryers are equipped with newcompressed air filters that comply with ISO12500-1. A dryer, designed for 100m3/h at35°C inlet temperature and 7bar(g)operating pressure, uses approx 15m3/h ofregeneration air during a fixed cycle. At anaverage compressed air requirement of60%, an average inlet temperature of 30°Cand average pressure of 7.2bar, the waterload still only amounts to approximately45% of the maximum value. On average,the dryer with load-dependent control now

Dialight’s semiconductor-based LEDBrightluminaires are built for frequent switchingoff/on, unlike traditional lights, so theyremove the need for 24/7 safety lighting.As ‘smart’ lights the luminaires also have‘instant-on’ ability, achieving full brightness innanoseconds, so they’re especially practicalas safety lights in low traffic areas wherethey can be left off or dimmed and triggeredto come on by proximity switches when

someone enters. They also offer superiorcolour rendition over sodium lights, thusproducing more useful CCTV footage, andtheir ability to focus light directionally makesthem more efficient at lighting shelving andstraight walkways with reduced light spill.

� +44 (0)845 6346161

� [email protected]


Safety benefits of ‘Smart’ Lights

Two automatic pump traps from Spirax Sarco have helped solve a serious control issue forSembcorp, one of the UK’s leading industrial utilities and services companies. The pump trapsprevent the company’s gas heater from stalling, which was previously making it difficult to controlthe gas temperature. Sembcorp uses gas to produce electricity in its own power generation plant onTeesside, as well as distributing gas to some of its industrial customers. The company must heat itsgas supply to 40°C to prevent it freezing as it enters lower pressure lines downstream. “Since we’veinstalled the pumps traps the improvement has been dramatic,” says Development Manager, Dr. Michael Capstick. “Prior to the new systems being installed the gas temperature varied widely,but the temperature control is now within 2°C of the set point”.

SEMBCORP takes control with Automatic pumps traps

� +44 (0)1242 521361 � www.spiraxsarco.com/uk � Reader Reply Number: 311

Lean&Fit


As a field service engineer in the pulp andpaper industry, I am well aware thatpreventing problems is infinitelypreferable to curing them. Establishing apreventive maintenance campaign meansthat equipment failures which result inproduction downtime and cut profits canbe kept to the bare minimum or evenprevented entirely.

Between 60 to 80% of all equipmentmalfunctions, on QCS (Quality ControlSystem) scanners, and other equipmentlocated on the actual production process,are caused by not carrying outmaintenance correctly. This should includebasic routines such as detailed cleaning,lubrication, alignment and followingoperation and installation procedures.

Harsh environments, producing lots ofdust and heat, are particularly challenging.Such environments are to be found in thepulp and paper industry. Elimination orreduction of the effects of these inherentchallenging environments keeps me busyduring my working week. These activitiesare carried out at three major papermanufacturers in the South East ofEngland, on a total of seven QCS and DCS(Distributed Control System) systems.

The paper machines all have ABB’squality control measurement scanners,which have onboard sensors measuringvarious properties of the sheet duringmanufacture. These can include: basis,weight, moisture, ash, colour, thickness, and

more. As well as this, I look after the ABBDistributed Control Systems used by themills to control the paper making process.

My experience working every day onthe maintenance of equipment installedwithin the paper industry has allowedme to draw up a list of the top ten tipsfor maintaining the health of pulp andpaper mills.

The following primarily applies to theQCS which is at the heart of the paperprocess. Other equipment, such asvariable speed drives, motors andinstrumentation may or may not be withinthe hostile dusty parts of the process.However, whenever this equipment islocated in a dusty environment, some ofthe following housekeeping practices canbe observed.

General advice

1 Keep it clean

One of the “by products” within themanufacturing areas is dust. If thisis not controlled, then it can causemany potential risks in terms ofmeasurement accuracy andoverheating of critical electroniccomponents. This is controlled usingwell-developed head packagedesign and well-engineered airwiping devices.

Distributed Control Systemequipment in particular should be

sealed against the ingress of dust,as electronics coated with dust areparticularly prone to overheatingwhich can cause failures.

Particularly dirty areas shouldideally be redesigned to protectequipment from dust. Keepingthings clean also allows otherproblems to be spotted andrectified more readily. Cracks,leaks, loose connections and otherproblems are more easily found ifthe item is not covered in a thicklayer of dust.

2 Be systematic

A good preventive maintenanceschedule is one that is based onfirst class record keeping. Alogbook should track what hasbeen checked; what was found;and any corrective action that wastaken. These records form aplatform on which to basepreventive maintenance schedules.

At a minimum, the logbook shouldinclude what, how and why aninspection was done.

Successful preventive maintenancedepends on information recordedon the service reports provided bythe system owner. If there is notenough information available, a

An old saying has it that prevention is better than cure and nowhere is this more

so than in the pulp and paper industry. ABB field service engineer Eva Moreno,

who works closely with a number of ABB’s pulp and paper customers, gave us

her top tips for ensuring maximum system availability of equipment installed

on the customer sites that she visits routinely

Top 10 tipsfor paper plant preventive maintenance

PREVENTIVE MAINTENANCE


site survey for the system shouldbe carried out before preventivemaintenance is undertaken. Anypreventive maintenance must beplanned well in advance in orderto reserve the resources andservice parts needed.

3 Inspect regularly

ABB’s planned maintenanceprogramme sees me visiting eachmachine weekly. Weekly checks onthe quality control scanners forexample, can mean inspecting thesensor window material fordamage or wear. Early detection ofthese problems will ensure sensoraccuracy and hence more efficientproduction costs.

Monthly maintenance andverification checks are also carriedout on the scanner and sensors. Ialso carry out an annual inspectionin addition to regularmaintenance, trying to ensure thatthe scanner and sensors giveoptimum performance throughtheir entire lifetime. I have foundthat it is best to inspect equipmentwhile it is operating, not only tominimise shutdown time, but alsoto detect such things as vibration,correct operating pressures andleaks, which cannot be assessedon stationary equipment.

ABB will advise on the frequencyof inspection for particularproducts, and will alwaysendeavour to work within theconstraints of an operatingproduction plant.

Machinery issues

Although I personally specialise inQCS and DCS equipment, othermachinery such as drives andmotors obviously play a major rolein paper production and alsorequire maintenance.

ABB has a product lifecyclemanagement model based onmany years of service informationand experience. In this model,there are preventive maintenanceprograms for different productfamilies, including QCS and DCSand drives and motors. Byfollowing these maintenanceschedules, lifecycle costs canusually be minimized.

As well as maximising availabilityof the equipment, it also provideslow price service parts throughpreventive maintenance kits,which are 15-40 % cheaper thanthe same parts sold separately.

Pre-defined, genuine service partsare provided according to themaintenance schedule, making iteasy to plan a long-termmaintenance material budget andincreasing the efficiency ofmaintenance tasks.

4 Inspect and maintain scanners

Scanners and their onboard sensorsare fundamental to maintainingquality and I am careful to givethem particular attention.

The probability that a scanner willfail increases after three to 10years of operation. One of themain reasons for failures is agingof components, but it can beaffected by environmentalconditions, such as dust and heatand therefore maintenance is key.

Preventive maintenance forscanners should involve:

� Visual inspection of the systemand its environmentalconditions

� Inspection of the connections

� Inspection of the ribbon andfibre optic cables

� Functional inspection of the fanand cooling system

� Inspection of the health pagesand alarm history

� Inspection and storage of theparameters

� Functional testing of thesystem under normalconditions

� Basic measurements withsupply voltage

� Inspection of the spare partinventory

� Cleaning of the system

All these are offered andrecommended by ABB and canform part of a Service Contract.

ABB has developed tools andservices to ensure its customersmaintain a high level of systemavailability and performance. I useABB software tools to check if thesensor is still reading the samevalues as it did when it was set upand that such parameters asmoisture and basis weight arestable and correct.

5 Apply regular maintenance to drives

Variable speed drives keep theplant moving, so regularpreventive maintenance is vital tomaintain their health. Keeping


Maintenance softwarejust got easier

� Delivering maintenance software benefits since 1990

� Proven by hundreds of customers in a widerange of industries

� Flexible system to meet your needs� Now even simpler to buy, implement and use.� Fully feature systems start at £1490

Don’t take our word for yourself. Call us now, and find out for yourself.

Tel: 0191 2963816 email: [email protected]: www.cayman.co.uk

Don’t take our word for it.Call us now, and find out for yourself.

For more information quote EMS Enquiry No. 111 on IBC For more information quote EMS Enquiry No. 116 on IBC

Ball Valves & Taps

Filters & Strainers

Pipe Fittings

Pressure Cleaning Equipment

Connectors & Couplings

Hose Reels

.....and don’t forget Pumps

pumpsmore than just pumps

www.dualpumps.co.ukfor more details call 01664 567226 or visit


drives and motors clean ensuresthey are within their operatingtemperatures and helps achievethe best possible efficiency.

One of the options we have is tokeep an eye on the drives in aplant remotely. This allows suchfeatures as drive systemparameter verification, parameterchanges, on-line measurements,changes to application software,upgrades to system software,remote guidance and writteninstructions sent to themaintenance PC. Remotemonitoring can also be carried out.

6 Upgrade motors

Motors are another essential in thedrive chain and those designed forhigh reliability will help maintainavailability. A recent motor forprocess industries has a 20-30%greater cooling surface thanprevious motors, reducing theinternal temperature considerably.

This gives longer component lifeand will protect your motors fromoverheating. With improved cooling,lubrication intervals are 50% longer,as lower temperatures increase thelife of the bearing grease.

