NZ’S LARGEST ABC AUDITED CIRCULATION TO THE ENGINEERING & MANUFACTURING SECTORS September 2011 $6 INCL GST
Meeting peak demand Contact Energy’s new 200MW peaker plant and underground gas storage facility.
Oil & Gas Industry update Welding & Fume Extraction Specialist Pumps & Valves Maintenance Matters & Industrial Cleaning
Not quite a Baker’s dozen IT has been almost 13 years since I took on the role of editor of DEMM. Since 1998 the magazine has undergone a lot of changes, many of them subtle and some quite significant. Of course, in that time the Internet has become a powerful force in our lives. Today it is the major conduit for reader enquiries generated by the magazine. DEMM Engineering & Manufacturing magazine, which is celebrating its 43rd year of publication in 2011, has much to be proud of. Over the years it has played a central role in linking buyers with sellers – it has been an industrial marketplace that has generated a lot of business for countless companies. Nowit has matured into a truly informative and educational publication, still with a strong focus on all engineering and manufacturing disciplines, not least of which is maintenance – arguably the most important discipline of all. The time has come to open a newchapter for the magazine. From this issue I’m handing over the editor’s reins to Stefan Richter whom I’m sure can give this old workhorse a fresh set of heels. It’s farewell from me – and I hope you’ll continue to support this great magazine. Glenn H. Baker Email: firstname.lastname@example.org
Product Watch Aroundup of newtechnologies and services designed to increase the productivity, efficiency and safety of the engineering and manufacturing sector.
Oil & Gas Industry Aquick wrap up of newtechnologies relevant to NewZealand’s oil and gas industry – plus a reviewof the recent Oil & Gas Expo held in NewPlymouth.
Meeting Peak Demand Jenny Baker reports on Contact Energy’s new200 megawatt gas-fired peaker plant near Stratford, and its associated underground storage facility for natural gas near Ahuroa. The project presented a significant geological, engineering and construction challenge for the company.
Welding Technology The latest developments in the world of welding and welding fume extraction. Read about the Miller AlumaFeed synergic aluminium welding system – designed to give optimum results when welding aluminium.
Pumps & Valves Discover howa custom chopper pump is dealing to egg pulp; howperistaltic pumping technology easily copes with sodium hypochlorite; and meet the unique Egger IRIS valve.
Maintenance Matters This month there’s a special focus on industrial cleaning; MESNZ secretary Craig Carlyle starts his two-part series on the issues surrounding NewZealand’s supply of tradesmen and apprenticeship training; and there’s a special report on the very successful Trades At School programme in South Auckland.
Industry Watch & Coming Events Supported by:
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PRODUCT WATCH Edit o choi r's ce
Kiwi designed ‘no-fog’ safety goggles FIRST showcased in this magazine in July 2005, Safe-Eyes safety protection goggles from Kiwi Ideas Company are nowpoised to make a safety statement in workplaces around the world. Former forester Phil Hall, who heads the company and originally came up with the idea for Safe-Eyes after his forestry employees experienced fogging problems with traditional goggles, says they are about to enter the worldwide market for eye protection. “We’ve been in discussions with possible global distribution partners and we’re planning to provide a range of mesh goggles to suit as many industry applications as possible.” Hall has been steadily improving and enhancing the goggles since he first started making them in his back shed. The unique, highly durable mesh screens make them ideal for a number of industrial applications – everything from engineering workshops to joineries, water-blasting and weedeating – at last count there were 60 different industries that have found Safe-Eyes suitable.
Mechanical actuators provide precision positioning AT this year’s AIMEX exhibition in Sydney Enerpac is introducing its latest Uni-Lift mechanical actuators in capacities up to 250 tons. The B and M series Uni-Lifts – utilizing respectively ball screw and machine screw mechanisms with strokes up to 6096mm – are designed to set a new standard for linear motion control in precision positioning and control in a mechanical package. They are so accurate and reliable that, in addition to positioning heavy machinery and plant, they have been used in roles such as satellite dish positioning and solar panel tracking. Ball screw jacks, with load capacities up to 100 tons, are well suited for high-cycle, high-speed applications. Machine screw jacks, with load capacities up to 250 tons, are ideal for
low-cycle, high-load applications needing a self-locking load screw. Uni-lifts complement Enerpac’s extensive range of high pressure (700 bar) compact and powerful hydraulic lifting and manoeuvring technologies, which range from the new RC-Series Duo and other cylinders from one to1000-plus tons capacity, through to synchronous PLC-controlled systems that can lift bridges, drilling platforms and structures weighing tens of thousands of tons. Enerpac says its extensive line of Uni-Lift accessories allows for easy connection and precise synchronized control of multiple actuator systems. Tight tolerance thread forms, heat-treated gear sets, and pre-loaded bearings ensure repeatability and durability of these Go to www.demm.co.nz/ linear actuators. enquiry quote: D110902a
“I can particularly see miners using them,” says Phil. “They work in hot, dusty and dangerous conditions and must keep their eye protection on.” Safe-Eyes goggles have nowachieved the UK, EU and US safety eyewear standards – complying with both BS EN 1731:2006 and ANSIZ87.1.2010. There’re around 4000 eye injuries at work each year in NewZealand. Wanganui emergency medicine physician, Dr Chris Cresswell says he frequently deals with eye injuries caused by industrial debris flying up and under standard safety goggles. “While trying my friend’s pair of Safe-Eyes when using a scrub-cutter I was immediately convinced of their value. I nowrecommend them to all patients with this type of eye injury and am working with ACC to get them recommended to local industries.” Safe-Eyes safety protection goggles are available from all Protector and NZ Safety stores. Go to www.demm.co.nz/enquiry quote: D110902
Anti-fog, anti-scratch lens HONEYWELL Safety Products (previously Sperian Protection) has released its innovative Durastreme coating technology for its high performance safety goggles – guaranteeing increased eye protection in a variety of workplaces. The Durastreme coating combines the benefits of industrial anti-fog and anti-scratch coatings onto a single lens. The Anti Fog layer on the inside prevents lens fogging, while the durable Anti Scratch coating on
the outside protects against harsh elements. Based on independent comparative life testing using the Bayer Abrasion Test Method, Durastreme extends the life of the lens by up to three times longer than that of competitive anti fog lenses. Durastreme’s Anti Fog coating absorbs and releases moisture at the same time as repelling it, allowing workers increased visibility even when temperature and humidity
levels peak. At the same time, the Anti Scratch coating is permanently bonded to the lens and won’t rub or wear off. The DuraMaxx safety goggle features the unique coating and is the first panoramic modern goggle to provide global performance including comfort, anti-fog capabilities, ease of use and durability. DuraMaxx goggles are engineered with a lightweight and flexible elastomer body and
provide a comfortable contoured fit for different facial profiles. Apivoting headband provides quick and easy fitting, and is adjustable to fit both male and female wearers. They can also fit over most prescription spectacles and half mask respirators. Go to www.demm.co.nz/ enquiry quote: D110903
APATENTED, compact in-line static injection mixer that’s designed for blending highly corrosive chemicals such as chlorine dioxide, has just been launched by UScompany Westfall Manufacturing. The static injection mixer is a fixed-plate that features an orifice pattern which mixes by a combination of alternate vortex shedding and intense shear zone turbulence to achieve greater than 98 percent dispersion within ten diameters downstream. Made from titanium, zirconium or Hastelloy, this mixer can be designed for injecting up to six chemicals simultaneously. Suitable for use in large and small piping systems, the Westfall Static Injection Mixer comes in 50.8mm to 3048mm diameter sizes which simply fit inside the mating flange bolt circle. The orifice pattern permits mixing with minimal head loss and the mixers are also offered in stainless steel, PVC, FRP and other materials. For more information visit Go to www.westfallmfg.com www.demm.co.nz/enquiry quote: D110903a
Controller simplifies development of tube cutter
An advanced 5-axis motion control system from Baldor is key to the performance of the plasma tube cutting machine.
AN innovative new plasma cutting machine for flue pipes has been developed by Techserv Cutting Systems, a manufacturer of CNC profile cutting systems. Advanced interpolated motion
of the cutting system is used to dramatically increase production throughput – using an economic real-time machine control module from Baldor. Capable of cutting aluminium and stainless steel flue pipes at any angle, as well as holes of any shape or size, the plasma tube cutter completely automates this aspect of manufacturing. Until now, for example, elbow pipes have traditionally been produced by first cutting complex shapes from flat metal sheet, which are then rolled and welded before assembly. This multi-stage fabrication process necessarily involves considerable movement of work pieces around the factory and is very timeconsuming. The new cutter dispenses with the need to pre-cut complex shapes. Instead, the flat metal sheet is first rolled into a tube and seam welded, then each tube is successively loaded into the machine. The entire
cutting operation is handled autonomously; a simple angled cut takes a matter of seconds. Cutting the angled end pieces for an elbow pipe and then assembling them can now be accomplished in around four minutes. The tube being cut is mounted in the machine with its top end held in a rotating pneumaticallydriven clutch assembly. The plasma cutting torch is moved up and down as the tube rotates, at a rate which determines the severance angle or the size and shape of the hole being cut. Both the main rotational axis and the plasma torch height axis are powered by Baldor BSM series AC brushless servomotors driven by Baldor MicroFlex digital servo drives, and employ interpolation to secure a constant cutting rate regardless of the profile of the cut or diameter of the tube. The tube cutter also uses three Baldor stepper motor driven axes. Two of these control the position of a pair of guide rollers, which support the tube during the cutting process and are driven closer together or further apart depending on the diameter of
the tube. They also move aside automatically during the tube reload phase to facilitate operator access. The third stepper-driven axis dynamically varies the distance between the plasma torch head and the wall of the tube during the cutting process, to provide optimum performance. All five electrical axes are controlled by a Baldor NextMove ESB-2, a compact real-time machine control module which receives commands direct from an on-board PC-based CNC system developed by Techserv specifically for tube profile cutting applications. The new plasma cutter was developed for UK company Flues & Flashings. According to Gary Watkins, works manager, “The performance of the plasma tube cutter is superb. Changing the process so that we are preforming the tubes before cutting them, instead of cutting complex shapes from flat metal sheets, has enabled us to virtually quadruple manufacturing throughput.” Go to www.demm.co.nz/ enquiry quote: D110904
Nifty folding earmuffs MSA’s range of hearing protection products now includes the nifty Blocka F80 folding earmuffs. The MSA Blocka F80 is certified to AS/NZS 1270 Class 5 27dB – and come visibly safe in yellow or orange. The folding earmuffs come supplied with a uniquely designed Velcro belt clip that
allows for ease of storage when the earmuffs are not required – particularly during meal breaks. The Velcro belt clips are also sold individually and can be used with MSA’s left/RIGHT range of passive and electronic hearing protection products. Go to www.demm.co.nz/ enquiry quote: D110904a
