August 2011 Engineering Maintenance Solutions

MAINTENANCE BEST PRACTICE – 90% OF TRAINING IS GOING TO WASTE

5

BEARING TECHNOLOGY – THE IMPORTANCE OF BEARING PRELOAD AND AXIAL ADJUSTMENT

27 & 28

PRODUCT SPOTLIGHT – CENTRIFUGAL PUMPS

36 & 37

5-7

8 - 12

Maintenance Best Practice – Training Been Wasted

Latest Industry News

16 - 18

Infra Red Imaging

22 - 23

OEE and Acquisition Standards

26 - 27

Bearing Technology and Maintenance

32 - 33

Product Spotlight – Corrosion Monitoring

36 - 37

Product spotlight – Centrifugal Pumps

40 - 41

Product Spotlight – Flow Meters

44- 45

Product spotlight – Online Condition Monitoring

49 - 50

Buyers Guide

Contacts Publisher Michael Dominguez

Editorial editors/contributing: Jon Barret, Christer Idhammar, Alan France

Advertising Paul Clappison - Magazine Paul Miles - Online Advertising

Email Info@engineeringmaintenance.info

Website www.engineeringmaintenance.info

Phone tel: +44(0)1634 731646 Fax: +44(0)1634 631644

Address MSL Group, Cobalt House, Centre Court, Sir Thomas Longley Road, Rochester, Kent, ME2 4BQ

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engineeringmaintenance.info August 2011

MAINTENANCE BEST PRACTICE

90%

OF ALL TRAINING IS WASTED!

I believe that most training efforts are wasted unless the training is focused on the training needs of each individual. After going through training, a person should immediately apply the new skills. As the saying goes, “If you do not use it, you lose it.�

There are many examples where the above has not been practiced.

on a piece of paper, but no flexibility in reality. The most common reasons for this are: Lack of training in additional skills. With few exceptions, mills spend a lot of time and money on new contracts, but never train their craftspeople in the new skills they need to become more flexible.

First line supervisors do not change the way they assign work. First line supervision often takes the easy

For example, in the last 15 to 20 years, most mills

path. Instead of assigning work so that cross training

have spent considerable effort in negotiating more

takes place as on-the-job training, supervisors

flexible work rules with their unions. However, after

continue to schedule work according to the old craft

agreeing to more flexibility on a piece of paper so

lines so that no new flexibility is introduced.

that, for example, millwrights could perform basic welding and pipe fitting, operators could perform

MULTI CRAFT OR MULTI SKILL?

some inspections and essential equipment care, and so on, most mills soon discovered that not much

To be successful in improving crafts skills and to

changed in reality. For example, operators did not

increase your work flexibility while maintaining high

do any maintenance work and a pump job still took

proficiency in critical skills, I advise that you first

two millwrights and two pipe fitters to complete.

determine governing principles. For example, are you implementing multi craft or multi skills?

The fact is that most mills have a flexibility agreement

More on Page 7 engineeringmaintenance.info August 2011

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MAINTENANCE BEST PRACTICE

Multi craft means a craftsperson is trained for

IMPLEMENTATION.

multiple crafts. For example, a person who is both an electrician and a millwright is multi craft. Multi skills

In implementing a training program that will support

means a craftsperson is trained for a craft along with

better performance-whatever level of flexibility you

additional skills from another craft. For example, an

strive for-I recommend you do a craft skills analysis.

electrician with skills in aligning a motor and a pump

The objective of this analysis is to develop individual

or an operator with mechanical inspection skills is

training plans for each craftsperson.

multi skills.

Start by documenting what skills are needed to maintain the equipment in your mill area. Then

Personally, I believe that the right thing to do is to

compare this to the actual skills of each individual in

implement multi skills, since it is more likely to result

the maintenance crew. The gap that presents itself

in flexibility and proficiency.

forms the basis for the individual training plans. Most probably, you will not need everybody in the top

INCENTIVE.

skills segment because everybody will not be able to acquire and maintain those skills. So, you might end

To motivate people to learn more and to use more

up with three skill levels in your organization.

skills, I believe that there must be an incentive beyond

I recommend that you do this analysis with much

self satisfaction. For example, the most successful

involvement from the craftspeople, because they are

multi craft mill that I have worked with required its

the best source of information. There are also many

craftspeople to have proficiency in one craft when

experts, as well as literature, in this area that can

hired. After three years, an additional craft had to be

help you.

acquired in order to maintain employment, with three crafts for each craftsperson as the ultimate goal.

As a result of the analysis, you will now train only the people who need and will actually use the training.