Managing preventive maintenance

7 Assign the right people for maintenance

A key strategy is to control whoimplements the preventativemaintenance procedures and tohave an agreed plannedprogramme of work. I have found that the best results areachieved when specific peoplewith the correct training are givenpersonal ownership.

8 Give the right training

Employees should be trained bothin correct normal operation, so asnot to exceed the device’sparameters, and in what to dowhen problems occur. Shiftengineers need the training sothey know all about the operationof the system. I have found thatcustomers might train their staffwhen the equipment iscommissioned but later may notbe so concerned aboutmaintaining current training. This

can cause more callouts to ourservice engineers than needed,resulting in production delays.

You can get a lot of help fromequipment vendors, many ofwhom will provide training to help you carry out your ownchecks on the equipment and alsohow to clean the areas mostaffected by dust.

9 Get professional help

Many vendors will also perform onsite preventive maintenance. Thebest vendors will assign dedicatedfield service engineers to a mill todevelop a close relationship withcustomers. In my case, this meansmy customers keep me informedabout their shutdown schedule so Ican plan the more intensivemaintenance activities and ensurethat the installed base is operatingin peak condition.

Beyond my maintenance duties,part of my work involves advisingcustomers about new products ordevelopments that could enhancethe functionality of their existingsystems and to warn them ofobsolescence issues. As ABB fieldservice engineers, we are taughtto be proactive – we don’t justlook at what repairs are neededtoday, but at what equipment thecustomer will need to support itsprocesses in the future.

An alternative to performingpreventive maintenance on site isto consider sending modules tothe vendor’s own workshop. If amodule is to be sent to theworkshop for repair, it is often practical to

perform preventive maintenanceat the same time.

Customers can also choose to haveRemote Diagnostic Services (RDS).We operate in a fast movingelectronic age and must keep pacewith technological changes andneed for cost control. RDS offersfacilities for monitoring currentperformance against benchmarkdata using asset monitors. Thisprovides opportunities for predictivemaintenance, and all of its benefits.

10 Develop models and programmesto enhance maintenance

Many companies, including ABB,provide the process andmanufacturing industries with astructured program to improve andsustain the performance ofproduction assets. The best of thesearrangements occurs when theclient and the vendor work togetheras a team to develop a businessmodel that supports the client byproviding world-class reliability andmaintenance services.

Look for a risk/rewardperformance mechanism thatensures that continuousimprovement opportunities areidentified and captured over thelife of the contract.

� www.abb.co.uk




MAR/APR 2009

Spotlight on

ATEX

ISSUE 1

ATEX EQUIPMENT SPOTLIGHT

SAFE ANSWERS TO HAZARDOUS QUESTIONS

EXPLOSIVE ATMOSPHERECOMPLIANCE

SERIOUS ABOUT SAFETY

THE INTERNATIONAL MAGAZINE FOR ENGINEERS WORKING IN HAZARDOUS ENVIRONMENTS

w w w . e n g i n e e r i n g m a i n t e n a n c e . i n f o

MACHINE

LINE No.

DATE

NAMEPRIORITY

EST. TIME

HIGH / LOW

SHIFT

DESCRIPTION OF FAULT AND POSSIBLE CAUSE:

INV NoQTY.

DESCRIPTION

COST

SPARES REQUIRED

MACHINE

LINE No.

DATENAME

PRIORITY

EST. TIME

HIGH / LOWSHIFT

DESCRIPTION OF FAULT AND POSSIBLE CAUSE:

INV No QTY.DESCRIPTION

COSTSPARES REQUIRED


New Chiller Technologies.ICS has the complete package

Maximise efficiency and save costs with the latest range of energy efficient chillers from ICS.

An extensive range of chillers are available to you incorporating the latest energy efficient technology, such as Turbocor Centrifugal compressors, ozone friendly refrigerants and free cooling capabilities.

Call ICS free on 0800 169 3861or log on to www.icstemp.com.

For more information quote EMS Enquiry No. 115 on IBC For more information quote EMS Enquiry No. 112 on IBC


2PAGE

EXPLOSION AND DUSTIGNITION PROOF VACUUMCLEANER SYSTEM

OILFREE VACUUM PUMPSWITH ATEX CONFORMITY

7PAGE

SAFE ANSWERS TOHAZARDOUS QUESTIONS

EXPLOSIVE ATMOSPHERE COMPLIANCE

8PAGE

AIRBENCH ATEX

FATA – INDUSTRIAL ELECTRIC HEATERS, SYSTEMS AND CONTROLSFOR HAZARDOUS AREAS

3PAGE

NEED ZONE 2 COMPUTER PROTECTION?

SSP OFFERS PUMPING SOLUTION FOR ATEX

5PAGE

IECEX SOLENOID OPERATORS FOR USE INEXPLOSIVE ATMOSPHERES

NEW LIQUID TIGHT CONDUITSYSTEM WITH ATEXAPPROVED GLANDS

4PAGE

EXD (FLAMEPROOF)BREATHER DRAIN

COMPLETE LINE OFINTRINSICALLY-SAFE TEST & MEASUREMENT TOOLS

6PAGE

KTR SHAFT COUPLINGS INACCORDANCE WITH ATEX

SERIOUS ABOUT SAFETY

CONTENTSSPOTLIGHT ON ATEX

1HES March/April 2009 www.engineeringmaintenance.info

SPOTLIGHT ON ATEX


ARC Technologies, is the authorised

distributor for ‘Tiger-Vac’ ATEX rated

Industrial Vacuum Cleaner Systems for

wet or dry recovery

’LEGALLY’ Certified for hazardous locations: Fuel, metal dust,pharmaceutical powder, shooting ranges, flour mills, carbonblack, nuclear, etc.

These vacuum cleaner systems are certified for explosionproof/ignition proof hazardous

locations by an independent laband can be used to vacuum upflammable and explosivematerials. Qualified forcategories 1, 2, & 3 asdefined in the ATEX directive

94/9/EC.Available in both electric

(single and three-phase), and air operated versionswith a variety of recoverytank capacities.

Constructed mainlyfrom stainless steel, theyare robust and yet easy

to manouvre. Acomprehensive range ofstatic-dissipating tools andaccessories are available.

There are filtration options too, HEPA for dry

dust, Activated Carbon toabsorb fuel and solventvapours, or both on one unit.

Whatever the hazard,we have a specificallydesigned vacuum cleanerfor your operation.

� Tel: +44 (0)115 928 1508

� Email: [email protected]

� www.arctechnologies.co.uk � Reader Reply Number: 501

For pumping gases and vapours in areas

with explosive atmospheres vacuum

pumps with ATEX conformity are required

fluoroplastics of high chemicalresistance. Connectors andother parts are likewise madefrom antistatic materials andstainless steel. A furtherfeature include integrated gas ballast with inlet for inertgas. Three pump versions areavailable to provide amaximum pumping speedbetween 1.9 and 8.1 m3/hand an ultimate vacuum of 12 to 2 mbar. Correspondingchemistry vacuum systemswith separators and emissioncondensers offer the possibilityof solvent recovery.

� Tel: +49 9342 808-0


� www.vacuubrand.com� Reader Reply Number: 502

Explosion anddust ignition proofVACUUM CLEANER SYSTEM

Oilfreevacuum pumpswith ATEX conformityVacuubrand offers chemistrydiaphragm pumps forequipment category 2 (e.g.for zone 1) with ATEXconformity. The pumpingchamber of the diaphragmpumps has ATEX conformity II2G IIC T3 X. It is designed tofulfil requirements forpumping a wide variety ofinflammable solvent vapoursas well as e.g. hydrogen.Design and operation of theseabsolute oilfree pumps arebenefitial, for certain ignitionsources had been avoided,they have no sliding surfaces,and the expansion chamber ishermetically sealed againstthe drive zone. The internalparts of the pump heads aremade from antistatic

SPOTLIGHT ON ATEX


Zone 2 computer enclosures from Armagard offer an

inexpensive and flexible alternative to conventional

industrial computers, offering complete intrinsically

sealed protection in potentially explosive atmospheres

without the need for compressed air

come fully equipped with ATEX compliantintegrated membrane keyboard andDuraPoint mouse.

Available in 316 food grade stainlesssteel they come fully assembled, wiredand earthed with 6mm thick acrylicwindow, internal circulation fan for heatdissipation and 4-way surge protectedmains block.

Using conventional PC’s in hazardous zone 2 areas allows thefreedom to change, repair or upgrade atwill - if the enclosed computer fails simplyreplace it - no more downtime waitingfor computer engineers!

� Tel: +44 (0)121 6087226

� www. armagard.co.uk


Our ATEX enclosures are certified zone 2compliant and are available in mild andstainless steel and fully adhere to ATEXdirective 94/9/EC for type N restrictedbreathing devices.

An Armagard enclosure allows aconventional PC and monitor to be used inhazardous zone 2 environments. Theyaccommodate both CPU and monitor and

NEED Zone 2computer protection?

Where safety is paramount the SSP Pumps product range offers customers ATEX

Certified rotary lobe pumps under the ATEX Directive 94/9/EC Group II, Categories 2

and 3, Gas and Dust

solution for mechanical seals to enablecustomers to maintain the highest level ofsafety. This takes the form of single, singleflushed or double flushed mechanical sealoptions which can be supplied with anembedded Type K thermocouple.Thermocouples can be connected to anyappropriate monitoring device or PLCsystem to warn of increasing high surfacetemperature at the mechanical seal facesin the event of some system failure.

� Tel: +44 (0)1323 414509


� www.alfalaval.com


SSP ATEX Certification applies to the SeriesS and Series X pumps that have, asstandard, metallic wetted componentsmanufactured from 316L stainless steeland the Series D pumps manufacturedfrom ductile iron.