Another grain processing plant ‘in the bag’ AFTER a significant change in operations, including the relocation of a grain cleaning facility and the implementation of a bagging plant, it is ‘mission accomplished’ for a Waikato-based grain supplier. But the successful outcome would not have been possible without the experience, knowledge and quality equipment supplied by Aurora Process Equipment. Aurora worked closely with the client to complete the project on time and within budget. The grain supplier’s requirements for the project were: • An infeed, plus a handling bin system for the internal transportation of grain. • Assisting conveyor system for moving cleaned grain to waste collection, crushing plant, bagging plant or mixing plant. • A 20kg bagger and automated sewing line. The experienced team at Aurora made recommendations and calculations to evaluate which equipment and systems would best suit the grain process and the available space. The team worked hard on the project – altering existing machinery, taking measurements, providing information and concepts, and constantly updating the client and ensuring they were at all times
satisfied. Aurora was awarded the contract to supply, install and commission all the necessary equipment to complete the project. The process equipment included: two ton portable handling bins, a cleaner frame and intake, cleaner discharge screws, crusher intake and discharge, two bulk bagging stations, a Floveyor elevator complete with an Aurora
Magnetics separator probe in the hopper to remove foreign metallic contamination, a nine ton vertical grain mixer, TE100 bagging scale, Fischbein mini system and conveyor, and a bag incline conveyor. The whole project ran smoothly with a few days of plant installation/adjustment and machine commissioning required. The client now has its plant
running at full production and is very happy with the outcome. “The whole project ran smoothly and any issues we had were handled professionally by Aurora,” says the client company’s project manager. Go to www.demm.co.nz/ enquiry quote: D110905
Stress-free crane installation
WHEN Peter Wilson, director of Independent Tube Mills (ITM), started planning the company’s new purpose-built manufacturing facility in Melbourne’s western suburbs last year, he had no hesitation in specifying overhead cranes from Konecranes to do the heavy lifting. “I’ve been in the steel industry for around 30 years and I have used Konecranes and other cranes previously, but I’ve always found
Konecranes to be a better crane. They are not the cheapest, but they are the best,” Wilson says. ITM has invested in the very latest technology available in rolled steel manufacturing and went into production last July. “We have four cranes operating, all utilising Konecranes’ high performance CXT overhead cranes, all with advanced radio remote controls,” adds Wilson. “Safety is
a very important issue for us and our workers. That’s why we have installed Konecranes. They have a far superior quality than other cranes, and a great name for service and reliability.” He explained that the company has the capacity to produce 55,000 tons of steel tube a year, and needed to manoeuvre some very heavy loads around the facility. “The lifts can involve weights up to 17 tonne, and it’s far safer if the operator can stand at a distance from the load, controlling the crane by radio remote control.” “We utilise a CXT 20 tonne hoist, on a double girder, to unload the coils when they come in on the trucks. At present, we are averaging three B-doubles a day. “The coils weigh around 16 to 17 tons, and sit in a specially designed cradle. The crane picks them up and put them down in their respective place in the warehouse. With these cranes we can unload a truck easily within 25 to 30 minutes and load a semi within 40 to 45 minutes. “We also have CXT 16 ton crane to service the mill. It loads the coil
on and off the mill plus it can be used to service the bundler when needed; to quickly and efficiently remove any rejects. “A special 10 ton twin hook rotating crane from Konecranes picks material up off the transfer table of the bundler on the end of the mill. It rotates and brings the material down and stores the product in the warehouse. “The fourth 10 ton single girder has two 5.5 tonne CXT hoists attached, and actually picks up the finished product and loads the vehicles going out. At present we’re dispatching, on average, six to seven semi trailers per day.” “When it comes to maintenance, Wilson said he didn’t hesitate signing with Konecranes. “If a company manufactures something then you’d be crazy not to get it serviced by their people. There are lots of maintenance/service people around but I figure if you go back to the manufacturer they will understand the product in far Go to www. more depth.” demm.co.nz/enquiry quote:
Relays simplify safety device selection ANEWfamily of Allen-Bradley Guardmaster safety relays can help machine builders and end users simplify safety relay selection and reduce component inventory and life cycle costs. The line includes basic units capable of supporting a range of safety devices in various applications,
such as single and multi-zone configurations. The relay line features a patented, single-wire communication capability that helps eliminate the need for dualchannel connection between relays. Users can expand and cascade safety functions up to a SIL 3 rating using
one single wire to connect devices. This provides a reduction in installation time and effort. In addition, “AND/OR” logic can be set via a rotary switch on the front of the relay, yielding a variety of configurations including regional and global e-stop architectures. Auniversal input feature allows devices, such as safety interlock switches, emergency stop switches and safety mats, to use the same set of input terminals on the relay. This helps eliminate the need to employ a specific safety relay for a specific type of input device, helping simplify system design and reduce hardware costs. The next-generation Guardmaster safety line also features dual-input modules, providing users with twice the functionality of a standard relay in a 22.5mm housing while reducing wiring for faster commissioning. A single TÜV-approved rotary switch with internal redundancy eliminates the need for double switches, helping to speed configuration while addressing
multiple functions such as reset modes and time delays. The Guardmaster family is designed to meet newfunctional safety standards such as ENISO13849-1 Go to www. or IEC/EN62061. demm.co.nz/enquiry quote:
Rotary screw compressors have their advantages ROTOR Compact series screw compressors from Industrial Air Systems promise a high quality, reliable and economic compressed air supply, says IAS director Nick Leonard. “Specification for specification and feature for feature, the Air Command RC screws come out on top when it comes down to analysing economical and reliable performance,” says Leonard. Air Command Rotor Compact screws feature the highly efficient direct-drive transmission system, normally only employed by much larger industrial screw compressors – which means utilising an over-sized air end, spinning at half the revolutions of the traditional belt driven screw model. Without any contaminating, wearing transmission belts, the RC screw runs much cleaner, and is fast and simple to service, says Leonard, which saves thousands of dollars in operating
costs over the compressor’s lifetime. Rotating at only 2900rpm (instead of 5000 to 7000rpm) the Air Command RC is very quiet running, and requires no noise insulation as found on any other belt-driven model. Unlike most rotary screw compressors, the RC model is designed to stop/start or run continuously – up to 100 percent duty cycle. This means it can be installed into most compressed air environments and only operates on demand, leading to power savings and reduced machine wear. The Air Command industrial RC screw compressor is available as a standalone or fully integrated model (screw, receiver, refrigerant dryer) in 7.5kW, 10kW and 15kW sizes – making it ideal for the one to seven man compressed air operation, in the automotive, engineering or manufacturing industry. One hundred percent European designed and manufactured, direct-driven Air Command RC screw compressors offer a very good investment for small industry wishing to improve efficiencies with a trouble-free clean Go to www.demm. compressed air supply. co.nz/enquiry quote: D110908
Faster field calibrations, troubleshooting PROCESS professionals have long relied on the Fluke 743/744 Documenting Process Calibrators for advanced instrument calibration, especially in rugged environments. Operating the new750 Series is similar enough to the 743/744 that existing users will be able to immediately start using the newcalibrators with no required training. These field tools calibrate
Heavy duty 8
temperature, pressure, voltage, current, resistance, and frequency and have three operating modes: measure, source, simultaneous measure/source. The three operating modes let technicians troubleshoot, calibrate or maintain instrumentation with just one tool. The 750 Series features an easy-to-follow, menu-driven display that guides users through tasks. Programmable calibration
routines let technicians create and run automated as-found/as-left procedures to ensure fast, consistent calibrations. The recorded results can then be easily downloaded to a PC via the USB port, eliminating the need for manual transcription. Improvements over the original model include a graphical display that is nowbright enough for readings to be seen in any light condition. Another popular improvement is the new, rechargeable Li-ion battery pack, which provides enough power for an entire shift and can be charged from within the calibrator. The 754 model is the first field calibrator for HART instruments that is both powerful and easy to use. The 754 offers fast HART communication and requires no external box or secondary tool to perform everyday HART calibration and maintenance. The 750 Series works with the newFluke DPC/TRACK 2 software for managing calibration records and data. It features an instrumentation database
that makes it easy to manage instrumentation, create and schedule tests, load and unload the calibrator, print a variety of standard reports, and manage Go to www. calibration data. demm.co.nz/enquiry quote:
Industrial strength UPS DESIGNED specifically for the industrial market, the Bulletin 1609 family of uninterruptible power supplies (UPS) includes three distinct series to meet requirements up to 10kVA. An Allen-Bradley UPS from Rockwell Automation can help prevent data loss, extended downtime and damage to equipment. For single-phase applications up to 500VA, the Bulletin 1609-U and S industrial series were specifically designed for industrial environment control panels. The U and S series provide surge and filter functions, in addition to bridging dips, sags, and brief power losses to help ensure operational efficiency. These UPS units have DIN rail and panel mount capabilities, optional 50 degrees Celsius battery and hardwired input/output connections. The U and P units include comprehensive network management and advanced communications capabilities such as Ethernet and RS232 to monitor and control a wide range of devices. In addition, devices can also be controlled via optional dry contact I/O communication cables. The units can communicate battery status to PLCs via
integrated dry contacts. To prevent downtime and equipment damage due to power outages, voltage fluctuations and transient surges, these UPS units from Rockwell Automation have a line interactive design with pure sine wave output. The Bulletin 1609-U Commercial units come in the traditional tower frame form factor and are available in 750, 1000, and 1500 VA models, which are ideal for helping to protect PCs, PLCs, servers, and data networks. High wattage, pure sine wave output, 16 segment LED visual display, and intelligent battery management make these exceptional UPSs. Additional features include; automatic voltage regulation, network manageability, USB connectivity,
front access servicing and predictive failure notification. The Bulletin 1609-P series features powerful high density double conversion on-line UPSs for the industrial environment. The range includes 3-10kVA power outputs for applications requiring 208/230V. The 3kVA is also available with 120V output. These units are typically assembled in a tower configuration and installed outside of a control panel. Key features of these UPSs are their hot swappable battery packs, extended runtimes, double conversion online topology, rack convertible and network Go to www. management capabilities. demm.co.nz/enquiry quote: D110909
Ullrich celebrates 50 years of achievement
Ullrich Aluminium operates two extrusion plants.
One of the company’s state-of-the-art extrusion presses.