However, the incentive to learn more involved not

Instead of the scenario described in the November

only job security, but also increased pay. Starting

column where 25 people are trained in hydraulics,

pay was about $15 per hour, but, after learning and

you will now train only five and you will do it much

using three crafts, the pay increased to about $26

more thoroughly.

per hour.

This particular multi craft mill produces over 500,000 tpy with 65 craftspeople. Overtime is 15% and contractor hours in maintenance are 14%. These figures put this mill in the league of world-class

Article supplied by : Christer Idhammar Founder and Executive Vice President IDCON, INC

reliability and maintenance productivity. It is one of the few mills I have worked with where true multi craft training has been very successful, although a major concern at the mill is that the instrumentation craft is having more and more difficulty keeping up with new technologies while maintaining multi craft skills.

For further information please contact us on: Tel: +1 919 723 2682 Email: info@idcon.com Or visit www.idcon.com engineeringmaintenance.info August 2011

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LATEST INDUSTRY NEWS

THE ANGELINI GROUP MAKES GEM®

ITS STEAMTRAP OF CHOICE

The international pharmaceutical and health-care group, Angelini, has made Thermal Energy International Inc’s GEM® venturi orifice steam trap its steam trap of choice following three years extensive testing. Now Angelini’s pharmaceutical plant, located in Ancona in central Italy, has instructed its staff and maintenance contractors to replace its mechanical traps with the GEM® venturi orifice design as the mechanical traps fail.

Following a presentation by Thermal Energy International in 2007, a partial survey was carried out on some of the steam equipment at the 180,000 square metre site which found that around 10% of the mechanical traps had either failed open, shut or partially open. Following these findings, Mr Alessandro Lazzari, Energy Manager at Angelini, Ancona decided to test a GEM® steam trap on a metered trial.

After carrying out two bucket tests on GEM®, Mr Rocchetti, Senior Engineer at Angelini, identified the area where the test could be carried out and the steam consumption monitored.

In 2008 the steam consumption of the mechanical traps was recorded and in 2009 eight mechanical traps, used on heat exchangers, air conditioning units, humidification systems and drip legs, were exchanged for GEM®.

In 2010, Angelini verified that six months after installing the GEM® steam traps, the company was making steam savings of 8% with low-pressure steam at 3-bar pressure, which will provide it with a payback to the company in just 12-months.

Following these findings, Angelini installed 20 GEM® venturi orifice steam traps in the oldest part of the production site with very positive results.

Since then a total of 30 GEM® traps have been installed on drip legs, kettle reboilers, heat exchangers, heating batteries and

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humidification systems with a further 20 traps being ordered for installation this year. Such as been the success of the GEM® trap installations that Mr. Rocchetti and his colleague Mr Guerra gave a presentation to Maintenance Managers on the GEM® technology at the pharmaceutical seminar, ‘Manutenzione Pharma’ in Milan.

Instead of utilising a valve mechanism to close off steam for maximum energy and water conservation, the highly efficient GEM® steam traps use the patented venturi orifice design to effectively drain condensate from the steam system. As the GEM® steam traps have no moving parts to wedge open or fail, it provides the ultimate in reliability necessitating only minimal maintenance and requiring no spares, testing or monitoring equipment.

Commenting of the GEM® venturi orifice steam trap, Mr Alessandro Lazzari said: “We were conscious that mechanical steam traps create endless problems in industrial plants as a result of their poor reliability and significant maintenance requirements. With GEM® we have identified a solution that encompasses energy savings and minimum maintenance”.

Available in a wide range of sizes for a full cross section of applications, the hardwearing GEM® steam traps are manufactured from corrosion resistant stainless steel and are guaranteed for 10 years, eliminating the need for repair or replacement. The GEM® steam traps can provide a fast payback from reduced energy costs and increased equipment reliability. In addition they can improve product processing by enhancing process control of the cleaning system, and also reducing equipment repairs, downtime and replacement costs.

Thermal Energy International Inc, 1 John Street, Bristol, BS1 2HR Tel: 0117 917 7010 Fax: 0117 917 7011 www.gemtrap.com

INDUSTRY NEWS

NEW DRAEGER WEBSHOP MAKES SAFETY EASIER Designed to make safety easier, the new Draeger Webshop provides easy access to a wide range of industrial safety solutions. Found at www.draegershop.co.uk this interactive, secure on-line web facility forms part of Draeger’s ongoing commitment to understanding and working alongside its customers.

Enabling UK customers to source Draeger products 24-hours a day, 7-days a week, the site offers fast delivery on thousands of personal protective equipment, occupational safety products, portable and fixed gas detection equipment as well as spares and accessories.