These pumps are capable of achievingflow rates up to 115 m≥/h and differentialpressures up to 20 bar.

One important consideration with theapplication of pumps in an ATEXenvironment is the primary sealing device.As mechanical seals can generate hightemperatures, particularly when subjectedto dry running, some safeguard should beconsidered to detect such conditions. Here,SSP Pumps have developed their own

SSP OFFERS PUMPING SOLUTION FOR ATEX

SPOTLIGHT ON ATEX


Following in the success of the model DPE

Breather Drain range, Redapt Engineering

Ltd has introduced the model BDU

Breather Drain for both Exd Flameproof

and Exe Increased Safety

installations in Zone

1 and Zone 2

hazardous areas

Steel (316) and Brass bodymaterials, with optional nickelplating and four thread sizes;M20, M25, 1/2inch NPT and3/4inch NPT.

The model BDU range hasbeen independently tested andapproved for ATEX and IECExcertification by SIRA Test andCertification Ltd.

� Tel: +44 (0)121 526 7058


� www.redapt.co.uk


The model BDU Breather Drainis designed with IP66 ingressprotection to be mounted inthe bottom of a flameproofenclosure to effectively drainany water from the enclosurewhilst allowing the air in theenclosure to breathe with thesurrounding atmosphere,minimizing moisture build up.The model BDU can also bemounted in the top of theenclosure to operate as abreather only.

It is available in Stainless

Exd (Flameproof)BREATHERDRAIN

Fluke, offers a

complete line of

rugged, intrinsically-

safe tools to meet

the needs of

technicians &

engineers working

in and around

hazardous areas

or source/simulate volts, mA,RTDs, thermocouples,frequency, and ohms.

The Fluke 707Ex LoopCalibrator is the ideal,stand-alone tool forcalibration and maintenanceof 4mA to 20mA controlloops. It provides 24V looppower while measuring mA.

The Fluke 718Ex PressureCalibrator is a self-containedsolution for pressuremeasurements and calibrationwith a built-in pressure sensorand a pump.

For more information visitthe Fluke Web site atwww.fluke.co.uk/process

� Tel: +44 (0)207 9420700


� www.fluke.co.uk


Meeting ATEX standards, thetools are ideal forenvironments in chemicalplants, oil platforms, refineriesand other locations where riskof explosion exists. They canbe used to install, maintainand troubleshoot equipment,as well as maintain andcalibrate sensors, transmittersand control loops.

The Fluke 87V Ex is adevelopment of Fluke’s high-performance, high-accuracy87V industrial multimeterwith special features fortroubleshooting motor drives,plant automation, powerdistribution and otherelectromechanical equipment.

The Fluke 725ExMultifunction ProcessCalibrator, based on the Fluke725, is an easy-to-use, toolwith the capability to measure

CompleteLINE OFintrinsically-safe test& measurement tools

SPOTLIGHT ON ATEX


Asco Numatics announced

IECEx Certification for a range of

products that are already ATEX compliant

for use in hazardous areas

together, provides machinerymanufacturers and OEM’s with access to anextensive range of explosion proofoperators for valves, that can be used onequipment for delivery and installationworldwide. End users benefit from accessto a wider selection of products andreduced costs for designing and

maintaining facilities that are replicated inseveral countries.

� Tel: +44 (0)1695 724270


� ww.ascojoucomatic.co.uk


The additional certification covers the AscoNumatics Ex d, Ex mb and Ex ia ranges ofexplosion proof operators for solenoidvalves for zone 1. IECEx certification meansthat these products are recognised andaccepted worldwide for installation in ahazardous area.

Combining the ATEX and IECEx approvals

IECEx solenoid operators for use inEXPLOSIVE ATMOSPHERES

For hazardous area applications where oil resistant electrical conduit systems are

required, Kopex International can now offer a system that combines the ATEX certified

flame HAM proof gland with EXLB oil resistant flexible metallic conduit

The glands operate within a temperaturerange for -60ºC to +80ºC and have a T6temperature classification of +85ºC. IP66ingress protection is also provided.

EXLB conduit is a general oil resistantproduct with a flame retardant PVCcovering. It is approved to IEC 61386 andis IP66 and IP67 rated. It has a generaltemperature rating of 25°C to + 105°C andin flexing applications, - 6°C to 105°.Conduit size availability is 10mm – 63mm(1/4 inch – 2 inches).

� Tel: +44 (0)1675 464276


� www.kopex.co.uk


The HAM ATEX approves flameproofgland range is designed to suit EXLB andEXSB conduits, and is available in brass,metal coated and stainless steel. Withepoxy resin, the glands are approved foruse in Zones 1, 2, 21 and 22 classificationswhere vapours gas or dust may bepresent for both EExd flameproof and EExeincreased safety protection certification.

This solution has been made possiblethanks to changes in certification of theHAM range and the new combination issuitable for EX II 2 GD gas and dust aswell as EExd IIC and EExe II applications.

New liquid tight conduit system withATEX APPROVED GLANDS

SPOTLIGHT ON ATEX


Preventing the release of dangerous

substances which can create explosive

atmospheres, and preventing sources of

ignition are two widely used ways of

reducing the risk of explosions. Using the

correct equipment can help

coupling, RADEX-N steel laminacouplings and servo laminacoupling RADEX-NC.

KTR have produced a leafletto explain ATEX specificationsand introduces the KTR rangefor explosion-proof areas takingeach product in turn to explainits own relation to ATEX.

The leaflet may bedownloaded from www.ktr.comby following the links from thehomepage: Service – Publications– ATEX95 Brochure.

� Tel: +44 (0)114 258 7757


� www.ktr.com


KTR offers a number of couplingsthat conform to ATEX which canbe used in hazardous areas. Asone of the leading globalmanufacturers of shaft couplingsfor chemical technology, KTRconformed to the ATEXspecifications at an early stage. Thevast majority of its products wereexamined by an independentinstitute with regard to their usein explosion-proof areas.

Among the ATEX certifiedcouplings are the torsionallyflexible ROTEX, POLY-NORM andPOLY jaw couplings in variousdesigns, the backlash-freetorsionally flexible ROTEX GS,the BoWex curved-tooth gear

KTR shaft couplingsin accordancewith ATEX

Sira is the leading UK Notified Body for

ATEX and a world-leader in the provision

of IECEx certification

Sira delivers the onlynationally-recognised andaccredited competencescheme, ‘CompetenceProfessional’, which assessesindividuals through training,experience and formalassessment to give a crediblequalification of competence.

Sira has developed a rangeof CASS Accredited servicesenabling manufacturers andintegrators to promote theirproducts and services in themarketplace to FunctionalSafety, 61508/61511.

� T: +44 (0) 1244 670 950

� E: [email protected]

� www.siracertification.com


Sira can undertake all thenecessary tests andassessments to certify productsin accordance with both ATEXand IECEx requirements. Siraalso provides world-wideapprovals through a networkof agreements with leadingapproval bodies, includingNorth America, China, Japan,Australia and South Africa.

In addition, Sira also offerscontinued surveillance of yourmanufacturing process byissuing Quality AssuranceNotification (QAN) and QualityAssessment Reports (QAR). Sirawas the first Body to receiveaccreditation to the IECExRepair Scheme, and issued theUK’s and World’s first IECExRepair Scheme Certificate.

SeriousABOUT SAFETY

SPOTLIGHT ON ATEX


STL International Ltd offers one of the widest available ranges of low

maintenance and maintenance free hazardous area and industrial light fittings and

luminaires including emergency lighting and for specialist applications such as dust

elsewhere on the plant or site.STL can achieve this with the supply of

lighting fixtures that are complete witheither LED or induction technology lightsources, or long-life fluorescent tubes fromAura or Philips; as standard. High quality,long-lasting materials and components egballasts are used and, where applicable,light fittings carry an extended warranty.Also, pricing is very competitive.

STL use computerised light calculationsand can custom-design and supplyancillary equipment such as UPS andbattery back-up systems as well as controlstations and panels.

� Tel: +44 (0)1622 749633


� www.stl-int.co.uk


STL has formed partnerships with majormanufacturers to provide front-line technicialsupport and application advice for theirleading-edge technology products that areATEX approved for Zone 1 (21) & Zone 2 (22).

The ongoing mission for STL is toeliminate the necessity to maintain lightingor, at least, reduce lighting maintenance toan absolute minimum so that skilled andvaluable time can be better spent

Safe answers toHAZARDOUS QUESTIONS

TRaC is an established explosive atmosphere testing, assessment and certification

body. As an EX test laboratory and an ATEX Notified Body (NB), TRaC provides a

certification, safety testing and assessment route to manufacturers, designers,

importers, exporters, distributors and operators of equipment and installations to

ensure that they fulfill their legal obligations and demonstrate full compliance with

the national and international requirements of explosive atmosphere safety

atmosphere regulations (DSEAR)assessment In addition to certifying equipment for

all ATEX and IECEx standards, TRaC alsodeliver global approvals for EMC, Safety,Radio and Machinery safety.

� Tel: +44 (0)1695 556666


� www.tracglobal.com


TRaC provides a full range of services to thesuppliers of equipment for use inhazardous locations. These services include: � ATEX and HAZLOC explosive atmosphere

product evaluation and testing� Product control audits� Pre-compliance design consultancy� Technical file service � Routine inspection of electrical

equipment in hazardous areas� Dangerous substance and explosive

EXPLOSIVEatmosphere compliance

SPOTLIGHT ON ATEX


an ATEX rated area. The newbench uses high grade,independently certified, ATEXrated components with 2-stagefiltration to ensure dustgenerated during manualprocesses is effectively capturedand contained. Various sizes areavailable and non-standard filterconfigurations can be providedon request.

