Know+How Issue 26: Mining & Quarrying

ISSUE 26

THE LEADING MAGAZINE FOR MAINTENANCE ENGINEERS FROM ERIKS

DIGGING DEEPER

ERIKS review Health & Safety in the quarrying sector

HARD HATS FOR HANDS: Skin protection for mining and quarrying workers THE WHOLE KIT AND CABOODLE: OEM maintenance kits with added value BREXIT: It's the uncertainty I can't stand

www.eriks.co.uk

IN FOCUS Golden Rules for Saving Lives

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6

IN DEPTH ERIKS capabilities

LATEST NEWS Hillhead

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TECH UPDATE Emission Impossible

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CONTENTS ISSUE 26 LATEST NEWS

SKF power of 3

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Getting ahead of EU MEPS legislation ERIKS talking extraction in advance of Hillhead Plans progress for world’s biggest offshore wind farm at Hornsea UK manufacturers upbeat despite tough quarter UK car manufacturing at 12-year high for Q1

IN-DEPTH 6 ERIKS has looked closely at the best way to meet the customer’s combined requirement for availability with capability in seven new “Regional Hubs”

TECHNOLOGY UPDATE

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IN FOCUS

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IN FOCUS: QUARRYING, MINING & BUILDING 13

The golden rules for saving lives How to perform under (less) pressure Would a coat make your pump more efficient How SKF lengthens service life by the power of 3 Five frustrating fan issues and five fantastic solutions Making shock [loads] less shocking Don’t be a lubrication dipstick

TIME SAVING

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The whole kit and caboodle

BEST PRACTICE

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Hard Hats for Hands ATEX excellence in Aberdeen Sparks won’t fly with RX Tools Emission Impossible with Elastagraph ERIKS and WEG: Bespoke motors that drive productivity NEW ERIKS Northampton Hose assembly production

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Know-How : Issue 26

DEBATE 46 Brexit: It’s the uncertainty I can’t stand

DON’T MISS OUT keep up to date with all the latest news from ERIKS

CONTENTS

With a vast array of challenges facing those working in the extraction industry – from extreme health and safety risks to meeting the high impact demands placed on mechanical equipment, it is an industry that has both a rich heritage in the UK, yet is also at the forefront of innovation.

This issue will play host to some intriguing developments and product launches affecting the wider industrial services sphere and the mining and quarrying markets; and we’ll also give you a sneak preview as to what to expect from us on our stand at this year’s Hillhead exhibition which is set to be another fantastic show.

WELCOME TO THE LATEST ISSUE OF KNOW-HOW Delivering the latest news, views, developments and technologies across the UK’s industrial services sector, this edition of Know+How delves deep into a market sector often touted as one of toughest to work in: mining and quarrying.

As ever, we will also hear from a number of experts from across the extraction industry. In this issue, SKF will be lifting the lid on how to enhance bearing life expectancy by the power of three; Henkel give an interesting insight into the positive effects of ceramic coating on pump efficiency; and we reveal five frustrating fan issues for underground extraction workers, and how to tackle them.

We are also very pleased to Eoin Redahan, an ex-senior reporter at Materials World – the official journal of the Institute of Material, Minerals and Mining, as our guest contributor for this issue. Quizzing four industry experts about their views on extraction efficiency, bridging the skills gap, and game-changing technologies, Eoin sheds an insightful light onto the issues keeping the industry awake at night, and what exciting trends lie ahead.

Finally, in a new twist on a classic, the TIG has been refocussed to debate some of the most pressing issues affecting the industry. This issue addresses the B-word that’s been on everyone’s lips in the first half of 2016: Brexit. Read on to find out what aspect’s sparked this debate.

DEBATE! Brexit: It’s an uncertainty I can’t stand!

Have you made your mind up?

See page 45

As ever, if you have any comments you would like to raise on the topics contained in this issue you can email the editor at: knowhoweditor@eriks.co.uk or you can visit Know+How’s own website: www.eriks.co.uk/KnowHow where you can register for your own personal copy, enquire about the subjects and products discussed or contact one of the contributors.

I look forward to hearing from you.

Mike Ferris Sales & Marketing Director, Editor in Chief UNREGISTERED

Published by ERIKS UK, Amber Way, Halesowen, West Midlands, B62 8WG

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GET AHEAD OF THE EU MEPS LEGISLATION

Now is the time to invest in the most efficient motors you can afford, to save energy and prepare for upcoming legislation.

From 1st January 2017, the IE3 European Minimum Energy Performance Standard (MEPS) will become mandatory for all 0.75-375kW electric motors. IE2 rated electric motors will remain on sale, but must be fitted with a variable speed drive to be compliant.

The UK Government estimates that improved motor efficiency will help reduce global carbon emissions by one million tonnes a year, and help businesses to save around £200 million per year in running costs.

So as well as ensuring compliance, this is also a great opportunity for motor users to ensure their businesses are as efficient as possible. And with the likelihood that future phases of the UK Government’s Energy Saving Opportunities Scheme will include motors in any energy audit, it’s clearly sensible to be prepared.

ERIKS can help businesses to ensure compliance and work towards the new legislative requirements. The ERIKS Total Cost of Ownership Calculator, and a wide range of electric motors from its supplier network, are both excellent aids for businesses wanting to save money and reduce their carbon emissions.

LATEST NEWS PLANS PROGRESS FOR WORLD’S BIGGEST

OFFSHORE WIND FARM AT HORNSEA The Hornsea Project Three, an offshore wind farm set to power over two million homes, has entered the consultation stage of its planning process, according to the utility company behind the project, Dong Energy

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Know-How : Issue 26

Hornsea Three will be located on a 696km2 site just off the Yorkshire coast and will be the world’s biggest offshore wind project when completed, with a maximum capacity of 2.4GW. Denmark-based Dong Energy has also recently declared that it has taken a final investment decision to build the 1.2GW Hornsea Project One, which is expected to become operational in 2020 and will consist of 7MW wind turbines, each more than 190m high. Hornsea Project One will be the world’s largest offshore wind farm before the completion of Hornsea Project Three later in the decade.

LATEST NEWS

ERIKS TALKING EXTRACTION

IN ADVANCE OF HILLHEAD ERIKS [stand: PA24/PB27] will be showcasing a range of solutions to tackle the tough and arduous working environments of the mining and quarrying sector, at this year’s Hillhead exhibition.

UK CAR MANUFACTURING AT

12 YEAR

HIGH

FOR Q1 A key feature of this year’s stand will be a CAD station, demonstrating ERIKS’ in-house design skills and show how end-users can use CAD to streamline system design and remove the risk of human error associated with hand-drawn designs.

Given the the robust operational demands for key mechanical processes across the mining and quarrying sector, ERIKS will be displaying an extensive a range of products, including bearings, belts and lubricants, all of which have been designed to reliably operate in arduous conditions and minimise unnecessary energy consumption.

Taking into account the the importance of PPE to safe working environments in this industry, where much of the work is carried out away from factory stores, ERIKS will be showcasing a new PPE vending solution which will help make equipment readily available as and when it is needed.

Finally, ERIKS will also be showcasing its repair and maintenance capabilities, including its Asset Guard condition monitoring system.

www.eriks.co.uk www.eriks.co.uk

UK cars were being produced at a rate of one every 16 seconds from January to April 2016, a 12-year high for Q1, according to the Society of Motor Manufacturers and Traders.

Up by over 10% year-on-year, UK factories manufactured 443,581 cars in the first three months of 2016, making it the strongest first quarter for automotive manufacturing since 2004. Buoyed by demands from Euopean and Far Eastern markets for British-made cars, roughly three quarters of all models produced in Q1 were exported.

The positive outlook looks set to continue, thanks to the success of major UK car plants such as Nissan’s factory in Sunderland, Toyota’s site in Derbysire, and the Mini factory in Oxford.