Serving general industry, oil and gas (upstream and downstream), fire and rescue and the water industry, this convenient website has both quick and extended search facilities and also allows visitors to browse via extensive industrial application and product catalogues. By using Draeger’s deep knowledge and understanding of the safety issues and risks that are faced every day, the site can also assist with product selection for those industries.

When searching via industry sector, for instance, visitors are automatically directed to the most appropriate products for their working environment.

Product catalogues are quick and easy to access and, for those who require further assistance or 10

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information, the site contains convenient productspecific enquiry forms and direct email links as well as telephone, fax and instant message “chat” facilities.

Fully committed to customer care and support, Draeger’s move into eCommerce means that customers can now source Draeger products, services and “know-how” at a time convenient to themselves. Quick and reliable, the new Webshop complements Draeger’s extensive team of UK sales and technical support personnel.

Existing Draeger account customers can access the site straight away and registration for new customers is quick and straightforward.

For more information: Visit: www.draegershop.co.uk Email: enquiries.shop.st.uk@draeger.com For further information contact: Customer Service, Draeger Safety UK Limited, Ullswater Close, Blyth Riverside Business Park, Blyth, Northumberland, NE24 4RG. Tel: 01670 561200 Fax: 01670 356266 www.draeger.com

engineeringmaintenance.info August 2011

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INDUSTRY NEWS

VEGA LAUNCH NEW REMOTE MONITORING SOLUTION FOR LEVEL AND PRESSURE A new transmitting and receiving unit, PLICSMOBILE, fits seamlessly into VEGA’s modular plics® system.

It’s available as an integrated module for the new plics®plus sensor generation, or as a standalone instrument PLICSMOBILE T61, which can be powered from the existing signal cable, by battery or other renewable energy source. The SIM card and integrated modem allow worldwide data transmission via the mobile network GSM/GPRS – including ‘dial in’ remote diagnosis and service using industry standard PACTware FDT/DTM software. PLICSMOBILE is stand alone, nothing else needed, no other intermediate signal boxes or modems nearby. Cabling can also be left out too: an integrated energy system manages any battery supply of sensor and emitting unit ( an integral in-housing mini battery pack, providing once-aday readings for over a year, will follow in October this year) .

This means PLICSMOBILE offers real capability and flexibility in deployment, especially in the area of Vendor Managed Inventory (VMI) they can be installed and operate independently with any VEGA technology - measuring liquid in tanks or silo levels up to 75m with battery power only, and sending data globally. With the options of ; PLICSMOBILE, PLICSRADIO and HART Wireless compatibility, VEGA can now cover practically any application in wireless communication from local to global.

PLICSMOBILE looks set to change the way remote inventory and VMI systems are deployed in future by integrating everything into the measurement device for level applications from water level to silo levels up to 75m

Doug Anderson-VEGA Controls Ltd Kendal House, Victoria Way West Sussex, RH15 9NF Web: www.vegacontrols.co.uk E-Mail: info@uk.vega.com Tel +44 1444 870055 Fax +44 1444 870080

INDUSTRY NEWS

ERIKS’ ENGINEERS SPEND WEEKEND LOCKED IN BANK VAULTS ERIKS, Europe’s leading industrial services partner, recently worked closely with facilities management specialists from Mitie on a high security operation in the regional headquarters of a major UK bank in Manchester.

Twelve engineers from ERIKS, all specialists in high voltage operations, were literally locked in over a weekend from mid afternoon on a Saturday to midday Sunday, while essential maintenance and upgrades to the building services systems were being carried out. This included work on both low and high voltage switchgear systems.

The switchgear upgrade operation was planned in order to ensure that the necessary standards of health and safety were upheld.

Under H&S regulations companies have a legal obligation to maintain this type of equipment to suitable standards and in full compliance with OHSAS 18001.

The complete project involved dealing with switchgear from 415V up to 11,000V, including an array of transformers, isolators and UPS systems. Much of the equipment was housed on the top floor of the bank building, though some was also located in the basement. To add to the operational challenge, the equipment present had been sourced from several manufacturers.

For the entire duration of the upgrade process the building was without power, with portable back up generators in use. This affected all of the bank’s safety and security systems, including CCTV. For this reason, all ERIKS and Mitie engineers had to

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undergo strict security vetting before they were allowed to work on this project. Furthermore, it was absolutely crucial that the power was back in operation by the start of business on Monday, fully tested and compliant.

ERIKS and Mitie had worked together before on a number of projects, though never on one as sensitive as this. A spokesperson from MITIE said, “This was a highly successful and professionally executed operation. Both teams have to be commended for working so well together, ensuring that work was completed exactly within the deadline and with no hitches.”

He adds, “The competence of both teams is certainly a credit to their respective companies.”