Ullrich Aluminium, a long-time market leader in the field of aluminium extrusion manufacturing, fabrication and distribution, is celebrating its 50th year in business in NewZealand, Australia and the Pacific markets. Supported by a loyal team of more than 700 personnel made upfrom many different nationalities, the company operates 43 distribution centres across NewZealand and Australia and exports to 23 South Pacific Island nations. Its specialised export department features multilingual employees, which allows Ullrich to maintain a high level of customer service. The company also supports a number of NewZealand trade initiatives, being a founder member of the Export Institute of NewZealand. Two state-of-the-art extrusion plants – one in Hamilton and the other in the Hunter Valley in Australia – provide extrusion to the company’s manufacturing, fabrication and distribution facilities. Ullrich also
operates a small foundry in Dunedin. The company employs a ‘hub-andspoke’ system, using distribution centres to shipproduct, and it has an 80-strong fleet of trucks. “Our management style is hands on, so we generally knowif there is a problem,” says Ullrich Aluminium CEO Gilbert Ullrich. “We have found that by staying involved at all levels works for us best. Many of our branch managers including a member of our board of directors started at lower level positions, such as storeman.” In celebration of its 50th anniversary Ullrich Aluminum is holding a series of events at the company’s main locations. The company hopes to usher in another 50 years of continued success, as it demonstrates to its clients and employees just howgrateful it is for their loyalty. Ullrich is also proud to be a sponsor of Emirates Team NewZealand. Go to www.demm. co.nz/enquiry quote: D110910
In the comfort ‘zonz’
RECOGNIZED for its excellent fit, feel, grip and durability, the general purpose knitted and dipped HyFlex 11-800 has been redesigned to further improve comfort and reduce hand fatigue. The 11-800, Ansell’s best selling industrial glove, nowfeatures patented ‘Zonz’ Knit Technology. The newliner knitting technology reduces hand fatigue by providing stress release in the knuckle area. This innovative technology uses a patented knitting process with a varying stitch design that enhances glove stretch for maximum flexibility and dexterity. Comfort is also enhanced by an additional knitting process that drops down the little finger. With
the upper palm portion below the middle-three fingers knitted separately from the rest of the palm, and the little finger joint mounted lower than the rest, independent movements are enhanced resulting in a better-fitted glove. Rounding out the changes is an “extra comfort” cuff which features an over edge that means the glove can be more easily pulled on and off. Workers using the glove for dry or slightly oily applications that require light mechanical protection and high levels of handling finesse will benefit from the improved comfort. Go to www.demm.co.nz/ enquiry quote: D110910a
Pipe bursting unit finds success underground The purchase of a Hammerhead HB5058 Static Hydraulic Pipe Bursting Unit from AB Equipment by Mole Tunnelling, a business unit of Nelson based Adcock & Donaldson Ltd, has led this company into some desirable contracts recently. Specifically suitable for pipe bursting applications, the Hammerhead HB5058 pipe bursting unit has 50 tonne of pulling force that is suitable for pipe replacements of 50-200mm in diameter. Small pit entry and exit points make for very little reinstatement, and reduce traffic management issues which gives it an advantage over other open cut methods. This system also allows for pipe upsizing in suitable ground conditions. Aninitial trial to the Kaikoura City Council on the capabilities of the HB5058 was successful leading to the council awarding Mole Tunnelling with the second stage of a sewer renewal scheme due to get underway in the coming months. Currently the Hammerhead HB5058 is pipe bursting a sewer pipe in Miramar, Wellington. This contract requires sewer replacement through the back sections of residential housing. The pipe bursting technique has proved to be a quick & efficient method of the work, as well as providing minimal inconvenience to the residents of Miramar. Despite being based in Nelson, Mole
Tunnelling has been willing to travel to other parts of the country to handle assignments. Completed projects have included installing multiple 700mm culverts in Taihape for Ontrack to the laying of 120kms of optical fibre network for FX. Adcock and Donaldson has been operating since 1986 and have four production teams that carry out specific tasks in different parts of the Civil Construction industry. One of these is Mole Tunnelling that operates a range of displacement hammers from 45 to180mm. These tools ‘mole’ their way underground, providing a cost effective trenchless technology solution for short distances. Previous purchases from AB Equipment of two Directional Drills and a Vacuum Excavator Unit have allowed Mole Tunnelling to offer other services including pipe bursting, pipe ramming, directional drilling & vacuum excavation to complete the full trenchless technology package. Awide range of splitter heads is available through AB Equipment for all types of pipe product including ductile iron & steel. Hammerhead Pipe Bursting equipment ranges from 30-175 tonnes of pullback and is designed for the contractor and Go to www. paid by the metre, not by the hour! demm.co.nz/enquiry quote: D110911
Single axles lighten load THE next generation of portable diesel compressors from Sullair Australia incorporate many improvements that benefit the construction and mining industry. The newseries is available in four models from December 2011 – providing a range of performance ratings and designed to withstand hot, humid and dusty conditions. Available in four capacities – 550, 600, 700 and 750 acfm – the portable diesel compressors deliver a range of working pressures from 80 to 250 psig. Several key features have been incorporated into the newdesign, including robust highway running gear with a newsingle axle configuration. The engine is available as a Caterpillar C7, Tier 3 emissions compliant unit, delivering an impressive 250hp. The combination of these features has reduced the overall weight of the compressor by 1.2 tonne, providing increased manoeuvrability and portability. Anewdesign for the canopy and
service doors is another feature of the portable diesel range, providing easier access for servicing and maintenance. The modular design of the canopy allows for sectional replacement or removal as one piece. The large service doors provide access to the fuel tank, engine, compressor and air filter, with a rear service
panel to provide access to compressor cooling components. Efficiency of the newseries has been enhanced by adopting three-stage filtration. Additional improvements include the SSAM shutdown system with an annunciator module to warn
the operator of high temperatures, low fuel or pressure. The control systems have been fully revised to provide real time information presented in a user friendly control panel. Go to www.demm.co.nz/ enquiry quote: D110912
A helping arm for confined spaces DOYOU have to enter a confined space or supervise somebody else who has to? Do you have to manage or comply with safety legislation for confined space entry? There are some real challenges to overcome for employers, managers, supervisors and employees who have to conduct work or repairs in confined spaces. The MSA SmartArm is a simple modular device that allows workers to quickly set up for entry into or exit from a confined space with flanged horizontal or vertical access points. A foundation for safe work practices, the MSA SmartArm is a portable modular arm that’s easy to use, transport and install. It has been specifically designed for horizontal or vertical vessel flange use in confined spaces. Designed and tested to meet the requirements of an ‘Anchorage Connector’ as per AS/NZS1891.4: 2009, the MSA SmartArm provides one of the safest options for entry and emergency extraction by eliminating the need for rescuers to enter the confined space. It provides a speedy single action recovery that greatly reduces the potential for injury. The MSA SmartArm is especially useful to the offshore oil and gas industry, emergency management organisations and any business that has a requirement for workers to carry out maintenance in confined spaces. Go to www.demm.co.nz/enquiry quote: D110913
CMMS on the iPad IN an industry first, Computerised Maintenance Management Software (CMMS) provider MEX has released its software on the iPad. With the growth of the iPad, particularly as a business tool, MEX saw the opportunity to integrate MEX and the iPad and give customers a new and exciting platform to manage their maintenance. “This is a huge progression and development for our software,” says MEX’s CEO and founder, Stephen Ninnes. “MEX is the first CMMS provider to make the Work Order software available on the iPad.” The system runs on iPad 1 or 2 and consists of the complete Work Order module of MEX. MEX for the iPad enables operations to: • Allow for a paperless workflow. • Increase time efficiency;
there is no longer a need to wait until you get back at your desk to enter or receive data. For example; you can inform tradesman of new work immediately. • It’s convenient, especially for MEX users who don’t regularly sit at a desk or use a desktop computer. • Increases data integrity, allows users to enter data while it is fresh in their minds. MEX’s software solutions help users increase the efficiency in maintaining assets. The software helps users record preventative maintenance, maintain work order data and scheduling, monitor labour productivity and reduce equipment downtime. Go to www.demm.co.nz/ enquiry quote: D110913a
OIL & GAS INDUSTRY
The best of oil and gas on display
(L-R) Swan Exhibitions operations manager, Keith Castellas, with New Plymouth Mayor Harry Duynhoven and Energy Publications account manager Mike Twiss.
SWAN Exhibitions, in conjunction with Energy Publications, the publisher of Oil and Gas Australia Magazine, recently completed yet another successful oil and gas event in New Plymouth. The New Zealand Oil & Gas Exhibition, held at the TSB Stadium from
August 10 to 11, marked its 17th year of operations in New Zealand. Officially opened by local Mayor, Harry Duynhoven, the event showcased the best of the local oil and gas industry and allowed participants to gain valuable industry leads
and contacts. Mayor Duynhoven said the exhibition displays were of a very high standard and the sundowners was very well attended with more than 100 people enjoying the hospitality. Exhibition organiser Keith Castellas from Swan Exhibitions said he was very pleased with the turnout of more than 60 exhibitors. “The general consensus among the industry was that the quality of visitation was of a high standard with lots of good leads and good business being done,” says Castellas. “We had the highest number of preregistered visitors ever and we had no complaints or environmental protests even though we were open to the public,” he said. This year’s exhibition had an international theme and attracted exhibitors from Russia, Canada, Indonesia, UK, US, India and Australia. Exhibitor Darren Deitz from Sensear said the event worked as a branding exercise for his company. “We were happy with the show, we had some quality visitors that will translate into some nice business for us,” he says. Honeywell HPS New Zealand attendee Dion Davidson said the event could not have been organised better. “The communication and professionalism from the start of the show was excellent. I would hope the event happens Go to www.demm.co.nz/ again next year.” enquiry quote: D110914
Laser measure for explosive areas THE handheld LaserMETER 3000XP is a new explosion proof laser measure from CorDEX Instruments. Scottish company Apex Tubulars, the largest independent casing and tubing inspection company in Europe, is using it to assist in its busy inspection programme. “We were impressed with the LaserMETER 3000XP because of its ATEX and CSA accreditation which means we can use it offshore without hot permits as well as onshore at our inspection
compound,” says Gary Park, operations manager at Apex Tubulars. “The handheld design is easy to use and it measures to the third of a decimal point as well as giving overall accumulative length, which saves time as well as improving accuracy.” The LaserMETER 3000XP is the first measuring device to be approved for use in explosive areas, making it ideal for use offshore and in the mining and petrochemical industries. It has been built to last, with a rugged
industrial-grade construction. Encased in tough aluminium, it can withstand harsh environments and has simple operating functions designed for workers wearing protective kit and gloves. The flameproof design incorporates a shock resistant, anti-static over mould with interchangeable battery pack and backlit LCD screen. For more information go to www.cordexinstruments.com
OIL & GAS INDUSTRY
Lordco brings M.T.Deason to New Zealand
LORDCO has been supplying pipeline and process equipment to the New Zealand gas, oil, water and process industries since 1975. The company is heavily involved in the development of the natural gas market in New Zealand and represents some very well known principals who provide specialised quality products for use in the pipeline, plant and process industries. In keeping with this, Lordco
NZ Ltd is proud to announce that it is now the sole distributor of M.T.Deason Company products to the Australian and New Zealand pipeline and process industries. M.T.Deason (MTD) has provided products and services for the natural gas, water, wastewater and industrial markets since 1982. MTD manufactures a vast range of products including its Trifusion Electrofusion system of fittings, processors, tools and accessories
for the construction, repair and maintenance of polyethylene pipelines. Also available is the PE-32 Polytapp universal polyethylene tapping valve which, used in conjunction with the Trifusion Processor, is the next step in electrofusion – designed to make fast, accurate hot taps on polyethylene pipe. Also in the line-up are the MTD Tapstop ST-30 and ST-18 tapping
machines. With half-inch to oneand-seven-sixteenth-inch drills and one-and-a-quarter-inch to six-inch hole saws/cutters these are. These are ideal for hot taps to fit MTD’s range of Tapstop fittings, including ANSI 150 and 300 weld fittings and tees. Along with a range of pipe repair products, and much more, M.T.Deason has you covered for all your pipeline needs. Mike Deason, MTD’s CEO, is a firm believer that customer service comes first. MTD believes that the success of the company has been based on listening to the needs of its customers. The company goal is to be flexible enough to meet customer needs with quality products and on-time deliveries. Lordco is very much looking forward to the opportunity to work alongside a world leading company such as M.T.Deason. Go to www.demm.co.nz/ enquiry quote: D110916
OIL & GAS INDUSTRY
Real-time wellbore video FOLLOWING successful testing in Australia, Europe and the US, oil and gas camera specialist EV has launched the world’s first fully digital sideview and downview wellbore camera. The camera enables the industry to make more informed decisions by gaining a significantly greater insight into the wellbore. EV’s Optis Electric-Line video camera, which is a modular design with both down and side-view cameras, provides high-definition digital and bi-directional transmission as well as surface control of resolution and refresh rate. It also has the ability to operate in temperatures as high as 125 degrees Celsius and can withstand pressures of up to 15,000 psi. Francis Neill, EV’s chief executive officer, said: “Being able to actually see what is happening inside the wellbore offers a major game changer for the oil and gas industry. Until now, it has relied far too heavily on guesswork or lead impression blocks to make key decisions. “Therefore, by being able to get an instant high-quality visual of inside the wellbore through the Optis Electric-Line, people can immediately make important decisions which not only result in significant cost and time reductions but improve the efficiency of operations and well performance.” For more information about EV, visit www.evcam.com
GAS DETECTION Technology
WIKA acquires DH-Budenberg
Whatever your industry - the early detection of harmful gases or depletion of oxygen in your environment can mean the difference between illness, life and death - both of your personnel and possibly even your business. Eurotec Instruments distribute a wide range of hazardous gas detection sensors and controllers for commercial, industrial and institutional applications. The range includes gas detection devices from leading industry manufacturers with brand names such as Sperian for personal protection gas monitors & Critical Environment Technologies and Gastron for permanently installed commercial hazardous and toxic gas detection products. Hand-held loggers and portable chart recorders are available for specialised gases. For further information on how Eurotec Instruments can help you protect your personnel and business contact us today.
WITHthe recent takeover of DH-Budenberg, WIKAintends to further expand its leading position in the field of pressure calibration. DHBudenberg's product range includes high-end primary pressure standards and transfer standards of the Desgranges & Huot brand, as well as laboratory and industrial standards of the Budenberg brand. “The acquisition’s another step, in addition to our innovative product developments, to expand our calibration technology division in a sustainable manner, and for the long term,” says Alexander Wiegand, CEOof the WIKA Group. “The worldwide unique technology of DH-Budenberg is an ideal addition to our portfolio and strengthens our position, so that we can offer our customers an even more attractive programme in all classes of accuracy, from primary standard to pressure controller.” DH-Budenberg has become a part of the calibration technology division of Go to www.demm.co.nz/enquiry quote: D110917 the WIKAGroup.
HEAD OFFICE : AUCKLAND Tel : (09) 579 1990 WELLINGTON : Tel : (04) 499 3591 CHRISTCHURCH : Tel : (03) 366 0017 Email : email@example.com WEBSITE : www.eurotec.co.nz
Meeting peak demand
Two massive new energy projects are bringing energy consumers closer to optimal use of New Zealand’s renewable energy sources, while enhancing electricity generation flexibility and security. Jenny Baker reports. The gas-fired peaker plant from the air.
Contact Energy recently opened a new 200 megawatt gas-fired peaker plant near Stratford. On the same occasion it also opened an underground storage facility for natural gas near Ahuroa. Contact chief executive Dennis Barnes says the projects, at a combined cost of $420 million, are significant additions to Contact’s portfolio and important assets for both Contact Energy and the country. “The projects are also representative of Contact’s dedication and commitment to enhance New Zealand’s energy security in an increasingly volatile energy market,” he said during the opening ceremony. Although gas storage facilities are common across the globe, Ahuroa is the first natural gas storage facility constructed in New Zealand and as such posed a significant geological, engineering, and construction challenge for the company. But, says Barnes, Contact was fortunate “to be able to draw on the expertise of our majority shareholder, Origin Energy, to develop Ahuroa from a concept to a working asset.”