The industry will be further bolstered thanks to luxury car manufacturer Aston Martin confirming the creation of 750 jobs as part of a new factory due to open in South Wales by 2020.

UK MANUFACTURERS UPBEAT DESPITE TOUGH QUARTER – CBI

More factory bosses have reported a rise in output than a fall in the three months to April, marking the strongest performance since last July for the UK manufacturing sector, according to a survey by the CBI. The quarterly survey of 472 manufacturers showed that even though the past three months had been tough, with export orders falling again, manufacturers are optimistic about future output and demand.

Factory output had been affected by reduced global trade and lower demand for manufacturers’ goods from the North Sea oil and gas industry.

The CBI have said that despite the positive outlook from manufacturers and a rise in employment over the past three months, the past quarter had been hard-hitting and the outlook remains challenging for the industry.

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STRUCTURED FOR

SERVICE Manufacturing industry traditionally has two options for service and support. Either they deal with a local, possibly independent supplier with focused and specialised capability across a limited range of products which means several suppliers to create one solution. Or they call on a national operation with a centralised resource, which inevitably means a less personal, less responsive, potentially slower service. But now they can choose a third option from ERIKS and get the best of both worlds.

IN-DEPTH

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Know-How : Issue 26

IN-DEPTH

"Supporting the products we supply... from cradle to grave" The first approach could be described as “regional” and is local. The second revolves around a single national “hub”. So ERIKS has looked closely at customer requirements and the best way to meet the combined requirement for availability with capability – bring together the two options – in seven new “Regional Hubs”.

As ERIKS UK CEO Steve Waugh explained at the launch of the Regional Hubs’ concept: “Our investment in new Regional Hubs is designed to bring all of our capabilities closer to the customer, both geographically and technically.”

Spanning the country from Aberdeen to Maidenhead, Swansea to Norwich, Birmingham in the Midlands to Leeds in the North, the Regional Hubs place a combination of products, logistics and engineering know-how where they can be quickly deployed to support customers, and where they can provide valuable back-up to ERIKS local Service Centres and Onsites.

There are many local independent specialists who offer a flexible and responsive service to their geographical area. That kind of on-the-doorstep offering is hard for a centralised service to compete with.

www.eriks.co.uk

Going further, nearer

However, though these local services may be convenient, they’re certainly not comprehensive nor do they have the same level of resource to call on.

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Product Customisation

One ERIKS Regional Hub will provide it all A trusted partner helping customers Capabilities closer to the customer, geographically and technically

Often, they’re provided by a specialist: in gasket cutting, hose assembly or drives, for example. Which is fine when you want a gasket, or a hose, or a drive.

But what if you need a drive, pump and the associated gaskets, valves and a hose assembly at the same time? And want them all fitted together and installed? And want to know you can expect expert maintenance and support for their whole service life?

ERIKS’ comprehensive know-how means this approach will lead to far more than simply better maintained, more efficient machinery.

That’s when you need the kind of all-round product knowledge and support which a national supplier with centralised support can offer, eventually. Or which an ERIKS Regional Hub can offer quickly, locally and cost-effectively.

The result is that ERIKS is not just a supplier or an MRO provider. Instead, the company can be a trusted partner helping customers to discover and implement upgrades and improvements, to meet or exceed production and performance expectations and targets, and to optimise unit costs.

Life means life The most successful companies are well aware that equipment purchasing decisions should not be based on purchase cost alone. The whole life cost – often known as the Total Cost of Ownership or TCO – is the truly relevant figure, and the greatest savings can usually be achieved through realising efficiencies and cost reductions in maintenance and operations.

Expanding on the concept of ERIKS’ Regional Hubs at their launch, Steve Waugh went on to make clear that “We will support our customers throughout the lifecycle of their industrial products, from selection, customisation and tailoring of solutions, through to ongoing servicing, maintenance and repair, up to the end of life and decommissioning. The ultimate goal is to support the products we supply to our customers throughout their entire life cycle, from cradle to grave.”

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Know-How : Issue 26

As a leading global supplier to a huge range of industry sectors, ERIKS is exposed to new ideas and innovations on a daily basis – many of which are transferable between sectors.

At the new ERIKS Maidenhead Regional Hub, for example, 70% of engineering work provided is carried out on the customer’s site. That’s not simply a standard supplier’s service. That’s a partnership which helps the customer’s maintenance and production teams achieve and exceed their goals.

Application and Design Engineering

IN-DEPTH

EXCEPTIONAL SERVICE AT EVERY LEVEL Technology Centre Home of a Product Business Unit (the new name to replace Core Competence Centre or CCC) undertaking product design, innovation and development often in conjunction with key brands and supply partners, building and managing supplier agreements and relationships, engineering turnkey solutions for large projects, owning and developing OEM business, supporting and developing technical knowhow for all ERIKS operations.

Regional Hubs Structured for service The difference the new structure makes is that the know-how and resources – including a manufacturing capability for those gaskets, hoses, drives, seals, valve packs and so on – will all be available much closer to where its needed and all from one location: the Regional Hub. Customers will have no need to search for a local supplier for each individual product or task; no need to wait for a national supplier to be able to get someone on the ground; and no need to try to co-ordinate different resources and capabilities. One ERIKS Regional Hub will provide it all.

Strengthens ERIKS local knowhow operating as a complete and comprehensive business unit supporting local service centres, integrated and onsites along with their own customers with engineering capability, parts customisation, commercial knowhow, application engineering and logistics across the complete ERIKS core product and service offering.

Technical Service Centres Service centres with additional areas of capability such as engineering/repair or customisation in specific product areas such as gasket cutting or hose assembly with the supporting application engineering anchor points. These sites will be located in areas with high demand for specific capabilities required by local industry.

Service Centres

This comprehensive service, positioned right where it’s needed, will ensure that ERIKS is in touch and in tune with customers, that timescales are optimised and that projects are kept on track. In fact, the Regional Hubs structure will enable ERIKS to operate as an extension of a customer’s maintenance, engineering and indirect supply chain teams.

The engineers that ERIKS work with have an extensive knowledge of their own products and the processes required in their manufacture, whilst ERIKS have an in-depth knowledge of the components those machines require. From innovation and energy efficiency to the ever changing legislation that surrounds them. ERIKS’ know-how will be invaluable in providing a broader overview which supplements and complements the customers’ own knowledge and experience.

www.eriks.co.uk

Support and service the ERIKS broad customer base calling on specific support from regional hubs or Technical service centres as and when required, these teams have the strongest relationship with our customers helping them achieve their specific goals and objectives.

Onsite Service Centre Located on a customer’s site to support the selection and specification of core products with support from technical specialists and the logistics operations of ERIKS. Integrated Service Centre Located on a customer’s site owning some or all of the indirect supply chain from specification, purchasing, stores, asset management and technical/application support directly integrated with the customers systems and procedures.

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ATEX EXCELLENCE IN ABERDEEN

The ATEX accreditation recently awarded to ERIKS’ Aberdeen workshop for rotating equipment and enclosures is clear evidence of the high quality of staff, workmanship and training in place in the branch.

The accreditation comes after a detailed inspection of the facilities available, and interviews with all AEMT-trained employees, to assess their ATEX knowledge.

Yearly audits will repeat the staff interviews and facilities inspections, and third-party witnesses will check ATEX work carried out in the EX work area.

The facilities include a dedicated EX work area, and a dedicated EX materials stock area.

SPARKS WON’T FLY WITH RX TOOLS ®

A new range of non-sparking tools from RX® provides protection against the risk of fire and explosion in potentially explosive environments.

The ATEX accreditation expands the capabilities and services available from ERIKS for the offshore industry. As Chris Hudson of ERIKS Aberdeen explained: “This licence gives us a benchmark in quality that shows our existing and new customers that we have the capability and expertise to service and maintain all their EX rotating equipment.”