For further information, please contact: Robyn Bradley, Marketing Executive, ERIKS UK T: +44 (0)121 508 6219 | M: +44(0)7740 452743 E: robyn.bradley@eriks.co.uk

engineeringmaintenance.info August 2011

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BLADELESS FANS

CONCEPTS NREC SOFTWARE BLOWS HOLES IN CONVENTIONAL FAN DESIGN Air Multiplier™ bladeless fans are the latest innovation from Dyson, a UK engineering company with a proven track record in redesigning everyday products from the ground up.

If a bladeless fan sounds counter-intuitive, it is. But that’s Dyson.

This is no ordinary engineering company, rather one that offers a proactive attitude to design, thinking outside conventional frameworks, and demonstrating a willingness to invest in the latest technologies. And this is why Dyson is a flagship user of turbomachinery design and development software from Concepts NREC.

Air Multiplier technology The blades on conventional electric fans chop the air before it hits you, causing unpleasant buffeting. Take the blades out, and the buffeting stops. Therein lay the challenge.

The breakthrough came when Dyson engineers noticed that accelerating air over a ramp amplified it by up to 20 times, drawing in surrounding air through processes known as inducement and entrainment. However, air intake remained a problem – the motor would have to suck in more than 20 litres of air per second to generate a powerful enough jet. It became clear that a 3D impeller was required, in effect to provide the ‘engine’ for Dyson’s first bladeless fan, AM01.

“The challenge was to minimise acoustic emissions and make the quietest fan ever,” he explains, “which is why the rotational speeds are low, not high,” says Frederic Nicolas, Manager of

Dyson’s Research, Design, and Development (RDD) Centre in Wiltshire, England.

RDD Engineer, Michal Nurzynski, adds: “We also had to consider carefully the pressure required to overcome the resistance of the main aperture, and then choose the most suitable impeller technology: radial (centrifugal); axial; or mixed-flow. However, using Concepts NREC FANPAL™ application, it was clear that a mixed-flow solution would give the best performance.

Design Wizard FANPAL users deploy a unique Design Wizard to design the stage, analyse the performance, refine parameters with data reduction, and simulate the machine according to several performance models. FANPAL also offers direct integration with Concepts NREC’s AxCent® CAE software for detailed blade design and fluid dynamic analysis – today Dyson has three seats of AxCent and three seats of FANPAL. “We used AxCent extensively to detail small changes in blade length and shape before running the software’s real-time interactive flow analysis through streamline curvature to assess performance,” says Mr. Nurzynski. “Using AxCent, we spotted that the acoustic performance of the blade was closely linked to blade shape, and we started designing to optimise flow conditions with blades unevenly spaced and blade angles developed to minimise end losses.”

The end result is an impeller featuring nine asymmetrically aligned fins with rows of tiny peripheral holes to reduce the friction caused by colliding high and low air pressure (birds of prey balance air pressure around their wings in a similar way).

Furthermore, simulating air flow using AxCent without the need for a physical prototype was of huge commercial advantage to Dyson.

“On AM01 and previous projects we have demonstrated that we can consistently make the first prototype on specification in terms of performance using Concepts NREC software,” concludes Mr. Nicolas.

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IR

THERMOTEKNIX MIRICLE CAMERA USED IN THE MAKING OF GROUNDBREAKING BIG CAT FILM

Ammonite Films is an independent film production company specialising in using innovative and high tech camera equipment to make high definition films about science and natural history. Ammonite Films first approached Thermoteknix with a view to making a film of big cats hunting at night back in 2008.

Renowned Ammonite wildlife photographer and film producer Martin Dohrn had been commissioned by National Geographic Wild (HD) and was looking for a high resolution thermal imaging camera to capture lions hunting at their most effective time, in complete darkness, in order to make the film ‘Night of the Lion’.

Discussions with Martin led to the selection of a Thermoteknix MIRICLE 307K camera with 640x480 pixel resolution.

Martin wanted to use both 32mm and 150mm focal length lenses on the same camera in order to change the camera field of view very quickly – a feature essential for

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filming fast-moving wildlife. Thermoteknix provided the technical support solution for Ammonite to be able to adapt the camera and lenses in order to fit onto the same MIRICLE 307K thermal imaging camera.

The subsequent stunning filming took place in the Masai Mara in Kenya in order to produce the never before seen stunning footage of lions hunting in total darkness and was first aired on Nat Geo Wild TV in September 2010.