A Contact Energy spokesperson explained to me the purpose of the gas storage and peaker plants and the challenging work that went into commissioning the two projects.
What is the purpose of peaker and gas storage plants? There are two types of electricity plants, base load and peaker. Base load plants operate continuously, stopping only for maintenance or unexpected outages. They generate electricity from geothermal, hydro, and wind energy (renewable sources) and from energy released by burning fossil fuels such as oil, coal, or natural gas (thermal sources). They take a long time to start and reach full operational power. The demand for electricity, however, varies widely, depending on time of day, weather and other factors. Peaker plants are generally run only when there is a high, or peak, demand for electricity. It ensures extra energy generation in times of high energy demand. Thermal energy, in particular
from burning natural gas, is the only energy source for a peaker plant. The Stratford peaker plant is capable of going from a cold start to full-power and producing enough electricity to power 200,000 homes in ten minutes, offering outstanding flexibility in its ability to meet spikes in demand. Gas production is a 24 hour enterprise, but demand for gas-fired base load and peaker electricity generation varies a lot, too, depending on how much electricity is being produced from renewable energy sources. A gas storage plant is a facility that provides storage of gas, so the gas can be injected into it during periods when it is not needed and withdrawn when it is. The spokesperson says approximately 70 percent of New Zealand’s electricity is generated from renewable energy sources: “This means the majority of our electricity generation depends on the weather. This weatherdependent generation needs to be backed up by reliable electricity generation, such as thermal,
which can be turned on when it is most needed.” Peakers in New Zealand therefore work not only during peak daily and seasonal demand periods, but also fill in the gap between what renewables can produce and what the country needs at any moment in time. “It is this thermal generation that keeps the lights on if the weather refuses to play its part,” the spokesperson says. In addition, meeting increases in demand with peaker plants means that larger combined cycle thermal plants can be used at a more constant, and therefore more efficient, rate to produce base load electricity. But even if the weather pulls its weight, renewable energy is abundant and demands for natural gas thermal power are lower, the Ahuroa storage plant now provides a way to better use natural gas. “The Ahuroa gas storage facility bridges the gap between the way gas fields would like to produce and the way in which the energy market likes to use gas,” the spokesperson says. Gas can now be stored during off peak
times such as summer and used during times when it is most needed, like winter, when demand peaks, or when fair weather impacts negatively on lake and wind levels.
Building the peaker plant The Stratford peaker plant is situated three kilometres east of Stratford on the site of Contact’s former Stratford power station, adjacent to the company's existing Taranaki Combined Cycle (TCC) power station, and nine kilometres southwest of the Ahuroa gas storage plant. The peaker is a 200MW gasfired, fast-start power plant. The stars of the plant are its two US-made 100MW General Electric LMS100 gas turbines, the first of their type to be installed in Australasia. The gas turbines are conventional aero-derivative gas units but with three important enhancements – a low pressure compressor, an intercooler, and a power turbine – that work together to increase the efficiency and power output of the plant. The total combined output of the two power stations at this site (the Stratford peaker plant and TCC) is 580MW. In March 2008, Contact signed a contract with United Group (NZ) Limited to design the plant, project manage, engineer and install the two peaking units, and procure and install the balance of plant required to complete the project. General Electric and
Contact engineers played a strong role in many of the design and build aspects. In September 2008, the foundations and subsurface work of the decommissioned power station were demolished. In January 2009 work began on driving 191 piles to an average depth of 11 metres. In June, the main foundations were poured by Fletcher Construction in an eight hour continuous pour with 180 concrete truck movements. In May the two Brush generators arrived from the Czech Republic at Port Taranaki on the Tampa, at 67 thousand tonnes the largest vessel ever to visit the port. Other equipment started to arrive on site from various locations around the world, notably Kobelco gas compressors from Japan, and Pauwel transformers from Indonesia. In July 2009, the gas turbines were positioned on their foundations. By June 2010, construction was completed and commissioning the plant began. In November the first unit was fired, and following a test period, the plant was opened on May 31 this year. The plant is designed specifically to operate within local compliance limits with minimal impact on the local community, and Contact spent more than $4 million to ensure this outcome. The model cooling tower the Stratford station uses is a hybrid wet-dry design. Its operation minimises the formation of visible moisture
plumes. A mixture of natural gas and high purity water are injected into the combustors. The combustion process produces the hot high pressure gases that drive the turbines. The addition of the high purity water reduces
the formation of nitrous oxide emissions. The power turbine that drives the generator is not mechanically connected to the other turbine shafts and can consequently deliver superior performance
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PM John Key and Contact CEO Dennis Barnes at the opening ceremony.
Contact staff commissioning the 2,000HP V16 Walker Shaw quad turbo injection compressor.
even should there be disturbances in the electricity grid.
Building the gas storage facility The Ahuroa gas storage facility is a near depleted fossil fuel reservoir modified to receive gas for storage. Oil and gas were extracted from this field from 1995 until 2007. Contact Energy acquired rights to the field from American energy company, Swift Energy, in 2008 through the sale of their assets to Origin Energy. It is in a body of porous sandstone rock sealed in impervious layers of clay stone. To accomplish the conversion, a large injection compressor, gas processing equipment, and four injection-extraction wells had to be installed. Contact plans to store gas in it from a number of sources. The system is fully pressurised with sealed pipes. All four wells can be used for both injection and extraction, although Contact
at present prefers to use two wells for injection and two for extraction. Isolation valves are installed at key points throughout the system so sections can be locked out if necessary. Extracted gas flows from the reservoir via a treatment plant into the transmission network. The treatment plant is similar to that used for conventional oil and gas production plants and removes water and oil from the gas. Contact contracted out the drilling, design, project, and operational management work to Origin Energy. Work to reconfigure the plant for injection started in June 2008. In May 2009, the new 2,000HP V16 Walker Shaw quad-turbo injection compressor, capable of 230 barg maximum discharge pressure, arrived in Port Taranaki. By the end of September, installation was completed, and in October 2009 the new compressor was commissioned.
In November 2009, drilling of the three new injection-extraction wells started, By March 2010 the job was completed and in July the coiled tubing rig was set up and well testing operations commenced. Transfield Worley Hawkins was engaged to engineer, procure and construct the gas extraction facility using a wide variety of subcontractors. In June 2010, site works commenced for the installation of an extraction train that enabled gas to be extracted at up to 45 terajoules per day – enough to supply the two fast-start gas turbine peaking units at Stratford power station – in addition to the existing injection capacity. In August 2010, the gas-to-gas exchanger and low temperature separator coalescer vessel were installed. Fitzroy Engineering from New Plymouth built the gas exchanger; Robert Stone from Auckland built the low temperature separator coalescer
vessel, and ITL, also from New Plymouth, provided the design services. By February 2011, the facility was fully operational, able to extract up to 45 terajoules/day of gas. The facility can be expanded with the addition of a second new injection- extraction train, and ultimately, could inject or extract up to 160 TJ a day if needed. The Ahuroa project won the award for ‘Innovation in Petroleum’ at the 2011 Deloitte Energy Excellence Awards, held on August 17 in Auckland. The Deloitte Energy Excellence Awards provide an annual opportunity to recognise excellence and achievement across the electricity, oil, gas and petroleum industries. Jenny Baker is an Aucklandbased freelance writer.
IMPROVE YOUR EFFICIENCY WITH SHELL RIMULA.
When considering your fleetâ€™s operating costs, you should also consider your oil. Shell Rimula helps reduce maintenance costs and minimise vehicle downtime. Its unique Energised Protection formula helps protect the engine and prolong engine life. To find out how Shell Lubricants can design solutions to address your challenges contact Orica Chemicals - New Zealandâ€™s Shell Lubricants Distributor on 0800 673 375 or visit our website at www.orica.co.nz.
*The savings indicated are specific to the calculation date and site. These calculations may vary from site to site depending on application, operating conditions, current products being used, condition of the equipment and maintenance practices.
Skilled workers – will you find them? FINDINGskilled workers is set to prove a challenge for New Zealand’s engineering companies. Latest research from Competenz, the industry training organisation for the engineering and manufacturing sector, shows that skilled fabricators, tradesmen, welders and engineers are, and will continue to be, in short supply. In June of this year, Competenz asked 194 companies about their on-the-job training needs for now and in the future. Results proved that the skills shortage everyone is talking about is real, with 64 percent of engineering and metal manufacturers needing at least one more skilled staff member by 2013. To put this into perspective, New Zealand has 7,062 companies in the engineering and manufacturing sectors, meaning 4,519 skilled workers will be needed. Fiona Kingsford, GM of trade training at Competenz, says this is a real concern for businesses. “The reality is that engineering companies will need to upskill their existing staff or take on newapprentices nowto meet their current and future skills needs.” Companies knowthey have to train – 60 percent of all staff employed in the engineering and metal manufacturing sectors are trained on-the-job. However, it’s not enough to meet demand. Lisa Frost, training manager at John Jones Steel, a structural steel fabrication company in Christchurch says, “We need considerably more skilled welders and we are scraping to find anyone.” With demand set to skyrocket in Christchurch when rebuilding commences, a lack of skilled staff is a bleak prospect. Key areas of concern are fabrication, tradesmen, welding and engineering; representing a current skills shortage of 35 percent or 2,471 workers – and set to growby
a further 2,542 workers in 2012 and 2013. The biggest shortage is for fabricators. Currently 444 fabrication apprentices are in training, but industry has said it needs 1,412 more fabricators in the next two years. Becoming qualified takes up to four years, so supply and demand is at a sizeable imbalance. With 49 percent of companies preferring to hire ready-trained staff, and only 18 percent hiring to train, recruiting skilled workers is not a viable option. Training is the best way forward, says Competenz. Whilst it is a considerable commitment, unless more businesses take on young learners and upskill their current staff, the skills shortage is inevitable. An option for businesses who do not want to take on the HR hassles of hiring is the ATNZ apprenticeship scheme. ATNZ eliminates the hassle for employers by recruiting, paying, mentoring, training and supplying the apprentice’s tools. Employers are provided the benefits of having an apprentice without having to handle the formalities. Staff already employed, yet never qualified, can gain trade certification via an assessment of prior learning, or APL. Designed especially for mature learners, APL assists individuals who missed out on qualifying earlier in life. The full report of the survey’s key findings and results, which covers the engineering and metal manufacturing sector and the food and beverage manufacturing sector, as well as ATNZ and APL apprenticeship information, is available on the Competenz website (www.competenz.org.nz) or as a hard copy on request by phoning 0800 526 1800. Go to www.demm.co.nz/ enquiry quote: D110922
Optimum results when welding aluminium THE Miller AlumaFeed synergic aluminium welding system, available through Weldwell NewZealand, is specifically designed to give optimum results when welding aluminium. The system is sophisticated but simple to operate and comes with a Miller True Blue three year warranty. Because aluminium wire is softer than most other welding wires, there are potential wire feed issues when MIG welding. This is overcome by the use of a push/pull welding feeder and gun. This makes use of the double feed system that pushes the wire into the gun at the wire feeder and pulls the wire via a drive motor at the gun handle. This enables the feeding of even a soft aluminium wire over extended distances. Push/pull guns are available upto 10.7 metres long. This gives the advantage of being able to weld at some distance from the power source and feeder and enables welding in difficult to access areas. The AlumaFeed system is capable of: • Pulsed MIG Welding – For reduced heat input, distortion control, reduced fumes, no spatter, good mechanical