TECHNOLOGY UPDATE ERIKS’ NEW

NORTHAMPTON HOSE TECHNOLOGY CENTRE Spearheading ERIKS strategic expansion in Industrial Hose and offers both MRO and OEM customers an extensive level of technical know-how, engineering and stock availability.

An excess of £500,000 of stock including Metallic, non-Metallic, Rubber, PTFE and Silicone hoses, is supported by major blue-chip manufacturers and partner brands.

From the new purpose built 24000 sq. ft. facility, a fast and efficient production process is maintained by 7 welding bays and a team of highly qualified welders. For complex or bespoke applications technical sales specialists and application engineers are on hand to provide know-how and solutions.

So, with combined experience and a wealth of knowledge spanning over 250 years, coupled with WRAS and Bureau Veritas approvals, ERIKS Hose Technology is the trusted partner for all industrial hose applications.

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Know-How : Issue 26

RX® Non-Sparking Tools are made from highestquality non-sparking Copper-Beryllium (Cu-Be) and Aluminium-Bronze (Al-Bronze) alloys, to ensure the highest possible levels of operator safety and tool life.

Cu-Be alloy tools can be used safely in all ATEX environments, while the Al-Bronze tools are suitable for use in all but ATEX zone IIC (hydrogen, acetylene, ethyl nitrate).

The range includes pliers, screwdrivers, spanners, wrenches, hammers, chisels, hex keys, brushes, wedges, hand scrapers and bars. Fully insulated versions are also available, suitable for use on live electrical installations. As well as its non-sparking qualities, the range offers advanced ergonomic designs and 2-component handles, for better performance and greater user comfort.

WITH ELASTAGRAPH®

Manufactured from a combination of high- and low-density graphite, the gasket has unique “humps” and “valleys” in the Elastagraph® corrugated steel, creating a bellows effect to counter the effects of movement and misalignment. The corrugation of the whole gasket – including the metal layer – creates a spring-back effect.

The Leader Elastagraph® gasket for standard EN/ASME and non-standard flanges is ideal for process piping, fuel refineries, and other locations where fugitive emissions pose an environmental and health and safety issue.

High density graphite (115lb) on the “humps” results in low gas permeability, super sealability and exceptional recovery. By contrast, the exceptionally low density (40lb) compressive inner ring provides an extremely low “minimum design seating stress” of just 800psi.

The patented DynaGraph™ bonding process eliminates volume loss due to adhesive bake off, resists over-compression damage, and allows for easy removal from flanges.

ERIKS AND WEG: Motor failure is a nightmare made worse by the need to decide under pressure whether to repair or replace. However, your nightmare can be resolved by the dream team of ERIKS and WEG. ERIKS’ Total Cost of Ownership online calculator helps you decide between repair and replacement. Then you can rely on ERIKS for a full repair capability, or on WEG for a cost-effective replacement.

BESPOKE MOTORS THAT DRIVE PRODUCTIVITY

Once your motor is installed – or repaired and running again – ERIKS can provide whole-life management to lower your total cost of ownership.

For example, Asset Guard predictive maintenance could increase your productivity by 15%, by eliminating costly downtime.

From technical support and evaluation to design advice and execution, and from removal to installation and commissioning, ERIKS and WEG together make motors drive productivity.

WEG can custom-make a motor (including MV & HV high-output designs) to fit exactly in place of the original, and design and manufacture the new motor as a direct “drop in replacement” for you application including shaft design, mechanically identical and electrically matched to your original performance requirements to suit your application and existing drive train and starters.

www.eriks.co.uk

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TECHNOLOGY UPDATE

EMISSION IMPOSSIBLE

The new Elastagraph® emission reduction gasket from Leader Gasket Technologies enables fugitive emission control to 50ppm or lower.

Fenner Ultra Plus 150 ÂŽ

The new generation of heavy duty drive belt for the harshest of environments...

50% more power

High Tensile Aramid Cords transmit 50% more power than standard wrapped wedge belts.

Unsurpassed strength Fibre reinforced polychloroprene rubber supports the cords and ensures unsurpassed rigidity when installed.

96% energy efficiency

fenner’s Ultra Plus 150 drive belts are specifically designed for applications where rugged durability is paramount, combining the highest level of performance with the longest service life possible.

State of the art, high efficiency drive belt engineering ideal for heavy duty applications : > Waste compactors > Shredders > Crushers > Heavy duty conveyors > Bucket elevators

> > > > >

Know-How : Issue 26

Energy Efficient

www.fptgroup.com

Woodworking machinery Quarry plant Saw mills Calendars Compressors

Fenner is a registered trade mark of J. H. Fenner & Co.

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A-symmetrical weave outer jacket produces belt length stability second to none, guaranteeing unbeatable efficiency.

The Mark of engineering excellence

IN FOCUS

DIGGING DEEPER ERIKS REVIEW HEALTH & SAFETY IN THE QUARRYING SECTOR The golden rules for saving lives

p14

How to perform under (less) pressure

p18

Would a coat make your pump more efficient

p22

Five frustrating fan issues and five fantastic solutions

p25

How SKF lengthens service life by the power of 3

p26

Making shock [loads] less shocking

p30

Don’t be a lubrication dipstick

p32

IN FOCUS

www.eriks.co.uk

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THE GOLDEN RULES OF SAVING LIVES Health and Safety is a literally life-saving topic in the Mining and Quarrying industry. And as a major supplier to the sector, ERIKS also take H&S very seriously. As CEO Steve Waugh explains, ERIKS UK believe Best Practice starts at “home”. Which is why ERIKS have developed the 6 Golden Safety Rules that lead to Zero Harm, Zero Injuries, Zero Compromise and Zero Accidents.

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IN FOCUS

A quick glance at recent industry headlines soon reveals the risks involved in mining and quarrying operations. However, there’s also good news to be found, such as the “Safer for All” campaign being run at Hills Quarry Products’ sites, where employees even took part in a special two-hour health and safety training session on their first day back at work this year.

And the launch of the Health and Safety Executive’s five-year strategy to “Help GB Work Well” promotes the clear links between risk management, and productivity. As Justin Tomlinson MP – who has responsibility within the Government for health and safety – pointed out: “Taking sensible steps to keep workers safe and well is something that the best-run businesses do. It’s good for people, it’s good for productivity and it’s good for growth.”

Steve Waugh CEO, ERIKS UK

Safety is golden

Creating the zero accident workplace

Talking the talk is one thing. Walking the walk is another.

Ensuring everyone returns home safely

Having taken the lead from a major public utility on health and safety – ERIKS adopted a Zero Accident approach and saw the importance of applying the highest safety standards throughout our own sites.

The same initiative was applied business-wide, and 6 Golden Safety Rules were introduced in tandem to support it.

www.eriks.co.uk

The 6 rules are:

1 2 3 4 5 6

I will never work under the influence of alcohol or drugs I will never walk, stand or work under a suspended load I will only undertake work for which I am trained, competent and authorised I will never misuse or tamper with safety controls or equipment I will always ensure that all energy sources are safely isolated before commencing work I will always wear properly the personal protective equipment required for the job

It is every ERIKS’ employee’s responsibility to ensure that these rules are followed at all times, and if anyone is seen breaking the rules, any employee has an obligation to challenge them at once – and report the incident to a member of the site management team.

ERIKS have also issued “Authority to Stop” cards to all employees, which make it clear that they have the authority – as well as a duty – to intervene in any incident of rule-breaking.

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Good for people, good for productivity, good for growth

Get home safely

The HSE’s 6 themes cover:

For ERIKS, safety is one of our business’s core values, which ensures everyone returns home safely.

One of the lessons ERIKS can pass on is that keeping employees safe doesn’t have to be expensive, or at the expense of productivity. In fact it can even help to maintain productivity by minimising downtime caused by accidents, and to reduce unforeseen costs by avoiding the risk of fines.