British company Thermoteknix Systems Ltd is regularly involved high profile projects including Formula 1 and Indycar racing, Aegis Ballistic Defense Tests and recently was selected to supply the thermal imaging camera to accompany NASA’s successful LCROSS mission to search for the presence of water on the moon…where the Thermoteknix camera in question now resides permanently…

For more information please contact: Thermoteknix Systems Ltd TEKNIX HOUSE 2 Pembroke Avenue Waterbeach, Cambridge CB25 9QR United Kingdom Tel:+44 (0)1223 204000 Fax:+44 (0)1223 204010 Email:sales@thermoteknix.com Web:www.thermoteknix.com

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IR

CRIMSON SEES INFRARED WITH FLIR Crimson Industrial Vision is a company that specialises in remote visual inspection technologies that support condition monitoring and NDT. Thermal imaging is a major element in its product programme and for the company’s founder, Paul Sacker, FLIR was the only option when it came to deciding the brand that best suited his company’s ethos.

“Thermal imaging is a growth market with enormous potential for Crimson with our broad and deep knowledge of IR applications. FLIR is the only IR company that truly understands this market and for Crimson it’s the natural choice,” he explains.

Systems that view across the spectrum from UV through to IR, including visual, complete the Crimson product programme. The company’s extensive knowledge of inspection applications enables it to recommend a solution, albeit off-the-shelf or bespoke, that has a lasting impact on the reliability of assets.

To address the scope of its business Crimson has chosen to become a value-added distributor for the entire range of FLIR’s hand-held and fixed mounted thermal imaging cameras. And this reflects the span of customer interest for this relationship-based business. Current IR projects extend from standard damp detection and air tightness in buildings through 18

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to food process monitoring and other automation applications.

Paul Sacker also confirms the newly launched FLIR Ebx-Series has been particularly well-received by customers servicing the built environment. “The ease of use of both the camera and software means that, for the first time, customers have an eminently affordable product that helps them to make informed decisions faster and to explain thermal issues to their customers with clarity.”

He continues: “More and more IR applications are becoming affordable and practical.

Segments such as health screening and automation are prime examples. And as the price of detectors comes down there will be even greater opportunity for sensor integration, allowing many more users to enter the market. With FLIR in Crimson’s armoury, the company is in a great position to meet this growing demand.”

FLIR Systems Ltd., 2 Kings Hill Avenue, Kings Hill, West Malling, Kent, ME19 4AQ Tel: +44(0)1732 220011 Fax: +44(0)1732 843707 Email: sales@flir.uk.com Web Site: www.flir.com Registration No. 1320288

INDUSTRY NEWS

KÄRCHER ANNOUNCES THE PROFESSIONAL CLEANING ROADSHOW IN SEPTEMBER 2011

The company will be inviting new and existing customers to come along and try out these products, which will be showcased in Kärcher’s purpose-built mobile exhibition truck. The truck features demonstration and presentation areas, and expert Kärcher staff will be on hand to offer advice.

The Kärcher truck will visit several high profile locations around the country, from Brighton & Hove Albion FC’s brand new AMEX stadium on September 2nd to Scotland’s national football stadium Hampden Park on September 28th. As well as product demonstrations and giveaways, there will be a prize draw at every event, where one visitor will win a Kärcher professional product up to the list price value of £2500.

Craig McKay, Kärcher’s Head of Distribution Sales and Marketing, said: “The roadshow gives us a fantastic opportunity to reach a huge number of existing and potential customers from all markets that require professional cleaning products.

From small garage owners to large contract cleaners, we have products that will make a vast difference to their businesses. We encourage all professional users of cleaning machines to come along and visit us at a venue near them.”

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The full Kärcher Professional Roadshow schedule is: Friday September 2nd: AMEX Stadium, Brighton Tuesday September 6th: Madejski Stadium, Reading Monday September 12th: The Etihad Stadium, Manchester Thursday September 15th: Edgbaston cricket ground, Birmingham Tuesday September 20th: MechanEx motor trade exhibition, Stoneleigh Park, Warwickshire Wednesday September 21st: MechanEx motor trade exhibition, Stoneleigh Park, Warwickshire Tuesday September 27th: Hampden Park, Glasgow For further information please visit www.karcher.co.uk

OEE

OEE AND ACQUISITION STANDARDS

“

I’ve taken a few trips to Germany recently to attend some workshops on an emerging Standard Methodology related to data capture from Programmable Logic Controllers (or PLCs)…

PLC Data Capture

So data capture companies had to obtain, or write, different Drivers for Allen Bradley, Omron, Mitsubishi and Siemens etc. Whilst some sites have been able to standardise on a single PLC family per plant, others have not and it is common to have 4 or 5 PLC types on a single plant, all with their own operating modes – and their own specific Drivers. The time and cost implications for rolling out automatic data capture across these sites are clear.