properties and all position welding. • Synergic Pulsed MIG Welding – Allows one knob control of all pulse welding parameters. • Profile Pulse MIG Welding – Adjustable double pulse welding for a TIG weld appearance. • Non-Pulsed MIG Welding – For when reduced heat input is not required. • Arc Length Control – The arc length is adjustable and stays constant regardless of operator gun position variations. • Dual Schedule – Allows you to pre-set different welding parameters and quickly switch between them. • Hot Start – Eliminates incomplete fusion at the start of a weld. • Weld Crater Control – Eliminates crater defects at the end of a weld. The AlumaFeed system consists of the Aluma Power 350 MPa welding power source, XR-AlumaFeed push/pull wire feeder, XR-Aluma-Pro or XR-Pistol Grip push/pull guns. There are air cooled or water cooled variants as well as a water Go to www. re-circulator option. demm.co.nz/enquiry quote: D110923
Extraction equipment essential for health and safety
WITH an increasing emphasis on workplace health and safety, the use of extraction equipment has now become essential. Many industrial work processes create significant dust and fume toxins which have long-lasting and adverse affects on employees. Egmont Air has a huge range of fume extraction equipment designed to extract contaminants from processes in the workplace and create a clean, productive and healthy workplace environment. Egmont Air provides a total design-to-installation solution with its range of extraction equipment and industry expertise. A free on-site consultation offers an initial analysis of any industrial
application and associated dust or fume issue. A solution and proposal is then designed by Egmont Air to provide a guaranteed performance result. Extraction at point of origin The secret to providing a clean and productive working atmosphere is 'extraction at point of origin'. Applying this principle involves an understanding of the work process and available extraction methods so that an effective system can be designed to extract the toxic dust and fumes before they reach the operatorsâ€™ breathing zone and spread throughout the work environment. Egmont Air features the popular
Clean-go mobile extractor, which is a compact and versatile mobile unit suitable for eliminating toxic fumes, solvents, gases or vapours and returning the purified air back into the work area. Articulating Suction Arms also provide a useful method of capturing smoke and fume and offer manoeuvrability for varying work process applications. These popular wall mounted articulating arms can be used in a welding-bay situation or general workshop area. They are ideal for fume and dust applications, extracting fumes over an area of up to nine metres radius. In machine-shop situations Egmont Air recommends oil-mist
collectors. These extraction systems protect employees from breathing oily fumes and smog. They create a clean and safe working environment by preventing the build-up of dangerous oily residue which covers machinery, floors and finished products. Egmont Air also specialises in wood dust and shaving extraction systems for sawmills, joinery shops, kitchen-makers, boat-builders and associated wood-working trades. Many bag-house filters and fans are available ex-stock and can be specified for large or small applications. Go to www.demm.co.nz/ enquiry quote: D110924
INDUSTRY TRAINING WELDING
Fume arms with smoother air flow
EXTERNAL joints to allowa smoother air flowinternally is just one of the benefits of the fume arm range launched by NewZealand Duct & Flex at the snowed-in SouthMACHTrade Showin August. The range of fume arms – available in diameters from 76mm to 200mm have arm reaches varying from one to four metres, dependent on the model. Geoff Ebdon from NZ Duct & Flex did the research on a recent trip to Europe and says the quality and performance of the products he selected are excellent. “Fume arms remain a very economical, versatile and durable method of capturing impurities close to where they are released – welding, grinding, polishing, cutting, soldering and even chemical fumes,” says Ebdon. “In our core business of supplying modular ducting and flex, we are frequently asked for these products, so it is a natural addition to our range of more serious filtration systems.” Most fume arm manufacturers offer two types. The competitive cost models have the hingeing and articulation on the inside of the tubes. Only the more expensive models have outside articulation. Internal components are harder to clean, become coated or abraded by the particles being sucked up the fume arm and affect flow. “We decided to offer a complete
range with articulation on the outside of the tubes, giving a better ‘smoother’ air flowperformance and no problems with particles becoming trapped in the articulation mechanism,” says Ebdon. “The fume arms are manufactured in Europe and we will be following our policy of supplying quality products and the widest range of diameters, lengths and price points in the NewZealand market.” Every fume arm is supplied with mounting brackets and a throttle valve (normally an extra cost) and they are easy to position due to the ‘all around’ grab handle. There’s a stainless steel range which includes a stainless steel hood and stainless steel tubing – ideal for laboratories using chemical applications, and food and pharmaceutical industries. “There will also be a wide range of extending boom arms to give even greater reach and telescopic arms,” says Ebdon. “Lights are also an optional extra.” For specialist applications, the fume arms can fitted with US FDA or EU approved food grade flexible connections, high temperature (300ºC) or antistatic flex from existing NewZealand Duct & Go to www.demm. Flex stock. co.nz/enquiry quote: D110925
PUMPS & VALVES
Custom chopper deals to egg pulp FOR more than 50 years, the heavy-duty Vaughan chopper pump has been responsible for solving some of the toughest solids pumping problems in industry. Recently, Pump Systems Ltd, the Vaughan authorised factory representative for Australia and New Zealand were called upon to offer a customised pump solution for processing egg pulp containing large amounts of abrasive egg shells. As standard, Vaughan chopper pumps are supplied with a twosegment cutter bar fitted directly in front of a sharpened chopping impeller. For most industrial and municipal waste applications, this time-tested design has proven extremely effective when dealing with heavy solids and/or rag and other fibrous material that would normally clog other pumps. In fact, this design has been so effective, that every Vaughan chopper pump sold comes with a non-clog guarantee. This particular application was slightly different in that the egg shells needed to be broken down
as small as possible prior to being processed. To achieve this, Pump Systems proposed a Vaughan E-Series model HE3G horizontal chopper pump fitted with a special four-segment cutter bar. The combination of this cutter bar and the HE3Gâ€™s four-blade impeller results in extra points of chopping per revolution and therefore a finer overall chop. In addition to this, the pump also comes with a special EC2 external cutter to pre-chop material as it enters the pump suction. Not only does the Vaughan chopper pump provide outstanding, non-clog solids handling and chopping performance, but in this case, due to the very abrasive nature of the egg shells, the heat treated and hardened components of the Vaughan chopper pump are also well suited to the application. Go to www.demm.co.nz/ enquiry quote: D110926
The Vaughan E-Series model HE3G horizontal chopper pump and its special four-segment cutter bar.
PUMPS & VALVES
Valves deliver precision aeration control PUMP Systems recently supplied eight special Egger IRIS control valves to South Australia Water for a project at the Heathfield Wastewater Treatment Plant in Adelaide. The equipment, consisting of one DN125 and seven DN100 electrically actuated type valves are to be used for air control applications at the plant where precise flow monitoring is required. Quality manufactured in Switzerland, the unique IRIS valve by Emile Egger & Cie SA is based on the same design principle as the aperture of a camera, which is continuously variable to provide precision flow control. The Egger IRIS valveâ€™s 0-100 percent continuous aperture with enhanced segment edge design combined with excellent regulation characteristics helps to maintain a central flow axis for outstanding, hysteresis-free performance. Non-clogging, self-cleaning and
designed for continuous operation, the IRIS valve has a free passage design enabling low turbulences and a smooth flow to reduce unnecessary pressure losses. This not only provides energy cost savings and low noise emissions, but also increases performance accuracy by optimising the valve Go to www.demm. apertures. co.nz/enquiry quote: D110928
PUMPS & VALVES
Pumps engineered for pre and post-stressing THE latest Enerpac ZU4 hydraulic pumps, engineered specifically for pre and post-stressing, contain fewer moving parts and generate less friction than conventional pumps to give more power and reliability. The ZU4 A300 series stressing pump with its 1.25kWmotor increases speed of operation which reduces cycle times. Outstanding flowdynamics also mean the energy saving ZU4 class 700 bar electric pumps will stay on the job longer, run cooler and be easier to service when the need eventually arises, says Enerpac. Rugged workhorses such as the ZU448REA300 double-acting pump can be coupled with Enerpac post-tensioning tools for mono strand construction applications common on building, mining and infrastructure development sites. These single-acting PT and doubleacting DPT post-tensioning tools deliver 20 or 30 tons tensioning capacity when coupled with the ZU4408REA300, which features remote pump control and advance/ hold/retract valving. Compact and highly portable ZU4T Series electric pumps, weighing between 30 and 32kg, employ a 1.25kWuniversal motor
that provides a high power-toweight ratio and excellent low voltage operating characteristics. The motor is coupled with a totally newpump element design that reduces oil flowturbulence; producing an industrial workhorse with fewer moving parts, less friction and which requires 18 percent less current drawthan comparable pumps. Enerpac says the universal motor offers important jobsite benefits. One is a lowstarting current draw, much reducing the likelihood of tripping breakers at startup. Another is outstanding tolerance for low supply voltage – in contrast with bulkier, heavier induction motors, which tolerate under-voltage poorly and quickly overheat. The universal motor can operate satisfactorily from a long extension cord or portable generator. The pumps’ increased flow rates, reduced heat generation and decreased power needs translate into higher productivity and reliability for applications such as construction, crimping, cutting, fabrication, lifting, lowering, materials handling, maintenance, pressing, pushing, pulling and production and process engineering.
The pumps are ideal for use with Enerpac pre-and-post stressing technologies including: • Durable field proven mono strand designs in capacities from 20 to 30 tons with soft-grip ergonomic handles to reduce operator fatigue. • Single acting PTJ models incorporating newEnerpac posttensioning cylinders with 254mm stroke, ideal for slab-on-grade
applications. • Double-acting DA models with 216mm stroke, machined from a single billet with gun drilled internal hydraulic passages. • Re-useable and one-time-use barrels and wedges from five to Go to www.demm. 15.2mm. co.nz/enquiry quote: D110929
PUMPS & VALVES
Ideal pumping solution for sodium hypochlorite A HIGHLY corrosive and toxic chemical with strong disinfecting properties, sodium hypochlorite plays an important role in the water industry. However, its tendency to release gas bubbles and cause gas locking at the valves poses a major challenge to conventional pumping techniques. The UK’s South East Water has overcome this difficulty by opting for peristaltic pumping technology from Watson-Marlow. Sodium hypochlorite is a corrosive chemical that has disinfection and bleaching properties, and is used in the purification of wastewater and the disinfection of drinking water. However, dealing with the chemical can be difficult as it is toxic and emits chlorine when in contact with acids. It naturally releases tiny bubbles of gas, which have a tendency to collect on the small ball valves found in conventional diaphragm dosing pumps. This can cause gas locks in the system, which prevent the pumps from functioning. South East Water had been using diaphragm pumps to dose sodium hypochlorite into drinking water. However, they found that gas locking problems necessitated maintenance on a regular basis. When the pumps were replaced with 520U/R IP66 peristaltic pumps supplied by Watson-Marlow, this problem was eliminated. Peristaltic pumps have no valves, seals or glands and the fluid only contacts the bore of the elastomeric hose or tube. South East Water found that the gas produced by sodium hypochlorite was able to pass straight through the tube without interrupting the dosing process, thereby reducing maintenance dramatically. “We’ve worked with Watson-Marlow for years,” explains Ray Lawrence, process engineer at South East Water, “so we understood the value of their peristaltic technology, and decided to use it
in an innovative way. Because peristaltic pumps retain the fluid completely within the tube and have no valves that can leak or corrode, they can be used for the accurate metering of substances as challenging as sodium hypochlorite, without the associated gas locking and maintenance problems.” South East Water is also using the pumps for dosing sodium bisulphite, in order to de-chlorinate the water after disinfection to remove the unpleasant taste. The chemical is dosed in very small quantities, which requires a high degree of precision and accuracy from the pump. Previously, it had been necessary to dilute the sodium bisulphite in order to control
the dosage procedure accurately. This added an extra degree of complexity to the process, but Watson-Marlow’s 520U/R IP66 peristaltic pump resolved the issue. The pump can be calibrated either by weight or volume, allowing very precise dosing and metering. South East Water is now able to dose small amounts reliably even at low pressure, without the need for dilution. Watson-Marlow peristaltic pumps are represented in New Zealand by Watson-Marlow Bredel Pumps, based in Auckland. Go to www.demm.co.nz/enquiry quote: D110930
Contact Frank Atkinson Email / firstname.lastname@example.org DDI / (09) 477 0362
MAINTENANCE MATTERS The power of purpose
One of the most extraordinary programmes to facilitate and manage young school leavers into trade apprenticeships has been quietly gaining momentum in South Auckland over the past three years. Editor
Year One 2011 cohort at MIT.