1 2 3 4 5 6

In a recent case where an employee at a quarry lost two fingers in an unguarded drilling rig, the employer was not only fined £7,200 but also ordered to pay costs of £27,000.

With experience in advising on health and safety for businesses of all sizes – including a major public utility – and through our own in-house activities – ERIKS have gained wide practical experience in the field.

That includes suppliers and visitors to ERIKS’ sites, who are also expected to adhere to the Golden Rules.

And the know-how ERIKS have applied to health and safety within our own organisation can also be shared with customers, to help create a zero accident workplace for them too.

Acting together to promote broader ownership of health and safety Highlighting and tackling the costs of work-related ill-health Simplifying risk management and helping business to grow Supporting small employers with simple advice Anticipating and tackling new health and safety challenges Promoting the benefits of Great Britain’s world-class health and safety system

Six of one…

Alongside ERIKS’ 6 Golden Rules, the Health and Safety Executive has introduced its own six themes to be pursued through its five-year health and safety strategy.

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If you would like to benefit in your own business, visit www.eriks. co.uk or contact your usual ERIKS Service Centre.

Olympian Plus 64 Series Heavy Duty Cylinders

SCVA & SCSQ Safety Valves

Super X, Robust & Reliable

Mining & Construction

Engineering GREAT Solutions

IMI Precision Engineering works closely with mining and construction vehicle manufacturers to deliver outstanding performance in the most demanding of applications. Our range of heavy duty products are tried and trusted in some of the harshest and most challenging environments.

Typical applications that we support today include: > Dust filtration systems > Drill flushing and cooling systems > In-cab seat controls > In-cab climate control > Brake interlocks > Emergency engine shut-off > Traction control

Find out more Visit www.imi-precision.com or email info@imi-precision.com

www.eriks.co.uk

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HOW TO PERFORM UNDER (LESS) PRESSURE

Name Title

Stefan Baier Head of Product Management Electrical Engineering and Pneumatics, Stiwa.

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Know-How : Issue 26

We’re all under pressure to do more and do it faster. But at the same time, whatever we’re doing, we’re also under pressure to do it for less cost, and with ever greater safety. Finding the right balance can be difficult, as an Austrian machine builder recently discovered.

IN FOCUS

Stiwa of Austria was looking for a way to speed up its production of flow control valves – which was already running at fractions of a second per valve. This meant finding a more efficient and faster way to: drive and operate the numerous axes within the machine as they incessantly move power and control high-speed handling systems as they pick up parts and transport them for processing operate numerous grippers, conveyors and feeding systems as they go through their operating cycles.

A rigid interlinking system sits at its heart, able to transport and assemble components at high speed.

But linked to this are no fewer than ten decentralised feeding machines, which supply the manufacturing process.

Depending on the type and number of individual parts required at any one time, these feeding machines can be attached or removed. And as each feeding machine provides two paths, the placing of individual components into the system can scale from as few as two to as many as twenty.

IMPROVED

operator safety

LONGER INCREASED

service life and

flexibility

COMBINING

pressure buildup function and on/off / exhaust valve

But, as is usually the case, they didn’t want speed at any price. They also wanted improved operator safety, a longer service life for the machine’s central components, and an increased flexibility in their production operations.

Minimal retooling time also means that the machine can quickly and easily switch between flow control valve designs, to seamlessly produce a wide and diverse range.

A first for flexibility The new machine developed to meet this long list of requirements makes the Stiwa assembly workshops a glimpse into the factory of the future. That’s because the machine has a unique modular design, which enables incredible flexibility to meet changing production requirements.

www.eriks.co.uk

19

To achieve the required performance, reliability and safety standards for their new machine, Stiwa chose compressed air as the energy source and Festo as the provider.

This means that devices can be fully exhausted, leaving no residual pressure – ensuring greater safety for operators during commissioning and maintenance.

Combining two functions in one housing also saves space, and protects central pneumatic components, axes and shock absorbers.

The complexity of the system creates a huge challenge in ensuring there is always sufficient energy available for every load situation.

The new Stiwa system first builds pressure up to 4 bar, then switches it through for a working pressure of 5.3-7 bar as compressed air is required.

The pressure’s off

Fine-tuned for flow The MS9-SV-C is a new service unit which was developed with Stiwa as the pilot partner. Even before the initial launch of the product, it was an integral part of the Stiwa machine, and was fine-tuned during intensive final tests before an early entry into production.

Stiwa now uses two of the units in its new system, due to the system’s high demand for compressed air during start-up. The new system offers 1,000l/min more compressed air than the service units Stiwa used previously, and its high nominal flow rate of 16,000l/min (up to 5,000l/min in the Stiwa system) means that it may even be possible to eliminate one service unit for especially large machines.

UNIQUE

modular design for the factory of the future

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Know-How : Issue 26

Festo rose to the challenge by installing two MS9SV-C service units, to ensure the quality of the compressed air remains constant whatever is demanded of it.

The two Festo service units incorporate pressure regulators, on/off and soft start valves, filters, dryers, sensors and lubricators to help in the preparation of the compressed air. But what makes the units special is their combination of a pressure build-up function and an on/off and exhaust valve.

You can find out more about the innovative Festo MS9-SV-C at https://www.festo.com/cat/en-gb_gb/ products_MS9_SV

MAKE HANDS MATTER ...IN YOUR INDUSTRY

The Deb Skin Care Programme Addressing and reducing occupational skin disease requires an integrated approach to protect, cleanse and restore the skin.

Protect creams help protect the skin against contact with various contaminants UV Protect creams help protect the skin against harmful UV rays Appropriate hand cleansers to prevent contaminants becoming ingrained in to the skin Restore creams help maintain the skin in healthy condition

FOR A FREE PRODUCT TRIAL CONTACT YOUR NEAREST ERIKS BRANCH

WOULD A COAT MAKE YOUR PUMP MORE EFFICIENT? 22

Know-How : Issue 26

Wear and corrosion are major threats to equipment and systems in mining and quarrying. Pump castings, impellers and volutes, for example, wear due to corrosion, erosion, cavitation and mechanical damage.

But a solution to restore performance and efficiency, and even extend operating life, can be as simple as a new coat.

IN FOCUS

The combination of ERIKS’ proven engineering know-how and Henkel’s experience and expertise in ceramic and energy-saving coatings, results in repairs to the highest standards, using the best products for the job. The products in this case being Henkel’s range of Loctite® surface engineering products and systems, for equipment build, repair and maintenance.

31.5% 28 £19,680 energy saving over 5 years

tonnes CO2 saving in year one

The suit that’s a coat of armour Henkel Loctite® polymer composites coatings and compounds protect pumps and other parts against attack.

Formulated with ceramic fillers, they can be brushed, sprayed or trowelled on, to create a sacrificial and renewable working surface with excellent wear resistance and superior adhesion, that protects the original substrate’s structural integrity.

The mechanical seal had seized, and the pump was out of alignment with the motor. The volute was cut-water worn, the bearings showed evidence of fretting and corrosion, and there was no inverter rating for the motor. In fact, it was the perfect test bed for Loctite® coatings and ERIKS’ engineering.

This means they can restore worn surfaces on old parts, extend part life on new products, and increase component efficiency in all cases.

One example is a 22kW ELPO pump used for handling process water, which ERIKS recently tested, evaluated, and rebuilt using Loctite® coatings.

Pump Performance Test No 1 (before pump rebuild) 35

30

25

Efficiency %

20

Rebuilt to perform

Total Head m

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Initial tests showed the pump underperforming by at least 30% against the manufacturer’s original test data. Dismantling and inspection at ERIKS’ Southampton EMS workshop revealed heavy corrosion, and a worn, burred and imbalanced impeller. But that wasn’t all.

www.eriks.co.uk

Motor Output kW

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Compared to the Manufacturers original test data this pump was under performing by at least 30%

23

Would a coat make your pump more efficient?