”

I’m always beguiled by new technology; on one of my trips to Dusseldorf I was excited to be able to use the mobile phone boarding card at the gate. It just shows how things have progressed in this sector, from waiting for the travel agent to post the 6-page ticket pack, to a paperless system and a 2D barcode image. There is a lot of negative feedback on the forums saying the paperless system fails to work on the iPad - too big to fit under the scanner apparently - but it works at both Heathrow and Düsseldorf.

What a perfect use of technology; check in, flight status, and boarding card accomplished - all before you leave the hotel (or in my case, before getting out of bed).

Admittedly, technology change relating to PLC data capture has not been quite so dramatic (and some may argue less exciting) - but there is at least one that intends to make data capture much easier, and this, for me at least, is something to be excited about. When implementing an OEE System in a new plant, acquiring the data that is used to calculate OEE is almost always the most complicated part of the process. This often means that factories chose to capture data manually, or semi-automatically, and this can have a real impact on the overall success of their loss management strategies. Even at the most sophisticated plants, the subject of ‘Automatic Data Capture’ invariably produces a groan from site staff – as acquiring any data (such as a product count for an ERP System for example) has traditionally proved both complex and costly.

This is because, up until recently there has only been one way to access data from a PLC, and that was to have Drivers written for that specific PLC family.

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‘The Weihenstephen Standard.’

To simplify this process, the Technical University of Munich began a research study to try and remove some of complexity by creating a Standard Methodology for machine manufacturers to provide equipment data to performance measurement systems such as OEE: ‘The Weihenstephen Standard.’

The Standard began in the bottling industry; in fact Weihenstephan is a famous wheat beer made in the oldest brewery in the world (not the real purpose of my visits to Germany, but a welcome addition!).

The concept is simple; in order to claim the Weihenstephen Standard, the machine manufacturer must ensure that all equipment provides access to operational data in the same way, irrespective of the PLC used to operate that equipment. This would

OEE

mean that when a new machine, with a completely difference PLC family, replaces an old one, the data would be obtained in exactly the same standard way.

be required. The Weihenstephen Standard ensures your data is consistently captured across your site, and throughout your group.

The Weihenstephen Standard comprises four parts:

Evaluation and Reporting

• • • •

The third part of the Standard is ‘data evaluation and reporting’, and it’s where the software supplier takes over with, for example, OEE analysis and reporting.

With a much simpler data acquisition layer we can concentrate on the real work of helping plants use their data to improve their performance.

Physical interface specifications Specification of interface content Data evaluation and reporting Approval and safe operation

The communication method is Transmission Control Protocol over Internet Protocol or TCP/IP, with each item of equipment being contactable via a unique IP address and port number.

Only a small number of commands are needed to acquire the data. One checks for signs of life, such as a machine healthy signal, whilst others read or write single values. Further commands can read or write lists of values as required.

At the core of the Standard are data tags that are used to define messages, including counters, failure notices, and expected operating states for production line equipment. For example tag number 50005 may refer to a ‘total bottle count’. The Standard ensures that any OEE client (such as a Human Machine Interface or Touch Screen) can guarantee that the value of tag 50005 will always hold a count of the number of bottles at that moment in time.

Operator Knowledge Automatic Data Capture from PLCs is the final step in the data acquisition journey for many manufacturers – and this new Weihenstephen Standard could really assist in the roll out of software assisted performance improvement programmes. But it’s worth remembering that data capture from PLCs should be used to support operators (by accurately and automatically capturing time losses for instance).

PLCs data should never replace operator information.

For example, if a bottle sensor PLC code shows the filler stop is due to bottle absence, but it’s actually because a guide keeps knocking bottles out of alignment – only the operator will be able to see and capture this detail. And the operator’s ‘eye for detail’ is vital to enable your Continuous Improvement team to be able to understand and resolve the issue effectively.

All the configuration definitions are held in xml files and act as ‘look-up’ tables. Many of the tags are predefined, and the equipment manufacturer must use the obligatory ones in order to meet the Standard.

The machine maker is also able to register and use it’s own tags for specific machines. The OEE client just has to check the xml configuration file to see what each tag holds.

Alan France, Operations Director of Idhammar Systems, has extensive experience in lean manufacturing with a background that includes several years as Engineering

The Vision The Weihenstephen vision is that any OEE client can be ‘aimed’ at a completely different piece of equipment, which adheres to the Standard, and begin to acquire data - without modification. In fact the OEE software doesn’t even need to know which PLC is used.

This means significantly reduced data acquisition and configuration costs and accelerated set up times. It also ensures the integrity of the data you acquire, whereas if you were extracting the data from lots of machines, in lots of different ways, a validation exercise would

Systems Manager for the largest food company in Europe.