Glenn Baker talks to Trades At School founder and CEO John Kotoisuva. You don’t have to be a rocket scientist to figure out that there has long been a problem getting young school leavers to focus on trades careers after high school, or to recognise a tangible purpose for their high school education. Thankfully, there is a scheme up and running, albeit still in its infancy, that has the potential to make a real difference – to give young people that real sense of purpose and help solve NewZealand’s ongoing skills shortage in the trades. It all began when John Kotoisuva, during his time as a modern apprentice assessor and tutor with Apprentice Training NewZealand (ATNZ), saw
the disconnect between the education sector and industry. “Young people coming into industry after training did not quite meet the requirements of the employers. They lacked understanding of the culture and the language of industry, and were coming into jobs quite ill-prepared,” he explains. “It was evident to me that the preparation of young people for industry wasn’t good enough – and so the concept for Trades At School began to form in my mind. “At ATNZwe were having a high termination rate of apprenticeships,” recalls Kotoisuva. “I also sit on the advisory board of Competenz, representing the steel industry. At our last meeting it was revealed that
60 percent of newapprenticeship sign-ups terminate in the first 18 months. I believe this is largely due to industry not really being truly represented in the education sector.” Signing contracts was often a case of ‘trial and error’ for apprentices, he says. “They would ask ‘is this for me or not?’ Trying to cope, especially in the initial stages of the apprenticeship, was a tough, lonely process for many.” Meanwhile, says Kotoisuva, students are sitting at secondary school, Year 11 through Year 13, not knowing why they are there. “They cannot relate the subjects they are doing to life after secondary school.
John Kotoisuva (right) with Grayson Engineering MD David Moore, who has employed a Trades At School graduate to train as a fabricator welder.
They can’t personalise NCEAor be motivated by it.” So industry ends up getting young people simply with NCEAcredits from all manner of subjects, he says.
Building a bridge “Trades At School is about building a solid bridge between industry and the education sector and bringing industry into the classroom for what it really is – presenting it in its truest form. Trades At School, with initial five-year seed funding from the ASBCommunity Trust and Ministry of Pacific Island Affairs, has already put runs on the board. Working with 11 secondary schools in South Auckland and the Manukau Institute of Technology (MIT), the three-year programme has already had its first intake graduates. 14 achieved the National Certificate in Mechanical Engineering Level 2 (NCME L2) – a tertiary qualification additional to their NCEALevel 2 and the equivalent of a one year apprenticeship for ten different trades. Furthermore, seven students have already found trades employment – even those that haven’t were still motivated and confident enough to go on to pursue other careers. There are no negatives in this scheme – only positives! The benefits to all parties are plain and obvious. Students become focused, motivated and, most importantly in this age of high youth unemployment, they have far greater earning potential at a young age. The schools benefit by having more engaged, high-achieving students with positive attitudes and behaviour – they can see a
purpose in their studies. Employers gain groomed, more productive workers with the right skill sets and the right attitude. There’re reduced training costs for them too because Year One apprenticeship unit standards are completed with the trainees attending MIT one day a week (three terms a year for two years). The trainee already has a two year track record (commitment) from secondary school and work experience in industry during the school holidays. And let’s not forget the macro socioeconomic benefits – less welfare dependency, minimised teenage joblessness and negative social behaviour, less need to bring in overseas trained workers, the list goes on. It’s no wonder John Kotoisuva wants the scheme to roll out from its current focus on mechanical engineering (fabrication/welding, precision engineering and maintenance) to other sectors – such as building and construction, rigging and scaffolding, manufacturing and infrastructure. “The simplicity of the programme makes it so easy to duplicate.” It’s also understandable that he wants additional support beyond the current five year timeframe – more buy-in from business leaders, employers and funding agencies. “With support from employers especially, Trades At School simply couldn’t function,” he says. “This is a home-grown human resource – your vehicle for the next generation of skilled workers.
We’re still losing far too many skilled workers to Australia. We must generate the numbers of new graduates and keep up the quality – and work at keeping these workers here with their extended families.” Kotoisuva is excited about the potential of the programme long-term. Trades At School deserves consistent funding in years to come, he says, if it is to successfully respond to the needs of industry. No more ambulance at the bottom of the cliff, he says. “This is not about throwing lifejackets to save young people – it’s a prevention programme. “It’s about empowering young people and walking beside them – helping them to cross that bridge between secondary school and employment, apprenticeship and traineeship. “Trades At School helps young people make the transition with pastoral care and mentoring, education and exposure to industry, into productive jobs in an industry of their choice.” Kotoisuva has an experienced board backing him, and a ton of positive testimonials from students and employers already to prove that this scheme deserves greater recognition. To become an industry partner or a school partner in the programme phone 09 270 4071, email email@example.com or visit www.tradesatschool.org.nz
How tHe programme works Trades At School comprises the following three stages: 1. Pre-Trades At School – Year 11 students are introduced to the programme through industry experts sharing their experience in the classroom and through on-site tours. 2. Trades At School – Year 12 and 13 students attend polytechnic one day a week for three terms over two years to complete the NCME L2 with more than 60 credits on top of their NCEA. 3. Post-Trades At School – Students exit secondary school and are supported through mentoring, pastoral care, career planning and assessing, and in industry through employment, apprenticeship, traineeship or higher education.
Automated parts cleaning manufacturing and for applications where space is limited. With a large wash capacity of up to 660mm x 356mm x 381mm (LxWxH), the Jetsink utilises dual 360-degree spray manifolds with 80 precision positioned jets to clean with just 95 litres of ordinary water and detergent. The solution is heated with a 1,650W, 110Vheater (13.5kW, 220Vheater optional) and then jet sprayed by a recirculating pump. No venting or special utility connections are needed. Only an electrical ANYtime a part is machined, the oil, grease and chips from the machining process need to be removed before further part production takes place. Otherwise, residue and chips inhibit later manufacturing processes, whether they are performed in-house or off-site. As many manufacturers can attest, it can be a challenge to clean machined parts to tight specifications in a cost-effective and environmentally sensitive manner.
Manual parts cleaning is not only cost- and labour-intensive, it also poses a risk for the operator’s health. With the EMC Jetsink Cleaning Station, Dimac Tooling nowoffers an automatic alternative to manual solvent wash tanks. Engineered to automatically clean oily or dirty parts without hand scrubbing or toxic solvents, the Jetsink cleans parts using only soap and water in a matter of seconds. The small footprint (711mm x 560mm deep) makes it ideal for cell
Cleaning and hygiene solutions for industry
CELEBRATING more than 30 years in business, Advance International Cleaning Systems is still offering premium ‘high spec’ machinery, chemicals and janitorial supplies suitable for all types of cleaning tasks within New Zealand industry. Advance International Cleaning Systems represents the Nilfisk range of cleaning equipment which is designed specifically for professional applications – meaning that while they are robust, powerful and reliable, the range is exceptionally energy efficient (minimising running costs). The Nilfisk range accommodates equipment suitable for large and small
hookup is required. For small items and screw machine parts, an optional Rotary Cleaning System is available. The rotary cleaning system gently tumbles your parts in a self contained basket while they are being sprayed. When the wash cycle is completed, the rotor continues turning, thereby dewatering and Go to www. drying the part. demm.co.nz/enquiry quote:
cleaning tasks. Its large portfolio spans small equipment such as backpack vacuum cleaners, to large ride-on sweepers and scrubbers. Advance International Cleaning Systems has 11 locations in New Zealand and more than 30 field staff deliver onsite machine service and repair, along with complimentary site inspections. Check out www.supershine. co.nz to view the Super Shine range of products to suit the automotive industry. And if you are looking for cleaning products with Environmental Choice Accreditation visit Go to www.demm.co.nz/enquiry quote: D110934a
Understanding reliability centred maintenance
The MSG process originally developed for the Boeing 747 was adopted by the wider aviation industry and later adapted for use by general industry and renamed ‘Reliability Centred Maintenance’. TRADITIONAL thinking that equipment failure can be determined by length of time in service is severely flawed, as most readers may be aware. Research carried out by the airline industry and US Navy found that the traditional bathtub curve could account for only four percent of failures. It was established that there are in fact six common equipment failure patterns and when all failures are considered, only around 15 percent can be determined based on hours or cycles run. This means that carrying out
scheduled replacement or restoration tasks based on hours or cycles run is inherently wasteful. It is our role within maintenance to ensure the reliability of all assets, and to achieve this we must consider methods beyond simply setting up time-based scheduled repair or restoration tasks. One of the tools we can use to determine the correct maintenance for any asset is Reliability Centred Maintenance (RCM), which grewout of the aviation industry. When the Douglas DC8 was in
service back in the 1960s, around four million maintenance manhours were expended between major 20,000-hour overhauls. With the introduction of the Boeing 747, a far more complex aircraft, it became obvious that a different approach was needed. This realisation prompted the industry to put together a series of ‘Maintenance Steering Groups’ (MSG) to re-examine everything they were doing to keep their aircraft airborne. After much research and development a process was formed with a maintenance focus, based on the function and failure effects of components. This process, known as MSG2, was released in 1970. The outcome was spectacular – the MSG maintenance programme on the 747 expended only 66,000 manhours between major 20,000-hour overhauls, and this on a far more complex aircraft. Unsurprisingly the MSGprocess was adopted by the wider aviation industry and shortly after by the military. In the early 80s the process was adapted for use by general industry by John Mowbray. It was renamed ‘Reliability Centred Maintenance’ (RCM) and has since been used successfully the world over.
RCM analysis Reliability Centred Maintenance enables the definition of a complete maintenance regime for any asset taking into account the context or environment in which it operates. The initial part of the RCM analysis is to identify the operating context of the machinery, and write a Failure Mode Effects and Criticality Analysis, or FMECA. During this process the function(s) of the equipment is clearly defined and the ways in which it could fail to meet each function is considered. All possible causes of the failure (failure mode), and the effect that failure will have, are determined before the final part of the FMECA process, which is to consider the criticality of each failure mode. The second part of the analysis is to apply the decision logic which is used to determine the most appropriate maintenance tasks for the failure modes identified in the FMECA. Once the logic is complete for all elements in the FMECAand all maintenance tasks have been identified, the resulting list of
maintenance is packaged so that the periodicities of the tasks are rationalised to be called up in work packages. Sounds simple enough! So why isn’t it carried out more widely? The reality is that to carry out an RCM analysis is a time consuming and detailed process, and requires a deep understanding of your equipment and the RCM process itself. Depending on the maturity of our current maintenance culture, bigger gains can also often be made by concentrating on the basics such as tightness of fasteners, lubrication, cleaning and alignment. However, there should come a time within all organisations when RCM is the most appropriate way to progress reliability to the next level. Working on the premise that a little knowledge is a dangerous thing, the first step should be to obtain a thorough understanding of the RCM process through reading or attending a training course. This will allowthe assets that are most likely to benefit from RCM to be identified and then provide the skills needed to get the process underway. Reliability Centred Maintenance is a high level maintenance tool that will determine the most appropriate maintenance for any asset, taking into account the context or environment in which it is operating. It will not increase reliability if we are not paying attention to the basics, but used in context it has the potential to reduce the amount of man-hours we expend on maintenance, while greatly increasing reliability. Phil Hurford is manager of the Skills4Work Maintenance Excellence Programme. Email p.hurford@ skills4work.org.nz Go to www.demm.co.nz/enquiry quote: D110936
What’s happening with our trades? Part one of a two-part series in which MESNZ secretary Craig Carlyle shares his views on the supply of tradesmen and training of apprentices in New Zealand, based on the Society’s survey results.