Firstly, all components to be coated were steam cleaned, and blasted to 75 microns surface roughness.

The substrates were then pre-treated with Loctite® 7515 to prevent corrosion and improve adhesion between the metal parts and the polymer composites.

Next, Loctite® 7117 was applied as a “hold coat” to smooth out surface imperfections, and to provide a better key for the thicker layers which would return the pump to its original dimensions.

Loctite® 7226 was applied next as the “build coat”, to provide a very tough, wear-resistant surface. Loctite® 7117 was then applied over this coat, to create a very smooth, friction-reducing finish to improve the pump’s energy efficiency.

Finally new bearings and oil and mechanical seals were fitted, the impeller dynamically balanced, the pump re-assembled, and a new 22kW high-efficiency motor fitted. Motor and pump were then fitted to the bedplate, and laser aligned.

Outstanding efficiency When a second performance test was performed, the results were outstanding.

45 40 35 30 25

ERIKS’ remedial work and the Loctite® coatings had restored the pump to original specification: increasing its efficiency by 30%.Test The initial the repair was Pump Performance No 2 cost (afterofpump rebuild) £5,542, but in the first year alone estimated energy savings equalled £3,936 – and attracted a Government incentive payment under the Enhanced Capital Allowance Scheme (for investment in % energy- savingEfficiency equipment) of £585.90.

20 15 10 5 0

Total Head So over one year the repair cost was effectively reduced to just £685. And over five years, energy Motor Output savings will amount to 51.90 MWh, or £19,680.

Carbon emissions were cut by 28 tonnes in year one.

Flow m /hr And all that on just one pump.

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Needless to say, the customer is now investigating the potential energy savings of more pumps receiving the Loctite® treatment from ERIKS. Pump protection plus That pump repair is just one example of the effectiveness of Loctite® coatings in restoring flow and pressure and reducing power consumption, for pumps suffering from cavitation effects and wear on impellers and casings.

In other cases there have been proven efficiency gains of up to 43%.

180

3

Comparison between Pump Test 1 and Test 2

In addition, there are energy savings to be had (a recent customer confirmed an 8% energy saving in their application), savings on replacement parts, and a reduced spare part inventory.

Loctite® product formulations also fully comply with the latest CLP Regulations, so users can be sure they are not only adopting best practice for pump repair, but also for workplace safety.

Which means Loctite® products protect pumps – and people too.

0

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Know-How : Issue 26

120

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Proven efficiency gains of up to

43%

Air Curt ain

Co ole rF an s

s yer Dr

Dust

Hot G as

Centrifugal Fan

HV AC

Axial Fan

rt po ns Tra Draft Forced

Fan Frustration 1 : Premature failure There's nothing more frustrating than this. The key is to find the root cause so you can prevent it happening again. In the mining and quarrying environment, dirt ingress is the most likely culprit, so the first step is to check seals.

Fantastic Solution 1 : SKF Explorer bearing An SKF Explorer bearing [see p.18/19] has been designed and proven to last longer in environments with high dust and dirt ingress. A Simalube automatic lubrication system can also help to reduce the likelihood of premature failure through lack of maintenance, which often happens in inaccessible locations.

Fan Frustration 2 : Excessive noise This is often a sign that something more serious is wrong, and can be an early warning of failure.

Fantastic Solution 2 : Find the cause Noise may be caused by poor alignment, or excessive vibration. Both need investigating by an engineer with fan know-how, before serious damage is done.

Fan Frustration 3 : Excessive vibration This is an irritation – and another sign that something more serious is wrong.

www.eriks.co.uk

FIVE FRUSTRATING FAN ISSUES AND FIVE FANTASTIC SOLUTIONS Fantastic Solution 3 : Investigation by a qualified engineer will reveal the problem – potentially an out-of-balance impeller, which is in turn placing excessive strain on the bearing. Rebalancing – a service offered by ERIKS Fan Services – will eliminate the noise, reduce bearing stress, and help all components achieve their full service life. Expert advice on coupling selection could also help with absorption of shock loads and reduction of vibration.

Fan Frustration 4 : Excessive heat or temperature change in the bearings An overheating fan is performing inefficiently and in danger of failing prematurely. Cross-location of the fan bearing is a common cause.

Fantastic Solution 4 : SKF CARB bearing Replacing the existing bearing with an SKF CARB bearing – which has better axial displacement – will help to reduce heat generation and extend the fan’s – and the bearing’s – service life.

IN FOCUS

Fans are frequently found in mining and quarrying equipment. So knowing the most common issues they suffer – and how to overcome them – can help you minimise unplanned downtime and maximise equipment productivity.

Fan solutions from ERIKS ERIKS Fan Services offers complete fan care and repair, to help you get the optimum performance out of your assets.

To find out more, call 0845 006 6000, visit www.eriks.co.uk or contact your usual ERIKS Service Centre.

Fan Frustration 5 : Poor access Maintaining or replacing a bearing is tricky if it’s difficult to access. This can mean maintenance is reduced – increasing the likelihood of premature failure. It also means more downtime when maintenance, repair or replacement is required.

Fantastic Solution 5 : Revolvo SRB A Revolvo Split Roller Bearing can cut maintenance and fitting times by up to 90%. It also reduces the need for lifting equipment to remove other drive components before you can even access the bearing.

25

HOW SKF LENGTHENS SERVICE LIFE

BY THE POWER OF 3 David Oliver Channel and Platform Development Manager, Bearings and Units, SKF

In the highly contaminated, dusty, dirty operating environment of a mine or quarry, machinery has a hard life. But even here, the power of the SKF three-barrier solution – combined with the new SKF Taconite seal – has been proven to lengthen equipment service life by up to three times.

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Know-How : Issue 26

IN FOCUS

24 months’

Quarry, coal, cement and other mineral dust isn’t just dust. It’s highly abrasive dust. Abrasive dust that can find its way into machinery, and mix with the lubricant inside to accelerate the wear and failure of bearings, seals, gears, couplings and other rotating parts. The low operating speeds and high loads of conveyors – and the sometimes high temperature environments – only make the problem worse.

failure-free operation of an SKF Explorer SRB saved 50% replacement costs:

over £18,000

And because of the difficulties of maintenance and monitoring in some of their operating locations, sometimes the first you’ll know about a problem will be a catastrophic failure.

In fact, contamination and lubrication failures combined account for over half of all bearing failures in mining applications. So in these kind of conditions, just one solution won’t cut it. Which is why SKF has three.

Three-barrier solution Faced with the challenge of protecting bearings against the ingress of a fine-grained, highly-abrasive iron ore called taconite, SKF developed a new cartridge seal for split housings, specifically for the job. SKF Taconite Seals proved so successful that they are now also used as an effective primary barrier in applications where many other mineral dusts – or even liquid contaminants during high-pressure washdowns – are present.

The seals work by incorporating three or four labyrinth stages, and an internal V-ring. Water is deflected by a rotating labyrinth ring – sealed to the shaft by an O-ring – which actively “flings” the water away.

Contamination and lubrication failures account for over half of bearing failures in mining applications

But if one barrier is good, two is even better.

So behind the Taconite Seal, SKF recommends a secondary barrier of grease, filling the bearing housing cavity.

And if two barriers are better, three barriers are unbeatable. So, the SKF three-barrier solution also incorporates an upgraded sealed SKF Explorer spherical roller bearing.

www.eriks.co.uk

Exploring economies SKF Explorer spherical roller bearings have been proven to significantly reduce the running costs of conveyors in a sand and minerals processing environment.

Askania – a processor based in Sweden – was replacing four open bearings across a total of 88 bearing positions every nine months, due to sand, dust and grit ingress. Replacing the bearings with SKF Explorer spherical roller bearings resulted in just three bearing changes over a 24-month test period.