A systems specialist, he now consults on the importance of underpinning lean initiatives with realistic targets and sound metrics.

Contact him by e-mail, alan.france@idhammarsystems. com, or visit www.idhammarsystems.com for more on CMMS and OEE software.

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LATEST INDUSTRY NEWS

MARSH BELLOFRAM ADDS AIR PREPARATION EQUIPMENT TO THEIR RANGE The Marsh Bellofram company have been appointed as UK distributors for the Shavo range of air preparation equipment, combining durability and performance while representing excellent value for money.

Shavo started manufacturing under licence with designs and drawings provided by C A Norgren Co, USA for their well established range of industrial pneumatic filters, regulators and airline lubricators including both the oil mist and micro mist versions. These are complemented by the Shavo range of FRL equipment including coalescing oil removal filters for breathing quality air. Stainless steel and precision filter regulators are also included for marine and other general corrosive or harsh condition applications.

The products include the Norgren design 07, 17 and 18 series of FRL’s together with the series 13 range of plug-in equipment.

These can be supplied in port sizes from 1/8” to 2” BSP covering flows from 6 to 1890 scfm.

The Shavo own design products include their Vayu 10, 20, 60 and 70 series. The Vayu 20 range is suitable for plug-in assembly and the products have a port range from 1/8” to 1.1/2” BSP, catering for flows up to 700 scfm.

The stainless steel pressure regulator and filter/regulator products have metallic parts complying with NACE MR0175 standard suitable for applications offshore, oil and gas, chemical, food processing, medical and dental environments.

These are available in port sizes of 1/4” and 1/2” BSP. Precision filter regulators model 11-4SN are also available for handling instrumentation air supplies.

Marsh Bellofram hold adequate stocks of all products at their trade centre in Nottingham, with further information available from: Marsh Bellofram Europe Ltd, 9 Castle Park, Queens Drive, Nottingham NG2 1AH Telephone: 0115 993 3300 | Fax: 0115 993 3301 e-mail: bellofram@aol.com | www.marshbellofram.eu

LATEST INDUSTRY NEWS

TOP CLASS – NEW TC FITTINGS RANGE HAS ALL THE RIGHT QUALITIES! Thorite has launched a new and improved range of TC Push-In Tube Fittings and Accessories that combines competitive prices with excellent, 2 year warranty-backed construction quality – and is supported by massive stocks.

The new range includes straight, elbow, “Y” and Tee Connectors, a wide variety of Adaptors, Banjo Assemblies, Check Valves, Flow Regulators and Manifolds, all featuring composite, brass and stainless steel components. Polyurethane and nylon tubing, metal or nylon tubing clips and lightweight plastic tubing cutters complete the comprehensive TC fittings portfolio.

TC fittings are designed to be fully compatible with polyethylene, polyurethane and nylon tubing and are ideal for air, vacuum and non-potable water system applications in tube sizes 4, 6, 8, 10 & 12mm, covering a pressure range of 0-10 Bar (0-145 PSI).

Each fitting features light weight, low cost and include fast assembly and equally rapid disassembly, thanks to an oval collet, with BSP Taper adapter threads which are sealant coated. Typical applications include repair, maintenance and new system installations along with OEM, workshop and testing requirements.

All TC Push-In Tube Fittings are available ex-stock from each of Thorite’s 9 Sales and Service Centres in Blackburn, Bolton, Bradford, Doncaster, Huddersfield, Leeds, Rochdale, Sheffield

and North Shields. Next day delivery can be guaranteed from Thorite’s National Distribution Centre on freephone 0800 0345 850 or all items can be purchased online at www.thorite.co.uk

Further Information: Ross Gowler, Marketing and Engineering Services Director.

Email: ross.gowler@thorite.co.uk Tel: 01274 663471

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BEARING TECHNOLOGY & MAINTENANCE

THE IMPORTANCE OF BEARING PRELOAD AND AXIAL ADJUSTMENT

Preloading and axial adjustment is a vital but still largely misunderstood area of bearing technology. However, when applied correctly, preloading can reduce or overcome the causes of bearing vibration, heat build-up, noise and fatigue. Gary Hughes, Product Engineering Manager at The Barden Corporation, describes the pros and cons of the three primary methods of applying preload to a bearing.

Preloading and axial adjustment is a method of removing or controlling the internal clearance of a bearing. This is important because the degree of internal clearance within a bearing can influence a variety of factors, including noise, vibration, heat build-up and fatigue life. When applied correctly, preloading reduces or overcomes the causes of these problems: it controls radial and axial play; provides predictable system rigidity; reduces non-repetitive runout; reduces the difference in contact angles between the

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inner and outer rings at very high speeds; and controls ball skidding under very high acceleration.