� Tel: +44 (0)1206 791191

� www.airbench.com


Workpoint are pleased toannounce their new air bench.AIRBENCH ATEX is designedspecifically for use in potentiallyexplosive dust atmosphereswhile providing the same highstandards of breathingprotection that users have cometo expect from the UK’s leadingsupplier of downdraughtbenches. The new unit hasalready been supplied tomanufacturers of medicalcomponents for use whenweighing powder mixes within

AIRBENCHATEX

Stoomwezen, AD Merkblatter,ISPESL (PED), TEMA, or anyother recognised code.

Control Systems designedto suit each processapplication, ensuring fullcompatibility, interfaces andsafety, especially whereheaters are located in ahazardous area.

� Tel/Fax: +44 01243 606007


� www.fati.com


Flameproof (explosive–proof)EEx d and EEx e constructionscertified to CENELEC standard EN50014/50018/50020 togetherwith air purged EEx p systemsare also readily available.Flanged Immersion heaters aresupplied with elementsupports/spacers or bafflesdepending on application.

Electric circulation heatersand process heating systemsfor heating a wide range ofindustrial liquids and gases .Mechanical design codesinclude ASME VII, BS 5500,

FATAIndustrial electric heaters,systems and controls forhazardous areas

A wide range of electric heaters for

the surface finishing industry including

Immersion heaters screwed flanged

can be supplied with a wide choice

of materials,

with terminal

boxes protected

up toIP65

EENNQQUUIIRRYY??F R E E P R O D U C T I N F O R M A T I O N S E R V I C ECCOOMMPPLLEETTEE AANNDD FFAAXX TTHHIISS PPAAGGEE BBAACCKK TTOO 00220088 77111133115533

enquiry no. enquiry no. enquiry no. enquiry no. enquiry no. enquiry no.


Please fill in your details if you (a) wish

to continue to receive a free copy of EMS

or, (b) wish to be included in the

magazine’s circulation list for the first

time. (Please use capitals and please

sign and date as indicated). Fax Back on:

00220088 77111133115533Please send me FREE information on:

(Delete as appropriate)(Mr, Mrs, Miss, Ms) First Name Surname

Job Title

Company

Post Code

Tel Fax

E-mail

Signed Date / /

PLANT MANAGEMENT

❏ Artificial Intelligence/Expert Sys

❏ Asset Management

❏ ATEX Equipment/Services

❏ Bearings

❏ Calibration

❏ Coding Systems

❏ Computerised Maintenance Management

❏ Condition Monitoring Consult

❏ Condition Monitoring

❏ Consultancy – unspecified

❏ Contract Maintenance

❏ Corrosion Prevention

❏ Couplings

❏ Data Analysers/Loggers

❏ Degreasers

❏ Descaling

❏ Drives

❏ Electric Motors

❏ Electrical Maintenance

❏ Equipment Rental

❏ Filters

❏ Flexible Hose

❏ Flexible Ducting

❏ Flow Meters

❏ Food Safety Lubricants

❏ Gaskets

❏ General Engineering Services

❏ Handling Equipment

❏ Hose & Cable Reels

❏ Hydraulics/Pneumatics

❏ Internet Services to Maintenance

❏ Labelling and/or Barcoding

❏ Laser Alignment

❏ Leak Detection Equipment

❏ Lubrication/Oil Analysis

❏ Maintenance Consultancy

❏ Maintenance Materials

❏ Measurement Instrumentation

❏ NDT Equipment or Services

❏ Pipe Freezing

❏ Pumps, Valves and Process Equipment

❏ RCM Consultancy

❏ Remote Monitoring

❏ Seals

❏ Sensors or Probes

❏ Specialist Maintenance Services/Products

❏ Surface Treatment and Coating

❏ Temperature Measurement

❏ Thermographic Services/Equipment

❏ Tools & Workshop Equipment

❏ TPM Consultancy

❏ Vibration

❏ Visual Planning

❏ Welding and Joining

TRAINING

❏ Institutes and Professional Bodies

❏ Recruitment

❏ Training Aids and Services

BUILDING MAINTENANCE

❏ Access Equipment

❏ Building Maintenance Consultancy

❏ Chemicals/Paints/Finishes

❏ Cleaning Components

❏ Cleaning Machines/Equipment

❏ Computer Aided Facilities Management (CAFM)

❏ Cranes/Hoists

❏ Doors/Curtains

❏ Flooring

❏ Lifts/Escalators

❏ Lighting

❏ Property Maintenance and Management

❏ Roofing

❏ Security and Fire Prevention

❏ Storage Systems

❏ Tank Linings & Bundings

ENVIRONMENTAL

❏ Dust/Fume Extraction

❏ Environmental Health/Testing/Equipment

❏ Noise Control

❏ Pollution Control Equipment

❏ Water Treatment

HEALTH & SAFETY

❏ Communication

❏ Health & Safety Products

❏ Legislation & Compliance

❏ Machine Guards

❏ Safety Showers & Eye Baths

❏ Workwear

ENERGY MANAGEMENT

❏ Boilers

❏ Burners

❏ Climate Change Levy

❏ Combined Heat & Power

❏ Compressed Air Equipment and Ancillaries

❏ Energy

❏ Energy Control Systems

❏ Energy Metering/Monitoring Systems

❏ Generators

❏ Heating, Ventilating and Air Conditioning

❏ Industrial Controls

❏ Power Quality

❏ Steam Traps

JJUUSSTT FFAAXX TTHHIISS CCOOMMPPLLEETTEEDD FFOORRMM BBAACCKK OONN 00220088 77111133115533

HES March/April 2009

RREEGGIISSTTEERR NNOOWWttoo ccoonnttiinnuuee ttoo rreecceeiivveeyyoouurr FFRREEEE ccooppyy ooff HHEESS

DUSTCONTROL SPECIALISE IN• ON-TOOL EXTRACTION• POWERFUL VACUUM CLEANING• AIR CLEANERS• TOOL CLEANING CABINETS• HEPA FILTRATION• ATEX RATED MOBILES AND SYSTEMS

DC 1800Workshops& odd jobs

DC 2800cMultipurpose & easy handling

DC AircubesClean air & healthy environment

DC 11-ModuleSource extraction & general cleaning



CONDITION MONITORING

By introducing a new regime of condition monitoring from scratch, a steel rolling mill has

not only avoided a number of costly breakdowns but also gained a greater understanding

of its plant and improved the perception of condition monitoring across the site

portable vibration monitoring device toobtain data on bearing defect frequenciesthey were able to report on some interestingfindings. “We found that we could obtainsome very reliable data from our handhelddevice which allowed us to understand thecondition of the six pairs of bearings anddetermine when a failure was imminent,”comments Ian Taylor, Business DevelopmentEngineer, PCM at Corus. “However, for healthand safety reasons, the manual approachwas not practical in the long term,” addsTaylor. “Rather than sending our engineersinto the working steel mill to obtain this dataon a regular basis, it was agreed to install anonline condition monitoring system.”

In September 2008, an eight-channel FAGDTECT X1 vibration monitoring system fromSchaeffler UK was installed on the rolling mill.One sensor was fitted to each of the six spindlesupport bearing sets, with a plan to connectthe two spare sensors to the pinion box.

“By using the online conditionmonitoring system we have been able togain a much better understanding of theplant,” says Taylor. “When we began toanalyse the first set of data, we realisedthat interference from other general plantequipment was masking the true bearingdefects. We therefore needed to eliminatethis in order to obtain true readings.”

Once this issue had been resolved, theFAG DTECT X1 system discovered two bearingfaults on two separate occasions within thefirst week of operation. The engineers wereable to plan the outage of the failed bearingand avoid a breakdown, which would haveresulted in a significant plant stoppage oneach occasion to allow time for strippingdown and replacing the failed bearings.

As Boyd points out: “By preventing twopotential plant stoppages, the system has alreadypaid for itself. Early detection means that we arein control of our plant. Not only are we spending

less time and manpower removing and replacingperfectly good bearings, or trying to identifywhich bearing has failed and why, but we arealso avoiding the added risks that humanintervention brings.”Asked what the futureplans are for condition monitoring atSkinningrove, Boyd confirmed that thecompany intends to further utilise suchtechniques and technology on other criticalpieces of plant. “People now believe in thistechnology,” concludes Boyd. “This haschanged the perception of conditionmonitoring as they can now clearly appreciatethe benefits to be gained from using thesystem. We are still on a learning curve,having only introduced this regime earlier in2008, but I am confident that we will obtain agreater understanding of the bearings.”

The DTECT X1 series is a cost effectiverange of online monitoring devices thatenables permanent frequency-selectivemonitoring. The advantage of the DTECTX1system is that it includes features that areusually only available in far more expensiveonline systems. The basic model is availableas a two-channel or eight-channel versionwith external multiplexer. All commonlyused acceleration, speed and displacementsensors can be connected to the system.Depending on the version used, processquantities such as speed, temperature,torque and pressure can be recorded.

The signal measured by the sensor isbroken up into its frequency componentsusing Fast Fourier Transformation (FFT),which enables monitoring of amplitudes forpreviously specified threshold values withinvery narrow, defined frequency bands,including the triggering of an alarm if thesevalues are exceeded. Therefore, damage canbe detected at an early stage by means offrequency-selective monitoring.

�www.schaeffler.co.uk

�Reader Reply Number: 320

Located at Skinningrove near Saltburn-by-the-Sea in Northern England, the plant ispart of the Corus Group and manufactureshot-rolled steel profiles for a wide range ofindustries, including earthmoving equipment,materials handling, shipbuilding and mining.