Previously, running costs for all 88 bearing units for 24 months were £36,000. The sealed SKF Explorer bearing lasted for the same period without failing, for less than £18,000: representing a 50% saving.

27

Built to last

Complete compatibility

SKF bearing housings are built to last, from high-grade cast material or ductile iron. Large ribs in the base, and extra material around attachment holes, resist shock loads and minimise distortion of the base and bearing seat at high loads.

As a crucial component of the SKF three-barrier solution, the SKF Taconite Seal is widely applicable, being compatible with both new and older housings.

It’s also easy to install and align and – once installed – helps to reduce grease consumption, and associated environmental impact.

The SKF Explorer bearing uses upgraded steel, developed with a new, patented heat treatment process. The bearing is factory lubricated, then wfitted with integrated seals to protect it.

The result is improved wear-resistance, improved sealing, and – even with a poor lubrication regime and in the contaminated conditions of a mine or quarry – more than three times the service life of wa standard bearing.

This combination of benefits has made it a highly attractive choice for the mining and quarrying industry, where it is already widely used on conveyor pulleys, grinding mill pinion housings, bucket elevators, winches, pulverisers and fans.

On one grinding mill pinion application at a gold mine, the previous non-drive end spherical roller bearings was failing every 15 months, due to water ingress to the housing. Replacing the bearing with the SKF three-barrier solution of SKF housings, SKF Taconite Seals and SKF Explorer spherical roller bearings, has led to elimination of bearing failure for at least two years and nine months (as at February 2015).

1: longer bearing life.

2: reduced maintenance costs 3: lower environmental impact.

You only need one good reason to upgrade to SKF Taconite Seals and the SKF three-barrier solution.

But now you have three.

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Know-How : Issue 26

ROBUST

well-protected bearings are key to machinery performance in this sector

YOUR FLUID POWER SOLUTION FOR: · HYDRAULICS · PNEUMATICS · CUSTOMISED SOLUTIONS · ENGINEERED SYSTEMS · CONTAMINATION MONITORING

FLEXION DELIVERS A WIDE RANGE OF FLUID POWER PRODUCTS AND SERVICES THAT OFFER VALUE TO DESIGN AND MAINTENANCE ENGINEERS, BOTH IN TERMS OF PERFORMANCE AND COST

Call us today on: 0845 006 6000 www.eriks.co.uk/flexion Untitled-1 1

THE FLEXION RANGE GIVES YOU: • • • • •

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YOUR FLUID POWER SOLUTION 16/06/2015 12:07:18

If you find yourself replacing your bearing housings as often as you replace your bearings, you have a crisis on your hands.

The usual ratio of housing to bearing swaps is 1:3, so replacing housings more frequently is a sure sign there’s something wrong.

MAKING SHOCK [LOADS] LESS SHOCKING 30

Know-How: :Issue Know-How Issue26 26

The advantages are obvious. For example, when a Timken customer switched to Spherical Roller Bearing Solid-Block Housed Units, the unit life increased from three-to-four months to more than two years, and downtime and maintenance costs decreased in proportion.

Keep production rolling In many applications, installation, routine maintenance and replacement are difficult, demanding, and result in too much costly downtime. In these cases, a Split Roller Bearing (SRB) is a cost-effective alternative.

In quarrying and mining applications in particular, bearings have a hard life. Conveyors and crushers often experience high levels of shock loads and, as the name suggests, vibration screens vibrate. So it’s essential to choose a bearing and housing which can take the punishment without failing prematurely.

Cut production losses from downtime by up to

Identify the cause of the bearing failure, and choose the most appropriate solution for the application, and you can extend bearing life, reduce downtime, and cut the cost of replacement parts and lost production.

When the going gets tough

90%

Identifying the cause of bearing or housing failure can be tough – not least because after a catastrophic failure there’s sometimes not much bearing left to analyse.

A simple dropin swap – no re-engineering required

However, an engineer with expert, specialist knowledge – like one from ERIKS – will be looking for tell-tale signs such as brinelling (denting of the raceway), which indicates that shock loading has caused the failure.

And if the housing has failed, a bearing with a tough steel cage is the obvious solution.

Timken Spherical Roller Bearing Solid-Block Housed Units, for example, have a solid block made from high tensile steel tough enough to survive even massive shock loads. The ends of the units’ feet on the pillow blocks are machined to allow a tighter fit of the keeper plates to the housing, for one-time shaft alignment.

And all piloted flange units have withdrawal holes, so they can be removed without breaking the housings.

The strength of the Spherical Roller Bearing SolidBlock Housed Units means that even fitting them upside down won’t shorten their service life. And fitting them in any position is exceptionally easy, with misaligned seals ensuring there’s no gap between bearing and shaft where dust, sand, dirt or other contamination can find a way in.

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SRBs have a “split to the shaft” design which means they can be installed, maintained and replaced without having to lift the shaft or remove it from the drive. This can cut production losses from downtime by as much as 90%.

Roller bearings also offer far more surface area than traditional ball bearings, giving them a greater capacity to absorb shock loads, and four to five times more load carrying capacity than spherical bearings.

A valuable SRB option for the kind of conditions encountered in mining and quarrying is a precisionmachined brass cage. Brass is a flexible yet high strength material, resistant to shock loads. The alloy’s smoother finish compared to steel, and the cage’s rounded edges, mean it maintains the lubricant film between the roller and the raceway, where a steel cage may scrape it off. And the brass cage is pocketed to the shape of the roller – preventing the roller from skewing, which is a common cause of premature bearing failure.

While some people resist changing from a traditional bearing to an SRB because of concerns about re-engineering costs, Revolvo SRBs from Timken allow for a simple drop-in swap of the plummer block unit, with no re-engineering required.

A split decision So the choice is yours: the sheer strength of the Spherical Roller Bearing Solid-Block Housed Unit, or the ease of installation of the Split Roller Bearing?

With a large range of sizes available in both bearing ranges, there’s no need for compromise. And as a Timken Authorised Distributor, ERIKS can help you to find the optimum, most cost-effective solution for your application, whatever that may be.

To find out more, speak to your usual ERIKS representative or contact your local ERIKS Service Centre.

31

IN FOCUS

Sheer strength or ease of installation?

DON’T BE A LUBRICANTS DIPSTICK Do you choose your lubricants and coolants on price or performance? If you think buying cheaper saves you money, then Total would like you to think about what those cheaper oils are really costing you.

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Know-How : Issue 26

do more than lubricate

Choose more protection

IN FOCUS

High quality hydraulic oils

Hydraulic oil from the Total Biohydran family can protect your equipment and the environment.

Biohydran TMP, for example, contains biodegradable synthetic esters , but its improved environmental performance doesn’t mean poorer performance in your equipment. It has a working temperature range from -20°C to 80°C, mixes well with mineral oils, and provides good protection against wear and corrosion.

For operating temperatures above 80°C, Biohydran SE has saturated synthetic esters with high thermal stability, compatible with elastomers.

Both these Total Biohydran lubricants carry an EU Ecolabel certifying they reduce the risk of environmental contamination and damage should a leak occur. As hydraulic failure is the leading cause of leaks, that’s an important benefit. Also from the Total hydraulic oils range, Hydroflo CT contains a blue dye which makes leaks easier to detect. This is a highpressure Poclain hydraulic oil, with good extended drain intervals.

Fire-resistant hydraulic grades are also available, in the Hydransafe range.

Family breakdown A breakdown of the other hydraulic oil families available from Total reveals a wide range to meet all your requirements.

Today’s high quality hydraulic oils do much more than simply lubricate. They also aid fuel efficiency, extend component life, and even reduce environmental impacts. The flipside is that lower-quality oils with a lower price tag can reduce fuel efficiency, shorten component life, and do absolutely nothing for the environment. Which means that in the longer term, those short-term savings on the purchase price are easily wiped out.

Choosing cheaper coolants can also have disastrous effects on your equipment and your bottom line.