Regular readers of this magazine will be aware that the Maintenance Engineering Society (MESNZ) has given itself the task of discovering what is happening with the supply of tradesmen and training of apprentices in NewZealand. Focused by continuing unrest in the media, our epiphany was to look for solutions rather than simply add our grumbles to the debate. We could have relied on our collective experiences and opinions as a bunch of grumpy old men, but instead we resolved that we should learn as much as we could about the subject and gather as much industry opinion as possible. This was achieved with an Internet survey and interviews with industry players, suppliers, employers and identities. While the MESNZ strawpoll survey professes no professionalism in research methods (hell we are only dumb engineers!), the results are conclusive enough that to deny that an issue exists would be to declare that there is no elephant in the room. Fewwould argue that our trades force nowcommands the global respect that it was once famous for. Either in engineering or with trades roots in engineering, Kiwis were
held in awe for their abilities and achievements. Yes, the world has changed, but why have we slipped from our pedestal? To understand the global perspective, I spoke at length with Ross Green, a Kiwi engineer whose global company, Drivetech, chooses to maintain a presence in New Zealand. As Ross puts it, in the 1950s we were ‘king of the world’, based on our investment in infrastructure and technical competence. We suffered hugely in the 1970s at the whim of global economies and have looked like a possum caught in headlights ever since. We nowcongratulate ourselves on our booming tourism industry without ever considering that the future of that industry can already be seen in places like Bali and Phuket. The result of the dumbing down of industry places great pressure on companies like Drivetech. The arguments for retaining a presence in NewZealand no longer hinges on our engineering base; the skills are not just getting harder to tap into, they are disappearing. Global industry is about NOW, with the transition from concept to tooled prototype measured
in days, not weeks. The only (perhaps romantic) reason for Ross’s company still connecting with NewZealand is our value as R&D innovators. Ross points out that NewZealand is the best country for inspired culture. We have an ideal market testing environment with pocket sized cities and increasing Internet connectivity. From an R&D point of view, we should learn from the infrastructure of Boston and ensure our entire education system is geared to once again generate craftsmen that lead world standards. Where our relative success in history has stemmed from our emphasis on science, (Rutherford), we need to place greater emphasis on converting science into wealthgenerating products and services. Take the iPhone, for instance – the infrastructure behind developing such technology and tooling could easily have come from NewZealand. As Ross puts it, “It is often the 71st idea that is the best and no-one is better at generating those ideas than Kiwis.” Unlike other countries, our culture allows us to make suggestions without losing face. Our problem is that we can’t finish the idea and the
skills to turn ideas into reality are disappearing. Ross does not have a labour cost issue in NewZealand; his issue is that there is no longer a labour supply here in the specialist skills that he requires. He also points out that as we lose the skills (for example, our Air Force strike force and associated sub-skillsets) we will never get them back. Ross puts his finger on the societal aspect. In the world’s leading economies, trades skills are respected and represented, right up to board level. Craftsmen have enviable status in industry and newrecruits clamour to obtain trade skills. Economies are based on entrenched value and depth, not stripping industry to match third world labour rates. In NewZealand, we have evolved into a commodity supplier, sitting on our hands thinking “We are clever, we are innovative”. Unfortunately other countries are clever too, but they also work longer and harder. Ross points to leading economies as a pointer to a culture change. Today’s major economies like Japan and Germany were built on the back of post war US investment. To expect that kind of investment here is wishful. What is needed from our politicians is the
to fully understand what stands them apart from other tertiary or professional training; cadetships, diplomas and degrees. We asked tradesmen if there is a fundamental difference between an apprenticeship and other forms of technical/professional training? The result was an overwhelming 88 percent – who said YES! Comments included: “Apprenticeships are an effective way of developing personal and work skills”, “Invaluable for transferring knowledge to the younger generation”, “An opportunity to practice and develop skills”, “Hands on training and mentoring”. My favourite comment though was: “Apprentices are taught from the start that efficiency, focusing on learning and applying correct skills and getting it right the first time are first principles in the trades. Poor work and scrap material can’t be hidden by clicking a button.”
Are schools doing the job?
testicular fortitude to map a path forward that is inspirational and achievable. Success is obtainable, look what Sir Peter Jackson has achieved for the film industry. While it took one man’s kahunas and backing, a visit to Miramar is evidence indeed of a whole newcraft pool supporting the success of one industry. Overseas, the skill base is valued, maintained and has evolved to include newmethods and materials. School leavers aspire to trades skills and only a small percentage move their focus onto degree level. The obsession of NewZealand Polytechs becoming “universities” can be compared with the British model, since rejected, which, in Ross’s words, “Simply generated third rate degrees. Ignore history at your peril.” Interesting comments from a man who employs engineers and craftsmen globally.
The tradesman’s view With Ross Green’s observations ringing in our ears, let’s take a look at what Kiwi tradesmen are saying. Our humble survey drew80 responses – 89 percent of whom were aged 36 and above. The majority (97 percent) were male. Our first survey questions to tradesmen revolved around the old apprenticeship board and its presence and value to them. The results showed that 60 percent had occasional to regular involvement with the authority; 67 percent had seldom or no site visits. We asked respondents what the authority did for them. The resulting comments fell into two groups: either companies were large enough to include their own in-house apprentice masters in which case the interaction was highly disciplined; or, for more humble companies, the apprenticeship authority was a ‘grey ghost’ that governed and only got directly involved when you were in trouble. Valuable commentary when we consider the “modern” replacement for the role of apprentice masters: our ITOs (Industry Training Organisations). While industry grapples with the number and funding of ITOs, the obvious questions should be: “Are ITO’s relevant?” and “Could the government get a better bang for its buck with an alternative method of managing apprentices?” The vast majority of tradesmen, 87 percent, rated block courses as vital or highly important to their trades learning. Comments included: “It made you much more aware of the available technology”, “You could measure yourself against your peers”, “Some guys really needed input from the tutors”. When it came to personal growth and maturing, 76 percent claimed that block courses were vitally or highly important. Feedback included: “Opportunity to discuss with peers our work environment, skills etc”, “The tutors provided the mentoring I needed to get my act together away from the workplace”. You need to complete an apprenticeship
With the knowledge that most of our respondents are nowparents of secondary age children, we asked if the way we are streaming, preparing or teaching school children through the school system is doing a better job of developing interest and preparing potential apprentices. “No” was the response of 84 percent of those polled. I wonder howthe respondent who stated that “the hands-on teaching of metalwork [at school] provided the seed that nowsees me managing complex, multimillion dollar projects” would have fared in the modern system! The modern apprenticeship system replaces the old hours-based version with achievement standards that generally occupy the same timeframe of three to four years. With the fiddling with apprenticeship hours in the 70s and 80s in order to turn out tradesmen faster, we thought it opportune to harvest our respondents’ opinions on the ideal apprenticeship length. Seventy two percent voted for 8000 hours, with the next popular choice (16 percent) suggesting 6000 hours. In our search for answers, we provided a 60 second opportunity to pass improvement suggestions onto John Key. The comments were prophetic: “Improve the linkage between schools and industry”; “Change the perception for young people”; “Incentivise the apprenticeship scheme.”; “Influence a culture change towards recognition that working with one’s hands can be exciting and profitable.”; “Introduce basic trades training in schools”; “Get back to basics”; “Return to the old system”; “Remove the ITOs.” My favourite? “You can’t learn howto sharpen a drill bit using a computer.” Wow! Unless tradesmen have a particularly bleary viewof the world, no amount of spin doctoring is going to convince this group that we are doing an equally good or better job of developing newgenerations of tradesmen. In part two next month, I’ll report on the survey responses from employers and trainers, identify ‘the elephant in the room’, and share some positive suggestions from the workshop floor.
Early peek at National Maintenance Engineering Conference papers By Craig Carlyle
WITH the November 2011 National Maintenance Engineering Conference now rapidly approaching, pressure is mounting on the organisers to reveal the speaking program. Whether to justify attendance or a specific search for solutions, the speaking program is always eagerly anticipated by prospective attendees. This year has seen no reduction in the pressure to deliver and speakers facilitator (and MESNZ chairman) Barry Robinson has finally shown his hand with the first release of the 2011 program. Featuring an eclectic mix of international, expert and peer speakers, this year’s program is well worth the wait – satisfying the ethos of reality-based maintenance management topics and the Society aim of raising the bar of maintenance engineering in New Zealand. From the opening root cause analysis paper of Assessco’s Timothy Smithson, the twoday conference will also feature papers on counterfeit materials, ultrasonics, employment law, earthquake engineering, variable speed drives, lean manufacturing, naval maintenance,
training and qualifications, machine tool alignment, case studies, computerized maintenance management systems, chemical safety and HASNO. Guests such as Commander Robert OchtmanCorfe of the Royal New Zealand Navy join perennial favourites such as Charles Willmot (IPENZ) to deliver a balanced mix of peer experience and expert learning. The speaking program is designed to inspire attendees and arm them with the maintenance engineering tools to take back to their own workplace.
Jewel in the crown The National Maintenance Engineering Conference is being held at The Distinction Hotel in Rotorua on November 9 and 10. Backed for yet another year by industry sponsor Hydac, the event presents a popular format of thought provoking papers, while providing ample breakout opportunities for engineers and suppliers to explore solutions to their particular issues. The annual conference is the jewel in the crown of the Maintenance Engineering Society
of New Zealand, (MESNZ), a technical group of IPENZ. Exhibitors too, will be pleased with the opportunity to get in touch with engineers over the two day event and the pre-conference Trade Expo. Entry level small business exhibition opportunities are priced from $550 plus GST. The attendance fee of $680 plus GST per person removes traditional hurdles for engineers normally prevented from attending comparable two day events by costs far in excess of this. The 2011 event goes further still, however, with the introduction of a $400 plus GST per person ‘bring a buddy’ rate for second and subsequent staff members. A better bang for your buck will not be found anywhere else for such an inspiring and informative event. Registration forms and background details can be found on the Society website at www. mesnz.org.nz/nmec/. Or for further details, contact Leanne Powley on 09 296 1333, or email firstname.lastname@example.org
Oils to match the application AS IT increasingly focuses on the industrial sector, Penrite is expanding its range of lubricants to suit commercial and industrial applications such as agriculture, mining and machining. Penrite has spent years devising products for automotive applications, consistently researching the latest technologies to improve and refine its product range to meet modern specifications. The company’s industrial products are similarly developed to ensure trouble-free performance. Penrite insists on the correct oil for the job. Incorrect lubricants can cause premature wear, damage to parts and, ultimately, costly downtime. Using the correct product can not only extend the life of equipment and provide greater confidence in the product itself; it will also reduce costs in the long term. Penrite provides a 100 percent guarantee on all its products when used in their recommended applications. Its range of products that can be used in many industrial applications, such as heavy duty engine oils, hydraulic oils, heavy-duty gear oils, greases and machining lubricants such as honing and rockslide oils. Contact Penrite when you need assistance in choosing the right oil for your machinery and they will send you updated hard copies of their Recommendation Guides, including supplementary Industrial (heavy duty diesel, earthmoving and construction equipment), Marine and Gardening Go to www.demm.co.nz/enquiry Guides. quote: D110939
Engineering creativity is Crighton’s competitive edge
In front of the production line are John Almond of Mechanical Support Systems (left) and Crighton GM Mike Grunig.
BYfocusing on creativity and a culture that emphasises thinking outside the square, Onehungabased metals engineering company Crighton is showing that it is possible for small, but smart, New Zealand companies to go toe to toe with the best of India and China and still come out tops. Having just launched its new branding ‘Engineering Creativity Everyday’, Crighton is living and breathing its competitive edge to the extent that clients are finding a better return on investment by keeping their manufacturing work here in NewZealand. Crighton GM Mike Grunig says the rebranding process was very useful because it led to some real soul searching. “When we took a step back and
had a real good look at ourselves, we realised our focus on creativity, our inclination to work as a team and to look at newand innovative ways to design and manufacture a product really set us apart.” One example is prominent New Zealand agricultural technology company TruTest, which took the production of its pigtail electric fence post range away from China and gave it to Crighton. As a result TruTest reduced its cashflowfrom eight months negative to just one month, while also slashing months off their lead times. Procurement manager for TruTest, Gary Walford, says the manufacture of pigtails – a fundamental farming item – was moved to Crighton because the company came up with a solution that produced the
same product as China (at a very similar cost), but with far superior manufacturing flexibility. “Crighton did a lot of pre-work on gearing their production line up to turn things around quickly. In addition, when we placed an order, they could customise to our size or style requirements.” When Mechanical Support Systems – a company specialising in the design and installation of electrical cable containment – required a cost effective cable tray range to be manufactured, they initially looked to China. Director John Almond says time is a huge factor in their business, as is the quantity of stock they are required to keep on the shelf. “Availability of stock can sometimes be the difference between
winning and losing a project.” Crighton was able to manufacture one of Mechanical Support Systems core product ranges for prices comparative to what those in India and China were coming in at. “This is unusual,” says Almond. “They did it by thinking a bit outside the square – they could also see the value in a product, and where they could potentially bring themselves into a newmarket. “Tenders happen on a very tight timeframe. For example, in construction situations – like the Victoria Street Tunnel – the call for our product is left to the last minute and we need to be able to meet that demand; to put huge quantities together in a very short time frame. Without Crighton’s support, we wouldn’t be able to do that,” says Almond. Abonus is not having to deal with language differences, time zone differences and consistency of quality. As a result of Crighton’s willingness to think outside the square, MSS can nowdeal with spikes in demand for any one of the products in their range. Mike Grunig says the biggest satisfaction for his company is surprising the customer and going beyond what they expected. “We take an analytical, practical and creative approach to understanding what the client wants to achieve and whether they’ve identified the best solution at the right efficiencies.”