Monitoring of the six pairs of spindlesupport bearings on the two-stand reversingmill was previously carried out by physicalinspection on routine maintenance shutdowndays. This involved two craftsmen strippingdown the bearing housings and manuallyinspecting the bearings. If no defects werefound, the same bearings were thenreassembled into the original housings andrefitted into the mill. The entire process isboth labour and overhead crane intensive.This task was done in rotation so that eachbearing pair was inspected every six weeks.

This maintenance regime presented theengineering team with a number ofchallenges. As Scott Boyd, OperationsEngineer, Mechanical points out: “It is notgood practice to tie up valuable labour for afull day disassembling and thenreassembling bearings when they could beworking on other areas of the plant andfreeing up valuable resources.”

Not only were these increased manninglevels an issue for the engineering team, butthere was also the risk of introducing newproblems as a result of human intervention.Boyd continues: “Due to the harshenvironment in which the mill operates,there is an increased risk of particulatecontamination within the bearings during thedismounting and remounting process. Wealso had to ensure that when we refitted thebearings we did so to the correct bearingclearance, and this all takes time.”

Following a request from Skinningrove atthe beginning of 2008, Corus’ Plant ConditionMonitoring (PCM) team carried out patrolmonitoring on the bearings. By using a

New condition monitoringregime met with approvalby engineers at Corus Skinningrove


The exhibition is now in its 34th year – butwith maintenance professionals undermore pressure than ever to make efficiencysavings, optimise plant availability, andextend equipment longevity, the March 17-19 event took on added importance.

easyFairs® UK Marketing ManagerHelen Woodbridge, said: “Budgets for newcapital expenditure are tight – and whencompanies can’t afford large scale

investment in new machinery, effectivelymaintaining existing assets is paramount.In fact, our pre-show studies revealed thatalmost 60 per cent of manufacturers andprocessors are planning to tackle theeconomic downturn through addedinvestment in maintenance technologies.

“This was certainly evident at the show.It generated a focused group of quality,influential visitors…those genuinely looking

for products and systems to improveefficiency and reduce costs.”

Among those visitors – which numbered1,530 over the three days – was PepsiCoEngineering Criticality Coordinator Bob Abbas.He concurred that, as capital expenditure iskerbed, investment in predictivemaintenance was becoming a priority.“Theeconomic downturn hasn’t impacted on ourmaintenance budgets, but there is a cut on

Maintenance’s key role in helping businesses survive the recession was evident as

leading companies turned out in force at easyFairs® MAINTEC to investigate the latest

advances in asset management and maintenance technology

easyFairs® MAINTEC appeal stronger than ever as companies search recession-beating

MAINTENANCE TECHNOLOGY


capital expenditure,” he added. “Conditionmonitoring will be a key area for us todevelop in coming years. As such, I want tostay abreast of upcoming technology –easyFairs MAINTEC pulls together all thesenew developments and gives me a chanceto make direct contact with OEM’s.”

Representatives from BAE Systems,Network Rail, Cadbury, AstraZeneca,Diageo, Birds Eye, Severn Trent Water andGlaxo Smithkline also attendedBirmingham’s NEC to assess technologicalprogress in fields ranging from conditionmonitoring, thermography and mechanicalequipment to energy management, health& safety, and maintenance software.

And buoyed by the strong turnoutfrom senior decision makers, almost halfof the 116 exhibitors have already signedup to be part of easyFairs® MAINTEC 2010– scheduled for 2-4 March again at theNEC – which is a greater proportion thanrebooked at the same time last year.

Stand bookings for easyFairs® MAINTEC2010 can be made by contacting SunitaPuee on 0208 622 4416 or e-mail:[email protected]

Lord Bill JordanThe learnShops™ seminar line-up ateasyFairs® MAINTEC again affordeddelegates the chance to tap into technicalpresentations, expert opinion, researchfindings, and best practice case studiesfrom industry leaders. A total of 36learnShops™ ran across two theatres over

the three-day exhibition – and at many itwas a case of standing room only!

In addition, this year’s educationalprogramme was complemented with thelaunch of the MAINTEC Summit. Overseenby former trade union chief and currentRospa Chairman Lord Bill Jordan CBE, theConference brought together authorities inthe field of plant maintenance to discuss‘lean’ plant management, lubricationtechnology, automation, and energyefficiency amongst other burning issues.

Lord Jordan, former President of theAmalgamated Engineering Union andmember of the Foundation forManufacturing and Industry, said: “TheConference provided a major injection ofconfidence and ideas to delegates whoseindustries are suffering the harsh realitiesof recession. For some companies, whatthey went away with may well be thedifference between survival and failure.

“Delegates heard presentations of provensuccess in cost-cutting maintenance systemsthat were delivering vastly improvedperformances from plant and equipment.”

And he was also impressed with theexhibitor offerings, adding: “I and otherdelegates got a hands-on feel for the power-packed futuristic technology that’s changingthe face of traditional maintenance.”

New arrivalsThis year’s event was also notable by thenumber of new companies that exhibitedalongside easyFairs® MAINTEC stalwarts

who have used the show as a platform tomeet influential industry professionals formany years.

In total there were around 30 newcomers, including Shell UK OilProducts. “Everybody was very receptive toour arrival,” said Shell’s Industry MarketingSpecialist Richard Lonsdale. “It's been abusy and valuable show, and put us intouch with the full spectrum ofmaintenance workers, operationsmanagers, senior engineers and MD’s froma cross section of different industries.”

Another debutante was oil filtrationspecialists Antech Hydraulics. Sales ManagerDavid Farrow, said: “The show facilitateddetailed conversations with some veryswitched-on maintenance professionals.We’ve been introduced to the types oforganisations that we might otherwise havestruggled to get in front of.”

And one of many easyFairs® MAINTECregulars was IR Window specialist Hawk IRInternational, which was recently acquiredby Fluke. Hawk’s Trish Fellowes said: “Weattracted quality visitors and, naturally,that transcended into high quality leads. Itwas noticeable how the new MaintecSummit Conference helped attract veryimportant maintenance professionals ontothe show floor. Top marks to the easyFairs’team for their organisation, support andexecution of an excellent show.

� www.easyfairs.com/maintecuk


Monitran, a world leader in thedevelopment and manufactureof sensors for the measurementof vibration and displacement,has devised a new stud optionfor mounting its vibrationsensors and accelerometers.

Adding to the company’scurrent mounting solutions -which include QuickFit, magneticand traditional screw type - thenew option sees the sensorbonding to the stud via a grubscrew (through the body of thesensor). This option is ideallysuited to applications where thevibration sensor has an integralcable, as opposed to connector,and is not necessarily apermanent fixture. For example,the sensor might be taken frommachine to machine as part of aregular vibration-based conditionmonitoring routine.

Compared to traditionalscrew-type studs, the newmounting option alsoovercomes the risk ofcompromising the stud’scontact with the machine towhich it is fixed. Specifically,when using a spanner totighten a sensor to a stud it ispossible to sheer the stud-machine screw. It is similarlypossible to damage themachine-stud bond in the caseof adhesive studs.

“Also, when unscrewing asensor from a screw-stud youmight be unscrewing the stud

as well,” comments Monitran’sOperations Director, AndyAnthony. “Attaching to one ofour new studs via a grub screwis quick, simple and establishesa good mechanical bond;which is essential for thetransference of energy [i.e.vibration or acceleration]. Italso has the same benefits asmagnetic and adhesivemounts, in that no rotationalforce [torque] is transferred tothe stud-machine bond whenattaching and removing.”

The new studs will beavailable shortly, as applicableaccessories to a range of new-bodied sensors, and will besupplied with grub screws andAllen keys. Further, subject todemand, adaptors may bemade available to interfacebetween the new studs andtraditional-bodied sensors.

Anthony concludes: “Likemost engineering solutionsour new mounting option issimplicity in itself and deliversimmediate and practicalbenefits to a wide range ofapplications. It’s also yetanother prime example ofhow Monitran continues toinnovate to meet the needs ofindustry, and providestestimony to the strength ofBritish engineering.”

� www.monitran.com


This high performance impacttool in six model variants.Producing impact power fromno other source but the humanbody. Delivering impacttorque’s depending on modelfrom 160 ft lbs to 7000 ft lbs.The Swench has virtually noreturn to body impact due to itsunique design thus no whiteknuckle syndrome. It has beenin use for years in theAmerican military and is theirbest-kept tool secret for anypersonnel using nuts and boltsof any form. From carmechanics to truck fitters, plantfitters, military engineers,industrial production line fitters,factory maintenance, pipelineand chemical plant engineersthe list goes on. This impacttool will do the job without the

need for air compressors,electric or hydraulic power, asthere is no need for externalpower saving cost on fuel orenergy and inspection andmaintenance of powersupplying equipment.

� www.swench-the-only-

manual-impact-tool.co.uk

� +44 (0) 7968310951


Monitran revealed details of an

innovative stud option for mounting its

vibration sensors and accelerometers

FIT FOR PURPOSE

SPOTLIGHT

Supremely easy software

Take control!

Increase uptime,

reduce costs,

enforce compliance

and prove due

diligence.

To find out more,

visit us online.

Call today

CMMS

+44 (0)23 8022 [email protected]

F R E E F U L L T R I A L . N O R I S K !

Register for a FREEroadshow near you!

shiresystems.co.uk 10 000+ customers

BROWSERBASED

BROWSERBASED

� Nimble, fast & powerful

� Information at a glance

� Fits like a glove

� Sure road to success

� Why pay more?

Be a winner with Shire!