So what should you be doing to make sure the lubricants you choose for your mining and quarrying static equipment really do make everything run more smoothly?

www.eriks.co.uk

The Azolla family of mineral hydraulic oils includes Azolla ZS (zinc stable) for general purpose applications; Azolla AF (ash-free) with good filterability, high thermal stability and good anti-wear performance; and Azolla DZF (ash-free with good detergency) to absorb water in hydraulic systems and provide good Extreme Pressure properties.

The Total Equivis family comprises two high-viscosity index versions of Azolla oils.

Equivis ZS (equivalent to Azolla ZS) has extra additives offering high- and low- temperature properties. Equivis AF is equivalent to Azolla AF. In addition, Equivis XLT is a very high-viscosity index oil designed to work down to -40°C. And lastly, Equivis HE is an energy-saving oil which has been shown1 to deliver fuel savings of up to 5% compared with hydraulic HM.

33

Buying cheap can cost you dear Hydraulic failure is the leading cause of leaks

Losing concentration

Impressive in compressors

Coolants for static equipment are another area where buying cheap can cost you dear.

Total’s family of UK-manufactured compressor lubricants offers a choice of oils with long drain intervals.

Concentrates are cheaper, but rely on the end-user to dilute them. Best Practice demands the use of deionised water to remove hard water chemicals, otherwise reaction with the coolant will lead to deposits blocking the heat transfer tubes and premature failure.

Total’s Coolelf Supra eliminates error by being pre-diluted with deionised water at the correct concentration for optimum performance. Being an Organic Antifreeze Technology (OAT) product it also gives the advantage of reducing or eliminating deposits and keeps the system clean – enabling effective heat transfer and extended system life.

Dacnis mineral oil is for reciprocating and rotary air compressors with drain intervals of up to 2,000 hours.

Dacnis LD is a hydrocracked oil for use in reciprocating and screw air compressors, with a drain interval of up to 4,000 hours. Lastly, Dacnis SH is a synthetic PAO for rotary screw compressors with an oil drain interval of up to 8,000 hours.

With such a large range to choose from, Total really does offer a comprehensive solution to your lubricant and coolant requirements.

All you have to remember is that with cheaper products, the price tag only shows you the price – not the ultimate cost.

1. Excavator field trial performed by Evonik Industries.

Glacelf Supra Organic Antifreeze Technology concentrate is also available from Total.

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Know-How : Issue 26

ThE RX® OPTIFLEX RANGE RX® Optiflex-C Impact test according to MIL-PRF-31013 standard (195-201 m/s)

RX® Optiflex-B Good colour recognition TSR (Traffic Signal Recognition)

RX® Optiflex-W Shade 5 lens for oxy-fuel welding and soldering

RX® Optiflex-V Fits over regular glasses without compromising comfort

RX® Optiflex-G CE approved, EN166 against splashes of chemical liquids, large dust particles, molten metal

See the difference.

Our Optiflex range of safety glasses are ergonomically designed for maximum wearer comfort - clearly a better choice!

PROTECTION, QUALITY AND DESIGN

Safety ProductS

RX® Optiflex safety eyewear is designed with the wearer in mind. Lightweight, stylish and strong, the Optiflex range also features our revolutionary “Shape Memory Technology”, ensuring a perfect fit and maximising comfort and protection in the workplace.

www.eriks.co.uk

Suitable for a large number of specialist applications, the RX® Optiflex range features our innovative RX® coating technology (tested to EN166 standards) ensuring superior resistance to scratches and fogging.

See the difference.

Order your RX® Optiflex safety glasses today.

Call 0800 006 6000 or visit www.eriks.co.uk

35

THE WHOLE KIT AND CABOODLE Kitting solutions for OEMs are nothing new. In fact they’re an acknowledged way to achieve lean manufacturing and value engineering. But there are kits of components – and then there are kits of components that come packaged with added-value design and engineering support, application expertise, distribution and logistics excellence, and all-round know-how.

TIME SAVING

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Know-How : Issue 26

TIME SAVING

Supplying kits saves time, increases efficiency and reduces the possibility of assembly errors. Adding value to those kits can also help add value to the end-products.

The chosen many

A supplier with expertise in the end-user’s application, for example, can help and advise at the very earliest stages of product design and development. Is that the most efficient hydraulic system design? Could it be routed better? Is there a way to reduce the number of fittings and joints – which will in turn reduce the risk of leaks?

A major distributor, on the other hand, will be able to offer a wide choice of components from a range of manufacturers, and at a range of price points. So as an OEM, you can choose the component which offers the most appropriate value for your customer’s application – whether that’s premium branded or a lower-cost generic solution.

A supplier won’t have the answers. A supplier with application know-how will.

However, in a high-risk operating environment such as a quarry, cost is not the only consideration. Health and safety are also major issues, with a huge influence on the design and specification of equipment.

ERIKS runs “Working Safely with Hydraulic Hose and Connections” foundation courses, in conjunction with the British Fluid Power Association (BFPA).

These provide inside knowledge on best practice and real-world operation, all of which can be fed back to equipment manufacturers to inform equipment design and component specification – and then ERIKS can supply the correct specification components in their kits.

Best in the field Knowing how and where equipment is used in the field is essential when designing and developing.

However, when it comes to upgrading, the knowledge gained from maintenance and repair can prove equally valuable.

A supplier who also provides an MRO service to end-users will have first-hand knowledge of how a particular piece of equipment performs in the field.

Maintenance and repair records will reveal the most common problems experienced with the equipment.

And a supplier with all-round know-how will also be able to provide long-term solutions which can be built-in to the upgraded equipment.

For example, an end-user experienced repeated failures of a hydraulic hose in a piece of equipment.

As the end-user’s MRO provider, ERIKS identified the problem as overheating of the hose due to its routing close to the engine.

Re-routing wasn’t an option in this case, but ERIKS was able to specify a hose with greater heat resistance. This kind of information is invaluable when fed back to the OEM.

www.eriks.co.uk

A component manufacturer offering kitting will offer only their own components.

Cut hose connection time in the factory by over

50%

For example, the Machinery Directive imposes a Duty of Care on OEMs for the fitting of burst- and leak-proof hydraulic hoses, if they pass within 1m of the operator. To meet the requirements of the legislation, ERIKS can supply Gates LifeGuard™ Line-of-Sight Sleeving System – an innovative solution with no direct competitor.

Gates LifeGuard contains and absorbs bursts at pressures of up to 10,000psi, and pinhole leaks of up to 5,000psi at temperatures of up to 121°C, for up to 5 minutes. It also meets ISO 3457, and the MSHA flame-resistance requirements.

37

The quick answer

Power to perform

Another example of ERIKS’ added value for OEMS is the Quick-Lok hose connector.

Another option to help ensure your production processes perform at their optimum is to purchase drives in modular form or ready-assembled in-house.

This saves crucial assembly time, maximises engineering productivity and – sourced from a reputable manufacturer such as Fenner – increases your product reliability.

ERIKS’ MRO experience has revealed the limitations of threaded hose connectors in terms of leakage, service life and serviceability – with their knock-on effects on warranty costs.

The solution is the Gates Quick-Lok from ERIKS, which cuts connection time in the factory by over 50% – from around 2½ minutes to just 10-20 seconds. And not only is Quick-Lok quicker to connect, but it’s also error-prof and tamper-proof, providing a verifiable connection which eliminates leaks, maximises service life and reduces warranty claims.

A large mineral company has taken this route – purchasing part-assembled Fenner belt drives comprising pulley, belts, and Taper Lock bushes.

As part of your ERIKS’ kitting solution, it’s one more way ERIKS adds value, reduces your costs, increases your equipment’s performance and maximises your productivity and profitability.