New literacy assessment tool THE Department of Labour has developed a new tool called ‘Take the Test’ to help employers assess the literacy skills of their workforce. Take the Test is a leaflet designed to help employers work out (in just five minutes) if a business is affected by poor workplace literacy and numeracy. Department of Labour, Skills Highway
information and promotion manager Lisé Hutcheon says “It collates the basic data a manager needs to talk about literacy and numeracy issues with colleagues. An employer might find reading is a particular issue in the workplace. Alternatively, he or she may find writing, maths and oral communication are crucial skills gaps. Overall, we want employers to use Take the Test to measure the issues, as
well as think about ways to address them.” Check out Take the Test and read more about skills training online at www. skillshighway.govt.nz/ind. Take the Test is available online (as an e-book) and in hard Go to www.demm.co.nz/enquiry copy. quote: D110940
Our largest workplace safety show THE National Safety Show, staged at the ASB Showgrounds in Greenlane, Auckland on 21 and 22 September, is billed as New Zealand’s largest event dedicated to workplace health and safety for 2011. More than 80 exhibitors from throughout Australasia are lining up to display their wares and provide visitors with the opportunity to explore new products, services and innovations from the safety industry. Looking to find the right mix of first-hand experience, critical updates and practical advice for their own organisations, visitors will be impressed by the number and variety of health and safety solutions offered in one dedicated venue over the two days. Exhibitors will be showcasing advancements in drug testing, safety products and services within power and automation technologies, chemical and hazardous goods management, hearing technology, skin and hand hygiene and injury prevention techniques. Computerised systems to manage risk, health and safety and environment portfolios will also be well covered – in addition to brand new, innovative software designed to manage safety more efficiently and effectively in the workplace. The National Safety Show, now in its third season, also features three streams of
professional seminars and workshops run by exhibitors and health and safety experts. The ‘Safety Matters’ seminars represent a great opportunity to talk to experts for free. And whether you are a dedicated safety officer or nominated staff member responsible for the health and safety in your workplace, you will be able to compare products, services and equipment in a relaxed, friendly environment.
All visitors attending The National Safety Show 11 must register to attend. Registration to the Showand associated events is free and includes the MHL Show(Materials Handling, Warehousing and Logistics Show), which runs concurrently, and onsite events. For further information, visitor registration and the exhibitor directory, go to www.safetyshow.co.nz
Cheap steel imports costing local jobs NEWZealand’s structural steel industry has come out strongly in support of a newreport from the NZTE-backed Industry Capability Network (ICN) which found local firms, and the wider economy, would benefit significantly from their improved participation in procurement processes for large-scale projects. Steel Construction New Zealand (SCNZ) manager Alistair Fussell says it should be mandatory for NewZealand steel firms with appropriate credentials to be considered as potential suppliers for major projects. “The reality is that too many procurement decisions for major projects in both the public and private sectors are based on price. This has seen imports of cheap fabricated steel tripling over the past five years. “Our analysis shows that in the
year to 2009, steelwork imported into NewZealand increased by $43 million, resulting in the loss of more than 150 jobs in the steel construction sector, as well as the associated tax revenue. “We fully support ICN’s development of Local Industry Participation Plans for major projects, but at present these are just voluntary guidelines. We believe the time has come for the Government to make the guidelines mandatory and help to growlocal industry.” Fussell says it is generally accepted that heavy engineering is of strategic importance to sectors including oil and gas, energy, infrastructure, manufacturing and defence, but the economic importance of local fabrication is often overlooked by those who make procurement decisions. “In the case of the public sector,
Government purchasing decisions are meant to be based on a whole-of-life approach, in which the true costs of a procurement decision are considered over the planned life of the product or service. Our concern is that this is not happening. “Lowest-cost purchasing decisions are invariably the most expensive option when whole-of-life criteria are applied. Unplanned additional costs are likely to arise associated with poor design, sub-standard materials, late deliveries, low-quality fabrication, inability to correct errors, and penalties incurred for project delays. “What’s more, all too often overseas competitors don’t followour high standards of safety; many have never heard of sustainability; often subsidies and special procurement conditions apply, which amounts to dumping; and what they pay in wages is well
belowwhat we would regard as fair.” Fussell says it is important to understand that SCNZis not asking for preferential treatment for local industry. He says local industry deserves a level playing field. More effective public sector procurement practices would see government entities working with local suppliers to build local capability and develop innovative solutions, according to Fussell. “If the Government takes the lead, the private sector will follow.The result will be local firms increasing their capability and capacity, and producing export-quality products. It should be our common goal to build competitive industries, but we won’t achieve this if we base our procurement on finding the cheapest option.” The ICNreport is available at www.icn.govt.nz
Brightwater appoints new CEO BRIGHTWATER has announced the appointment of Chris Ellis to the position of chief executive officer. Ellis was most recently chief executive of the Building Products Division of Fletcher Building Limited. This role involves the leadership of a portfolio of businesses across Australasia. He is also a member of the senior executive committee of Fletcher Building.
Ellis was previously GM of Winstone Aggregates, and prior to that GM of Fletcher Construction Engineering Division. In addition to his Fletcher roles, Ellis is chairman of the Business Leaders Health and Safety forum, and a member of the Minister of Building and Construction’s Construction Strategy Group.
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‘Hands on’ engineering qualifications launched THE Institution of Professional Engineers (IPENZ) and the New Zealand Board for Engineering Diplomas recently celebrated the launch of the New Zealand Diploma in Engineering (NZDE) and Diploma in Engineering Practice (NZDEP). The two Diplomas are key outcomes of the National Engineering Education Plan project. The NZDE is an applied academic qualification offered through a number of Tertiary Education Organisations, whilst the NZDEP is a work-based qualification achieved on the job
through an Industry Training Organisation. Students can choose to complete the NZDE full time and then enrol in the NZDEP once they commence work, or take advantage of increasing numbers of industry cadetship programmes, which enable concurrent progress towards both qualifications while working. Forecasts predict a sustained demand for increasing numbers of skilled technicians, particularly in the infrastructure and manufacturing sectors. For some time, industry has been calling for technician-level qualifications that combine quality academic
The Hon. Dr Nick Smith congratulating recent graduate Scott Payne from Fulton Hogan Dunedin at the launch of the new qualifications.
study to national standards with rigorous assessment of practical skills “The unified New Zealand Diplomas in Engineering and Engineering Practice are practical qualifications which is why we have branded it as a Hands On Career” says Fulton Hogan Group
Civil Engineer Lindsay Crossen “Technician qualifications have proven to be a good place to commence a successful career and employees with knowledge and practical experience have measurable benefits in both quality and productivity”.
Energy efficiency training for RHAC specialists THE IRHACE Industry Training Charitable Trust (IITCT) and Energy Efficiency and Conservation Authority (EECA) have co-funded the development of four online web based training courses to provide high quality industry training to improve electricity management and efficiency in the Refrigeration, Air-Conditioning and Heating Services Industry. The courses are aimed at: • Commercial Refrigeration and Air Conditioning Service Companies. • Industrial Refrigeration Service Companies. • Heating, Ventilation and Air Conditioning
(HVAC) Services Companies. • Commercial Refrigeration and Air Conditioning Design Engineers. The courses focus on equipment, systems components and newtechnologies relevant to the particular industry sector. Topics include air conditioning and air handling systems, refrigeration, water handling systems, automatic control systems and aims to give participants ideas and tools to: • Help identify opportunities for saving energy • Explain in practical and numerical terms the reason why the matter is important.
• Show some of the design methods and procedures that lie behind a good system. • Assist in deciding what should be done to improve the system. It is hoped that this knowledge will allow staff to more-confidently raise issues with other staff and clients. An IITCT and EECACertificate of Attainment in Energy Efficiency is issued to attendees who complete the course and pass the assessment. To find out more email debbie@ irhace.org.nz or visit www.nzhvacr.org.nz
Dear reader! Is your business associated with any of the following industries? OCTOBER IssuE:
• Energy Efficiency • Motors, Drives & Transmissions • Maintenance • Recycling & Waste Management
• Food Processing • stainless steel Fabrication • Heat Treatment • CNC/CAD/CAM
Key suppliers to these industries will be profiling their products and providing productive solutions in the upcoming issues of DEMM Engineering & Manufacturing magazine, please enjoy the magazine and stay informed. All we ask is that you tell the supplier where you saw them, here in DEMM magazine. Best regards The DEMM Engineering & Manufacturing magazine team. PS: If you are a supplier to the engineering and manufacturing industries and would like to know more about highlighting your business, your industry or product news in this magazine please contact Frank Atkinson on email@example.com or 09 477 0362, mob 021 464 156
in association with
telstraClear pacific MHL 11 21-22 September, 2011 ASB Showgrounds, Greenlane, Auckland New Zealand’s materials handling, warehousing and logistics trade show. For further information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www.mhlshow.co.nz
Quality visitors ensure SouthMACH success
National Safety Show 2011 21-22 September, 2011 ASB Showgrounds, Greenlane, Auckland New Zealand’s largest dedicated workplace health and safety event. For information, exhibiting enquiries, visitor registration and a list of current exhibitors, go to www.safetyshow.co.nz
Safety in Oil & Gas: Health, Safety and Risk Management 4-5 October, 2011 Quality Hotel, New Plymouth An industry specific event, addressing the critical issues of health and safety in the oil and gas sector, featuring case studies from industry leaders. For information and registrations go to www.conferenz.co.nz
NZ Clean Energy Expo 14-16 October, 2011 NZ Clean Energy Centre, State Highway One, Taupo A showcase of clean energy innovation – including geothermal and bio-energy initiatives. For more information call Rob McEwen, CEO, NZ Clean Energy Centre on 021 728 875 or visit www.nzcleanenergycentre.co.nz
Water New Zealand Annual Conference & Expo 9-11 November, 2011 Rotorua Energy Events Centre ‘Advancing Water Reform’. For more information visit www.waternz.org.nz
PaintExpo 17-20 April, 2012 Exhibition Center, Karlsruhe, Germany A leading international trade fair for industrial coating technology, organised by FairFair GmbH. For information go to www.paintexpo.com
Read an article in this magazine and want to know more? It's simple, fill out the form and fax it in to 09 478 4779 or mail it to: DEMM EnginEEring & Manufacturing reader enquiry, Freepost 4359, PO Box 65 092 Mairangi Bay, Auckland City 0754, Auckland, or for quicker results go to
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SouthMACH2011, held in Christchurch on 17 and 18 August, was once again a success despite appalling weather conditions unseen in NewZealand for more than 50 years. SouthMACH2011 was a great achievement, with 90 of the 95 exhibiting companies participating and more than 450 of their exhibiting staff working hard to create a professional and polished event (despite the snow), attracting a good quantity of trade visitors over the two showdays. The visitors were highly impressed by the range of innovative and newtechnology on display at NewZealand’s only engineering, manufacturing technology and machinery event for 2011. More than a static trade show, SouthMACH11 featured three streams of ‘Focused on Industry’ seminars and workshops run by exhibitors and the NewZealand Manufacturers and Exporters Association (NZMEA). The seminars and exhibitor workshops covered a range of topics designed to keep visitors up-to-date with new and emerging technologies and were extremely popular. Seminar attendance was high, a direct reflection of the quality and variety of topics that were offered. Visitor surveys were conducted by TouchScreen Marketing and all visitors to the showwere asked to complete a short survey upon departure to provide feedback on their show experience. The results of the survey showed that 89 percent of visitors rated the showvery good or excellent, and 95.2 percent of visitors were intending to visit the showagain in 2013. “We were extremely pleased with the quality of the visitors to the show, and that exhibitors were happy with the contacts and sales generated,” says exhibition director, Rachel HobbsPrice. “SouthMACH was postponed originally from May due to the earthquake. And then a snowstorm, the worst since 1945 hit just as we were starting to build the show. The fact that the exhibitors still managed to build the showand the visitors still turned up in great numbers just goes to show howwell respected this event is.” The organisers, HayleyMedia, wish to thank all exhibitors and visitors for making the showterrific despite the many obstacles that could have jeopardised the fourth instalment of what has become an important reference point for the industry. “Onwards and upwards for SouthMACH 2013!” says Hobbs-Price. Visit www.southmach.co.nz for the SouthMACH 2011 postshowreview.