MANUALLY OPERATEDhigh performance impact tools


Euromaintenance, the international travelling industrial maintenance event, comes

to Italy for its 20th year in 2010. The international industrial maintenance event will

take place from the 12th to the 14th of May in the Veronafiere Conference Centre

The conference is aimed at a very hightarget: general managers, operations andmaintenance heads, plant managers,project managers, efficiency and reliabilityprofessionals, consultants, researchers, etc.

The themes covered by the conference will be those of most interestto operators: from predictive, conditionaland predetermined maintenance to RAMEngineering (Reliability, Availability,Maintainability); from enhancing theproductivity of maintenance personnel toimproving energy footprints andenvironmental protection; from reducingoperating costs to revamping industrialplants, from E-Maintenance (Cmms, Rfid,Infomobility) to technological innovation, etc.

We are particularly proud of the directinvolvement of OSHA, the EuropeanAgency for Safety and Health at Work,which has included Euromaintenanceamong its key appointments for the2010/2011 European Commissioncampaign for the reduction and preventionof accidents during work and maintenance.

The speeches and the specific interestsof visiting professionals will focus onmaintenance for the processing industry

(Oil & Gas, Chemical & Petrochemical,Cement, etc.), energy production (Gas,Coal, Nuclear, Alternative sources, etc.),manufacturing (Cars, Plastics, Aeronautics,Electronics, etc.), the pharmaceutical, foodand drinks industries, other “heavy”industries (Mining, Steel, Paper), and, ofcourse, infrastructure and transport (Portsand Airports, Rail, Roads, Electricity, Waterand Gas Distribution, Telecoms, Networks,etc.), facilities and building maintenance,and more.

These will all incorporate the analysisof case histories and workshops on the planning and/or execution ofmaintenance projects, down to budgetingand benchmarking.

As well as the conference, Verona willalso host the linked international tradeexpo, open to the main industry players.These will also be able to participate in theconference through technical andapplication workshops that will allow themto introduce their solutions on “hot” topicsto all attendants.

�www.euromaintenance.org


In 2008, the Brussels event was visited byover 700 managers and heads ofmaintenance and operations from 47countries, with over 200 companies and atotal of 5,000 professionals exhibiting.

The new Euromaintenance event isscheduled for the 12th to the 14th of May2010, and will take place in Veronafiere.

The organisation of the event has beenentrusted to EIOM (“Ente ItalianoOrganizzazione Mostre”). Since 1956, EIOMhas been the Italian leader in industryevents. It is also the creator of MCM, atrade show that has become the Italianevent of note for industrial maintenance,despite having been held only twice.

The coordination of scientific andcultural events will be handled by AIMAN(Italian Maintenance Association), assistedby the various other members of EFNMS(European Federation of NationalMaintenance Societies).

The Italian edition of Euromaintenancewill also consist of a conference and an expo:this international conference of world-classimportance (both for the issues discussed andthe quality of the speeches) will take place inthe presence of all the main industry players.

Euromaintenance 2010RENDEZ-VOUS IN VERONA


EUROMAINTENANCE

For more information quote EMS Enquiry No. 121 on IBCFor more information quote EMS Enquiry No. 120 on IBC

AUTOMATIC LUBRICATORS

A.T.S. Electro-Lube offer a full range of self contained Automatic lubricators

Electro Series Electro-Luber Series —ATEX certified gas driven

Lubricators in 4 sizes filled with thegrease that the user requires.

Refill/recycling service for used units

Ultimate Series Ultimate Series —Refillable high pressureLubricators for single or multi-point applications

Refilled by grease gun

Titan Series Titan Series —Refillable high pressure lubricators

For single or multi-point application

Refilled by changing standard grease cartridge

A.T.S. Electro-Lube (UK) Ltd383L Jedburgh Court, Team Valley Trading Estate,

Gateshead, Tyne & Wear, NE11 0BQ

Telephone: 0191 4914212 Fax: 0191 4914224Email: [email protected] Web: www.atselectrolube.co.uk


Belzona Polymerics Limited, providing solutions to industry for over 55 years through

the design and manufacture of polymer repair composites and industrial protective

coatings has a proven solution to prevent the detrimental effects of erosion corrosion

within heat exchangers

By treating heat exchangercomponents in this way, efficiency can berestored to levels approaching the originaldesign parameters and can be maintainedwithout subsequent deterioration.

During a recent maintenance outage,Belzona’s team of Power industry specialistsrevisited the heat exchanger and found it tobe in excellent operational condition, withoutthe need for further maintenance repairs.

Said Gordon Cairns, National SalesManager, “Our technology and experience has culminated in a costeffective repair and protection system thatcan prevent the associated implications ofin-service deterioration within heatexchange equipment.”

This is just one of numerous Belzonaproduct applications that have stood thetest of time, remaining in service manyyears after installation. Due to this provenlongevity, many product applications havebeen internationally approved by engineers,contractors and maintenance personnel.

Meanwhile, according to Gordon Cairns,Belzona has, of late, seen a significantincrease in the use of Belzona products fornew equipment. He commented, “Severalof the major and specialist originalequipment heat exchanger manufacturersare considering coating new equipmentwith Belzona’s range of protective coatingsdue to the outstanding performance theyoffer under many and varied arduousservice conditions.”

David Norton of Wellman Hunt–Graham,an international leading supplier of vacuumand heat transfer equipment explains,“Belzona materials were recently used on a

major heat exchanger project as analternative to titanium with great effect.”

“Traditional methods of manufactureinvolve machining an expensive titaniumtube sheet. The short application time ofthe Belzona solution coupled with theinexpensive coated carbon steel fabricatedcomponents, ensured the heat exchangeroffered the same performance andreliability of a titanium manufactured heatexchanger - Belzona is a real alternativeto high grade expensive alloys.”

�For more information about repairs to heat exchangers or other machinery andequipment repairs, contact Belzona directon 01423 567 641 or visit www.belzona.com


In-service deterioration can occur througherosion damage and galvanic corrosiondue to contact between dissimilar metals,commonly used in the construction ofheat exchangers. If this damage is notaddressed the efficiency of the systemwill be seriously undermined with thepotential for complete failure ofcomponents, resulting in expensiveoperational downtime and potentiallyhigh replacement costs.

In 2003, a heat exchanger in a majorPower station in the UK had beenremoved for refurbishment. Followinginspection, it was discovered that galvaniccorrosion, coupled with erosion hadcaused a loss of metal thickness on thetube sheet surface. Consequently, coolantwas able to contaminate the process fluid,necessitating immediate shutdown of thesystem, with the customer facingpotentially high cost maintenance repairs.

Belzona was able to provide a costeffective solution, utilising maintenancetechniques that have been developed,whereby components can be both rebuiltand protected using polymericcompositions. A multi-purpose, twocomponent system, based on a ceramicsteel reinforced polymer was used torebuild the eroded tube sheet and sealthe leaks. To prevent future deterioration,a low temperature curing, highperformance erosion corrosion resistantcoating system was applied. Theelectrically insulating Belzona materialsisolated the dissimilar metals used in heatexchanger construction, therebyeliminating further galvanic corrosion.

A polymer solutionto in-service deterioration of heat exchangers

Corroded tube sheet priorto Belzona application

Tube sheet repaired andprotected before beingreturned to service

Belzona erosion corrosion resistant coating systemapplied to a newly manufactured heat exchanger



IR-Fusion®:Now put problems

clearly in the picture

The rugged Ti25 and Ti10 thermal imagers

help you identify the exact problem area

The Fluke Ti25 and Ti10 make thermal imaging easy tounderstand and help you solve problems in industrialapplications. With patent-pending IR-Fusion® you can view afull thermal image, or one combined with a visual image, toidentify the exact problem area.

• See small temperature differences and fine details on thewide, full VGA display

• Engineered and tested to withstand a two metre drop

• Voice recorder simplifies adding comments to each image(Ti25)

• Store over 1,200 IR-Fusion® thermal images withtemperature data and voice comments

• Measure up to 350°C (Ti25)

Prices start from £2,986 for the Fluke Ti10

Fluke. Keeping your world up and running.®

Order your Ti25 or Ti10 now!

Check www.fluke.co.uk/tifor your nearest distributor

� 020 7942 0700

Full IR

Blended

Picture-in-Picture



VISITwww.engineeringmaintenance.info

for the latest � Jobs� News� Interviews� Online Seminars� Events� Training� Products� White Papers� Case Studies� Forum


High Performance Adhesive Technology

StructuralAdhesives

Cyanoacrylates(instant adhesives)

UV Curing Adhesivesfor bonding acrylic,

glass and metals

ElectricallyConductive Adhesives

ThermallyConductive Adhesives

ConformalCoatings

Glob Tops ThreadlockerUltra High

Temperature Ceramic Adhesives

Bonham Drive, Eurolink Industrial Estate, Sittingbourne, Kent ME10 3RY

UK Distributors of Reinhardt-Technik Metering Mixing Dispensing Systems

www.eurobond-adhesives.co.uksales@ eurobond-adhesives.co.ukT 01795 427888 F 01795 479685

Let’s create our own small factory tocalculate an ROI. We’re going to make paintin 10 litre pots. We have a process plant tomake the paint, but for this illustration weconcentrate on the filling process only.

Here is our simple plant, with just 3filling lines. We currently work hard butcan only just meet the weekly productionorders with lots of extra agency staff andovertime. IR issues make the prospect offixed extra shifts difficult so projectsengineers are beginning to make a casefor a 4th filling line.