Fenner power transmission products can be tailored to meet your specific requirements – however exacting – in a number of ways. For example, Fenner inverters can be commissioned on site to speed up installation. Fenner gearboxes can be reworked with any special ratios and output speeds you need, before delivery. And components can be specially bagged, tagged and barcoded, then delivered as and when required to meet your production schedules.

Within the Fenner range we can also manufacture special design product – as it does for a large crusher manufacturer needing specialist steels and ductile irons to run at very high speeds.

These are all proven short-cuts to efficiency and productivity. But ones that don’t cut corners. Product quality and reliability, continuity of supply, worldwide availability and competitive pricing all remain as you would expect from a brand with Fenner’s reputation.

Whatever your kitting requirements, a call to your local Authorised Fenner Distributor or ERIKS Service Centre will tell you all you need to allow you to rationalise your stockholding, simplify assembly during production, and realise cost savings for your business.

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Know-How : Issue 26

Adding value to kitting adds value to your endproducts Inside knowledge of best practice and real-world operation

Spitzenqualität...

...the very highest quality.

FORMAT has become the brand of choice among Europe’s engineering professionals. Precision engineered in Germany, our range offers an industryleading blend of ‘Spitzenqualitat’ or professional quality products that won’t cripple your budget.

●

In fact, we are so confident in the quality and technology behind our German origins, that every product is backed by a lifetime guarantee.

●

And remember: every single one of our 11,000 products, from drills and bits to advanced abrasives and measuring equipment, is available from ERIKS – many of them at very short lead-times through their Fastrack system. When you buy FORMAT products through ERIKS, you’re getting superb technology at superb prices – backed by our superb service.

● ● ● ●

Hand tools Abrasives Precision and measuring tools Cutting tools Work holding Storage

HARD HATS FOR HANDS: SKIN PROTECTION FOR MINING AND QUARRYING WORKERS

BEST PRACTICE

A hazardous environment, dangerous equipment and heavy loads are all obvious dangers to health and safety. That’s why hard hats and safety boots are essential wear for workers in mining and quarrying. But the largest and most delicate organ of their bodies, which can be exposed to hazards all day and every day, often goes completely unprotected.

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Know-How: :Issue Know-How Issue26 26

And hands don’t have to be immersed in the chemical for it to make contact with the skin. A simple splash, or even picking up tools which have themselves been contaminated, can be enough to do the damage.

Many jobs carry a certain amount of risk of skin damage. But the figures show that mining and quarrying workers have the highest risk of all.

The sun’s shadow Alongside the dangers of exposure to chemicals, the effects of the sun also cast a large and dangerous shadow over the mining and quarrying industry.

A report by the European Agency for Safety and Health at Work revealed that the construction sector has 9.1 incidences per 100 employees, and manufacturing has 10.4. However, at 31.5 incidences per 100 full-time employees, there are over three times more in mining and quarrying than in manufacturing – the next highest sector.

Workers in this sector spend eight hours a day or more outside, often in close proximity to concrete which is highly reflective of UV rays. So the effects can be the same as eight hours stretched out on a sunlounger.

And though they will wear hard hats and safety boots, it’s the rare worker who slaps on sunscreen before starting work. In fact, it’s been revealed that only 59% of outdoor workers use sun cream at work1, and 70% have stated they haven’t received any training on the risks of working in the sun1.

Chemical cocktail The level of skin disease in mining and quarrying isn’t all that surprising, considering how many different potential irritants are present in the workplace: fossil fuels and their by-products cleaning products organic solvents metalworking fluids cement wet lime (in limestone quarries) diesel lubricating oil grease coolant.

But with no protection against hazardous substances or UV radiation, workers can find their hands badly affected. Visible skin problems range from sore, chapped skin to the commonly diagnosed occupational dermatitis – with 70% of occupational skin diseases now being diagnosed as the more serious contact dermatitis2.

70% 31.5%

of occupational skin diseases diagnosed as more serious contact dermatitis1

www.eriks.co.uk

BEST PRACTICE

That organ is the skin. And skin on the hands in particular is at frequent risk from hazardous substances, and suffers exposure to UV radiation from the sun every single day.

incidences of skin damage per 100 full-time employees

3

A three-step plan is the most effective

41

Hard hats for hands

Save their skin – and yours

3 steps to skin care

Occupational skin disease isn’t just unpleasant for workers. It can also lead to absenteeism, which reduces productivity and increases costs. It can reduce employee efficiency. And it can create poor staff morale. Employees may also lose income through prolonged absence from work, and there will be a negative effect on their well-being and personal life.

For effective protection of the skin on employees’ hands, a three-step plan is usually the most effective in the mining and quarrying industries:

Excessive sun exposure without effective protection can have even more damaging effects. The skin damage that can result may cause excessive ageing, sunburn, eye damage and skin cancer.

So the employees themselves clearly need to take care – but employers have a legal duty of care towards their workers. This means employees should be effectively protected from hazardous substances in their workplace, and from UV rays.

Reducing contact with harmful materials where possible is one part of the solution. Providing employees with effective skin care protection products, and education on risks, is the other part.

1. Protect the skin before it comes into contact with any contaminants, using a perfume-free, non greasy cream, which protects against water-based and non-water based irritants.

2. Clean the hands thoroughly to minimise skin irritation, using effective products to wash away any dirt and grime that comes into contact with the skin.

3. Apply a carefully formulated after-work cream to restore and replenish the skin.

Following this simple three-step hand care plan, together with an effective UV protection plan, won’t just protect your workforce. It will protect your productivity and profitability too.

FREE SAMPLE! Visit us at Hillhead on stand PA24 / PB27 for your free 30 ml sample of DEB Stokoderm Sun Protect 30 PURE or request your sample here http://knowhow. eriks.co.uk/ debsample

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Know-How: :Issue Know-How Issue26 26

BREXIT

DEBATE

IT’S THE UNCERTAINTY I CAN’T STAND! Brexit, have you made up your mind yet?

If you haven’t and you have been watching the TV or reading newspapers looking for some guidance, you are probably sick to the back teeth of it already.

Dave says it’s a leap into the dark, Boris says that with one bound we’ll be free from the Brussels bureaucrats. Obama wants us in, Trump wants us out.

The Germans think we’d be mad to do it, the French don’t seem all that bothered and you get the feeling the Danes secretly want a referendum of their own.

Listen to our leaders and you variously get warnings of impending apocalypse (crashing house prices, economic implosion, that sort of thing) or absolute confidence that we’ll revert to our traditional status of world traders merrily hawking our wares across the globe.

I’ve spoken to senior people working in multi-nationals who are in favour of Brexit and small shopkeepers, who have never exported anything in their entire lives, who want us desperately to stay in.

I’d look to the opinion polls for answers, but after the last General Election we can’t really trust them.

However, there is one thing I do know. We definitely need to make a decision one way or another because business hates this uncertainty.

www.eriks.co.uk

The problem with uncertainty is you can’t see it and it’s difficult to monitor its impact. It just creates inertia.

Nothing happens. Investment decisions are put on hold and plans are left on the shelf. That final decision on the factory extension is ‘parked’. The big order you’ve been expecting is ‘delayed’. The meeting in Dusseldorf to talk about 2017 strategy is ‘postponed’.

And this inertia reverberates down the supply chain.

That factory extension I mentioned needs new cranes, conveyor systems and automation equipment. None of that can be ordered until there is a final go-ahead.

What’s more, the supplier of the conveyor system can’t put in their order for bearings, or steel for the rollers, until they have a firm order themselves.

In turn, the bearings distributor decides to run down stock rather than order more, ‘just in case’. The bearings manufacturer, who supplies the distributor, senses the market is weakening and cuts a shift. It goes on and on and on. Before you know it, the Bank of England is talking cryptically of ‘softening demand’ and the CBI is talking about economic ‘headwinds’.

Which is why after the vote in June we need to stick to the decision, whatever it is. No talk of re-runs like after the Scotland referendum, we need to make a decision and accept it.

Business needs nothing less.

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