I spoke recently for Johnson & Johnson at their European Council meeting. Beautifullakeside venue, not far from Geneva, good profit margins but recognising the best can bemade better. Most of their sites are already using OEE as the catalyst for change andhave implemented the measure with a series of spreadsheets. As usual for spreadsheetsmost sites have shown good initial progress but typically there are concerns over toomuch time spent manipulating data instead of improving the plant. The underlyingmessage from delegates was ‘we have outgrown our spreadsheets, we knowwe’re on the right track but how can we justifyCapex for a more powerfulOEE application?’

OEE – thefinancial justification

OEE


If we continue at this rate for the yearwe will have wasted €1,736,800.

So would the €1m Capex for a new linemake sense?It would increase our throughput targetfrom 900 per hour to 1,200, but we wouldneed extra staff and what if our OEE scorestayed at 40%?

We would reduce the extra hoursneeded to meet the order from 38 to 28,but our labour and energy costs haveincreased so we would still waste effortand money, to the tune of €1,627,600.That means that unless the new line canperform much better than 40% OEE, theactual ROI on the €1m Capex is closer to10 years than the 2 years anticipated. Isthere a better alternative?

Thankfully the answer is yes.What if we could use OEE properly; as

a catalyst for change, accurately identifythe losses and making people accountablefor resolving them. What if we couldimprove the OEE by a modest 20%, from40% to 60%?

That would make a big financialdifference; availability increases to 79%,performance to 80%, and quality to 95%.More importantly we reduce the extraproduction hours required to only 16 hours.

Labour 16 hours @ €200 per hour €3,200

Energy 16 hours @ €300 per hour €4,800

Materials 2,880 @ €3rejects per unit €8,640

We are still wasting €865,280 butthat’s down from €1,736,800 ... a savingof €871,520 a year.

On the subject of improving operationsto mitigate the need for a new line, MarkRogers, Site Maintenance Manager atSmith & Nephew sums it up:

“We have seen real sustainableimprovements in our assets throughreducing the six losses of OEE. Oneparticular asset was running seven days aweek and still struggling to meet customerdemands. Now it typically does the samevolume in four-and-a-half days.”

The Hull manufacturing site of Smith &Nephew implemented an OEE System, akey component that drives its TPMprogramme, and is now well on its way tobeing the leanest and most efficienthealth-product operation in the world.

So think carefully before you considernew capital plant to overcome pooroperation of existing equipment. Instead,accurately measure your OEE, discoveryour loss structure and improve what youhave. As Hansen showed in 2001,investment in OEE initiatives can be tentimes more cost-effective than purchasingnew equipment.

� www.idhammarsystems.com


To make the calculations simple thefactory price of a 10 litre pot is €15. Thelines are quite slow and the target is 900pots across all three lines. Materials, pots,paint and labels cost €3 per unit. Labourcosts average €200 per hour and energycosts €300 per hour. The sales order tomeet is 60,000 pots.

Project engineers have calculated theCapex cost for a 4th line at €1m with anROI of 2 years.

The OEE spreadsheet shows an OEE of40% with an improvement of 10% in the6 months we have been recording data.Unfortunately the performance rate is lowwhich appears to be due to many minorstops and slow running - difficult to recordmanually. Availability losses appear betterthan expected but we suspect that’sbecause many of these losses are notbeing recorded.

It’s a simple rule, if the speed of theplant cannot be slowed, but initial figuresshow a poor performance rate, not allavailability losses are being recorded. Ifthat’s the case all data should beconsidered suspect; we may be generatingan OEE value, but we need to do muchmore to improve accuracy to be able todrive improvements.

So, let’s look at the financial position.In the last week, at target throughput weshould have completed the weeks order inless than 70 hours. However, because of65% availability, 67% performance and92% quality values, we had to work anextra 38 hours. That means lots of agencyovertime and wasted energy costs. It’sclear why project engineers areinvestigating an additional line, but is itthe most cost effective solution at €1m ofnew capital. What if we then run the newline at 40% OEE; how much better off willwe actually be?

With our low OEE score of 40%, thecosts of those extra 38 hours of wastedeffort across our 3 lines all adds up:

Labour 38 hours @ €200 per hour € 7,600

Energy 38 hours @ €300 per hour €11,400

Materials 4,800 @ €3rejects per unit €14,400

ABOUT THE AUTHOR

Alan France is Operations Director of Idhammar Systems Limited.

Contact him by e-mail:[email protected], or visit www.idhammarsystems.com for more on OEE software.

OEE



In November 2008, Carbon budgets became

law under the UK’s Climate Change Act.

The UK’s target is to reduce emissions of

greenhouse gases by at least 80% by

2050, and in order for us to be on track

for this, there is an interim target of 21%

reduction by 2020, (or 31% if a global

deal is reached)

Before rushing into installing add-ongadgets to the existing boilers to improveefficiency take the opportunity to reviewthe boilers themselves. It is astoundinghow many 40 year old boilers are still inoperation. The boiler men may have giventhem pet names and have grownattached, but the truth has to be faced.They are probably not the right size andwill certainly be inefficient. Replacementwith new boilers of the correct size,optimum design and efficiency will givepayback in a relatively short term.

When comparing boiler from differentmanufacturers, it will pay dividends to askexacting questions about the wayefficiency figures are calculated, as thereare many unseen variables which can givemisleading results. If possible run yourown calculations using the same fuelcalorific values (don’t mix nett or grossvalues), use the same ambient airtemperature and use the British Standardmethod of calculation.

Having specified the most energyefficient boiler, then look to further reduceemissions by installing extra features whichwill be effective on that site. In the case ofsteam boilers this may be flue gas

economisers, TDS and blowdown controls,and heat recovery systems. Variable speeddrives on burner fans and feed pumps willreduce electrical consumption and makefurther improvement to the carbon footprint.

The current financial climate may seemto present an obstacle, however SME’s canovercome this with a Carbon Trust interestfree, unsecured loan for energy savingequipment. The amount of loan offered isbased on the amount of carbon savingsand application is easy as all forms arecompleted by the equipment supplier.

�www.byworth.co.uk


One key area mentioned by theCommittee for Climate Change is energyefficiency in buildings and industry, and asignificant proportion of energy use in thisarea relates to industrial steam or hotwater boilers. 2020 may seem a long wayoff, but it’s only 11 years and industrialboilers installed now will only be part waythrough their life span (on average over25 years). It is crucial, therefore, that anynew industrial boilers installed now arethe most energy efficient possible in orderto attain the 21% emissions reduction.

Boiler efficiency is a measure of theproportion of useful heat output comparedwith heat input. A recent survey of 300boilers over 100 sites shows an averageboiler efficiency of 74% (Carbon Trust), sothere is ample opportunity forimprovement. The 26% losses will mostlikely arise from inefficient boiler designwhich can’t utilise all the heat input beforeit reaches the flue outlet; heat losses fromthe boiler, pipes, valves and blowdownwater; and poor load scheduling, operationand maintenance.

Obvious first steps towards improvementare to ensure that all boiler and pipeinsulation is present and in good condition.

BOILERS

WHAT’S YOURcarbon footprint


qualified engineers to join our growing PowerGeneration teams based in Glasgow and arekeen to hear from candidates with previousrelevant experience gained within the UK poweror energy industries

Salary £ 30 TO £ 50 K (PER YEAR)

Reference 9367Job Description ENGINEERS - NUCLEAR GENERATION

You will be required to undertake projectmanagement, engineering design and computersimulation modelling as part of a growing teamproducing work for the nuclear industry. Workwill typically include liaising with clients andmanaging projects; feasibility and conceptualdesign studies; computer simulation modeling;site survey and inspection activities; analysisand design; specification writing; troubleshooting and problem-solving and technicaldue-diligence advice

Salary £ 30 TO £ 60 K (PERMANENT)

Reference 9368Job Description POWER GENERATION ENGINEERSSalary £ 30 TO £ 50 K (PER YEAR)

Reference 9326Job Description MECHANICAL MAINTENANCE ENGINEERSalary £ 40 TO £ 55 K (PER YEAR)

Reference 9228Job Description CORROSION SCIENTISTSalary £ 25 TO £ 45 K (PERMANENT) +

ATTRACTIVE SALARY PACKAGE

Reference 9199Job Description C&I ENGINEERSSalary £ 25 TO £ 55 K (PERMANENT) +

ATTRACTIVE SALARY PACKAGE

Reference 9330Job Description PLANT MANAGERSalary £ 50 TO £ 70 K (PERMANENT)

Reference 9508Job Description POWER AND ENERGY DESIGN ENGINEER

ROLESWe are very pleased to offer the superb chanceto become part of one of the worlds mostsuccessful engineering firms as a designengineer in their Sunder land office to beinvolved on their current benchmark projects.

Salary £ 40 TO £ 50 K (PER YEAR) + PACKAGE

Reference 9449Job Description ELECTROMECHANICAL ENGINEERS

Award winning company is recruiting for 10Electromechanical Design engineers for theirSaudi Arabia office. Due to winning newprojects they are again expanding their designteam. Ideal candidates will have a degree incivil, electrical or mechanical engineering.Projects include water & power generations,substations, transmissions & distribution,watertreatment plants and pumping stations to namea few.

Salary £NEG (PER YEAR)

Reference 8777Job Description PRINCIPAL OR SENIOR SAFETY

CONSULTANTYou’ll hold an honours and/or masters degree (orequivalent) in a relevant subject e.g. science orengineering. You’ll also have considerable safetycase production and/or management experienceeither with a consultancy or a licensee, effectivecommunication skills, good report writing skillsand the ability to work effectively bothindividually and in a team. At the Principal levelwe’re looking for specific team leadershipexperience.

Salary £NEG (PER YEAR) + WE OFFER ACOMPETITIVE FLEXIBLE BENEFITS PACKAGE

Reference 9368Job Description POWER GENERATION ENGINEERS

We are seeking applications from degree

www.mslrecruitment .com jobs@mslrecruitment .com

www.mslrecruitment .com jobs@mslrecruitment .com

Company Website Email Contact Telephone Number

ACCESS EQUIPMENT

Planet Platforms www.planetplatforms.co.uk [email protected] 0800 0854161

ASSET MANAGEMENT

Rockwell Automation www.rockwellautomation.co.uk [email protected] 0870 2425004

BOILERS

Byworth Boilers www.byworth.co.uk [email protected] 01535 665225

Certuss Steam Generators www.certuss.co.uk [email protected] 0121 3275362

Wellman Robey www.wellman-thermal.com [email protected] 0121 543 0000

BOILER HIRE

Kings Boiler Hire www.kingsboilerhire.com [email protected] 01992 451629

Wellman Robey www.wellman-thermal.com [email protected] 0121 543 0000

BOLT SECURING SYSTEMS

Nordlock Ltd www.nord-lock.co.uk [email protected] 44 (0)1980 847129

CMMS

Cayman Venture www.cayman.co.uk [email protected] 0191 2963816

Idhammar Systems Ltd www.idhammarsystems.com [email protected] 0117 9309300

PMI Software www.pmisoftware.co.uk [email protected] 353 (0)1404 0000

Productivity Europe www.productivityeurope.org [email protected] 01234 215867

Shire Systems www.shiresystems.co.uk [email protected] 44(0) 23 80224111

Softsols Group Ltd www.getagility.com [email protected] 44(0)1924 200344

SolutionsPT www.assetpt.co.uk [email protected] 44 (0)161 495 4600

Spidex Software Limited www.spidex.co.uk [email protected] 0121 779 0888

SRO Solutions www.srosolutions.net [email protected] 44 (0)845 408 4250

COMPRESSED AIR

Airchannel Ltd www.airchannel.co.uk [email protected] 0800 526581

Atlas Copco Compressors www.atlascopco.co.uk [email protected] 0800 181085

Gardner Denver www.gardnerdenver.com [email protected] 01452 338116

COMPRESSED HIRE

Speedy Compressors www.speedyhire.co.uk/compressors [email protected] 0845 307 0777

CONDITION MONITORING

Alpine Components www.alpine-components.co.uk mike@alpine-components .co.uk 01424 437000

Artesis www.artesis.com [email protected] 0845 634 3854

Elcomponent Ltd www.elcomponent.co.uk [email protected] 01279 503173

Holroyd Instruments www.holroyd-instruments.com [email protected] 01629 822060

Monitran www.monitran.co.uk [email protected] 01494 816569

Proviso Systems www.proviso-systems.co.uk [email protected] 01777 817536

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info


TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355

Company Website Email Contact Telephone Number

TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355

ANNUAL BUYERS GUIDE continued

CONDITION MONITORING CONTINUED

Pruftechnik Ltd www.pruftechnik.com [email protected] 44 (0)1543 448350

Schaeffler www.schaeffler.co.uk [email protected] 0121 351 3833

SPM Instrument UK ltd www.spminstrument.co.uk [email protected] 01706 835331

CONDITION MONITORING EQUIPMENT/SERVICES


DATA ACQUISITION

Metrum www.metrum.co.uk [email protected] 0118 973 3000

HEALTH & SAFETY

Integrity&Compliance Management www.icm-uk.com [email protected] 01779 474748

HEALTH & SAFETY PRODUCTS


HOSE AND COUPLINGS

Dixon Europe www.dixoneurope.co.uk [email protected] 44 (0)1772 323529

INDUSTRIAL COOLING

TPC(Total Process CoolingLtd) www.totalprocesscooling.co.uk [email protected] 44(0)121 711 4014

INDUSTRIAL DOOR SERVICES

BID Group www.bidgroup.co.uk [email protected] 0870 607 5050

INDUSTRIAL HEATING

Ambirad www.ambirad.com [email protected] 44 (0)1384 489700

INDUSTRIAL FLOORING

CG Flooring Systems Ltd www.cg-flooring.com [email protected] 01484 600085

Dura Composites www.duracomposites.com [email protected] 44 (0)1255 423601

INSTRUMENT HIRE

Bisra www.biz.fm [email protected] 44 (0)1344 459314

LUBRICATION

ATS Electro-lube (UK) ltd www.ats-electro-lube.co.uk [email protected] 0191 491 4212

PLANNED MAINTENANCE

T Cards Direct www.tcardsdirect.com [email protected] 01732 871417

THERMOGRAPHY

Express Instrument Hire www.expresshire.net [email protected] 01772 815600

Flir www.flir.com [email protected] 01732 221245

Fluke www.fluke.co.uk [email protected] 020 7942 0700

Hawk-IR www.hawk-ir.com [email protected] 01642 497000

Testo Ltd www.testo.co.uk/testo880 – 01420 544 433

THERMOGRAPHY TRAINING

The Institute of Infrared Thermography www.infraredinstitute.co.uk [email protected] 44 (0)151 424 4060

TRAINING

National Fluid Power Centre www.nfpc.co.uk [email protected] 01909 504700

VIBRATION ANALYSIS

Hansford Sensors www.hansfordsensors.com [email protected] 0845 6801957


FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info

EENNQQUUIIRRYY??F R E E P R O D U C T I N F O R M A T I O N S E R V I C ECCOOMMPPLLEETTEE AANNDD FFAAXX TTHHIISS PPAAGGEE BBAACCKK TTOO 00220088 77111133115533



Please fill in your details if you (a) wish

to continue to receive a free copy of EMS

or, (b) wish to be included in the

magazine’s circulation list for the first

time. (Please use capitals and please

sign and date as indicated). Fax Back on:

00220088 77111133115533Please send me FREE information on:

(Delete as appropriate)(Mr, Mrs, Miss, Ms) First Name Surname

Job Title

Company

Post Code

Tel Fax

E-mail

Signed Date / /

PLANT MANAGEMENT

❏ Artificial Intelligence/Expert Sys

❏ Asset Management

❏ ATEX Equipment/Services

❏ Bearings

❏ Calibration

❏ Coding Systems

❏ Computerised Maintenance Management

❏ Condition Monitoring Consult

❏ Condition Monitoring

❏ Consultancy – unspecified

❏ Contract Maintenance

❏ Corrosion Prevention

❏ Couplings

❏ Data Analysers/Loggers

❏ Degreasers

❏ Descaling

❏ Drives

❏ Electric Motors

❏ Electrical Maintenance

❏ Equipment Rental

❏ Filters

❏ Flexible Hose

❏ Flexible Ducting

❏ Flow Meters

❏ Food Safety Lubricants

❏ Gaskets

❏ General Engineering Services

❏ Handling Equipment

❏ Hose & Cable Reels

❏ Hydraulics/Pneumatics

❏ Internet Services to Maintenance

❏ Labelling and/or Barcoding

❏ Laser Alignment

❏ Leak Detection Equipment

❏ Lubrication/Oil Analysis

❏ Maintenance Consultancy

❏ Maintenance Materials

❏ Measurement Instrumentation

❏ NDT Equipment or Services

❏ Pipe Freezing

❏ Pumps, Valves and Process Equipment

❏ RCM Consultancy

❏ Remote Monitoring

❏ Seals

❏ Sensors or Probes

❏ Specialist Maintenance Services/Products

❏ Surface Treatment and Coating

❏ Temperature Measurement

❏ Thermographic Services/Equipment

❏ Tools & Workshop Equipment

❏ TPM Consultancy

❏ Vibration

❏ Visual Planning

❏ Welding and Joining

TRAINING

❏ Institutes and Professional Bodies

❏ Recruitment

❏ Training Aids and Services

BUILDING MAINTENANCE

❏ Access Equipment

❏ Building Maintenance Consultancy

❏ Chemicals/Paints/Finishes

❏ Cleaning Components

❏ Cleaning Machines/Equipment

❏ Computer Aided Facilities Management (CAFM)

❏ Cranes/Hoists

❏ Doors/Curtains

❏ Flooring

❏ Lifts/Escalators

❏ Lighting

❏ Property Maintenance and Management

❏ Roofing

❏ Security and Fire Prevention

❏ Storage Systems

❏ Tank Linings & Bundings

ENVIRONMENTAL

❏ Dust/Fume Extraction

❏ Environmental Health/Testing/Equipment

❏ Noise Control

❏ Pollution Control Equipment

❏ Water Treatment

HEALTH & SAFETY

❏ Communication

❏ Health & Safety Products

❏ Legislation & Compliance

❏ Machine Guards

❏ Safety Showers & Eye Baths

❏ Workwear

ENERGY MANAGEMENT

❏ Boilers

❏ Burners

❏ Climate Change Levy

❏ Combined Heat & Power

❏ Compressed Air Equipment and Ancillaries

❏ Energy

❏ Energy Control Systems

❏ Energy Metering/Monitoring Systems

❏ Generators

❏ Heating, Ventilating and Air Conditioning

❏ Industrial Controls

❏ Power Quality

❏ Steam Traps

JJUUSSTT FFAAXX TTHHIISS CCOOMMPPLLEETTEEDD FFOORRMM BBAACCKK OONN 00220088 77111133115533

EMS March/April 2009

RREEGGIISSTTEERR NNOOWWttoo ccoonnttiinnuuee ttoo rreecceeiivveeyyoouurr FFRREEEE ccooppyy ooff EEMMSS


Date post:	31-Mar-2016
Category:	Documents
Upload:	michael-dominguez
View:	233 times
Download:	0 times

march/april 2001

Documents