Bearing Yield Axial yield is the axial deflection between inner and outer rings after end play is removed and a working load or preload is applied. It results from elastic deformation of balls and raceways under thrust loading. Similarly, radial yield is the radial deflection caused by radial loading.

Both types of yield are governed by the internal design of the bearing, the contact angle and load characteristics (magnitude and direction).

In all bearing arrangements where preload is deemed to be necessary, it should be applied as lightly as possible in order to achieve the desired result, avoiding excessive heat generation, which reduces speed capability and bearing life.

In addition, it is important to select the most appropriate method of preloading, of which there are three main types: springs, axial adjustment, and preload ground Duplex bearings.

Springs Of the three preloading methods, springs are usually regarded as the simplest and should be considered first.

Spring preloading provides a relatively constant preload

BEARING TECHNOLOGY & MAINTENANCE because it is less sensitive to differential thermal expansion than rigid preloading, and better accommodates any minor misalignment. Also, it is possible to use bearings that have not had the added cost of preload grinding.

One disadvantage of using springs is that they cannot generally accept reversing thrust loads. Space must also be provided to accommodate both the springs and spring travel. In addition, springs may tend to misalign the ring being loaded due to the required clearance fits.

to the precise requirement of the application.

Despite the disadvantages of spring preloading, this method is still a popular one, illustrated by the fact that there are numerous types of springs available for preloading, including coil springs, Belleville, wave or finger spring washers. With regard to mounting, the spring is normally applied to the non-rotating part of the bearing, typically the outer ring. This ring must have a clearance fit in the housing at all temperatures to ensure the preload force from the spring is effective.

Duplexing is used mainly where the requirement is for predictable radial and axial rigidity. Duplex bearings can withstand bi-directional thrust loads or heavy unidirectional thrust loads. Other advantages include their ease of assembly and minimum runout.

Axial Adjustment Another method of achieving internal clearance control is axial adjustment. This technique calls for the mounting of at least two bearings in opposition, so that inner and outer rings of each bearing are offset axially.

Threaded members, shims and spacers are typically ways of providing rigid preloads via axial adjustment. This technique requires great care and accuracy in order to avoid excessive take up of internal clearance, which may occur during setup by overloading the bearings, or during operation due to thermal expansion. Precision lapped shims are normally preferred to threaded members here, as helical threads can lead to misalignment. The shims should be manufactured to parallelism tolerances equal to those of the bearings, because they must be capable of spacing the bearings to accuracies of 1-2 micrometres or better. Bearing ring faces must be well aligned and solidly seated and there must be extreme cleanliness during assembly. Axial adjustment does not increase bearing friction and is therefore preferred for very low torque applications.

Duplex Bearings The third main method of applying preload is to utilise Duplex bearings. In contrast to springs and the axial adjustment method, using Duplex bearings offers the advantage that the means of achieving preload is built-in.

In effect, this method of preload can be the simplest for the customer, who receives the bearings ready to mount and with the confidence that those bearings are preloaded

Duplex bearings are matched pairs of bearings that have their inner or outer ring faces selectively relieved by a precise amount known as the preload offset. When the bearings are clamped together during installation, the offset faces meet, establishing a permanent preload in the bearing set. Duplex bearings are normally speed-limited due to heat generated by this rigid preload.

When using Duplex bearings, consideration should be given to the following: increased torque; reduced speed capacity; sensitivity to differential thermal expansion; susceptibility to gross torque variations due to misalignment; and poor adaptability to interference fitting.

Most Barden deep groove and angular contact bearings are available in universal Duplex sets or can be furnished in specific DB (back-to-back), DF (face-to-face) or DT (tandem) configurations.

DB mounting is suited to most applications that have good alignment of bearing housings and shafts. It is also preferable where high moment rigidity is required, and where the shaft runs warmer than the housing.

In contrast, DF mounting is used in only a few applications, primarily where misalignment must be accommodated.

Speed capability is normally lower than a DB pair of identical preload.

DT mounting employs tandem pairs that offer greater capacity without increasing bearing size, through load sharing. The DT pairs can counter heavy thrust loads from one direction but they cannot take reversing loads as DB and DF pairs can. DT sets do not have inbuilt preloading and should be used in conjunction with spring preloading.

For

more

information

on

bearing

preloading, please request a copy of Barden’s ‘Speciality Products Catalogue’ or download a copy from: www.bardenbearings.co.uk

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ENERGY MANAGEMENT

ABERDEEN ROYAL INFIRMARY ESTIMATES THAT SPIRAX SARCO EASIHEAT™ SYSTEMS HAVE DELIVERED ENERGY SAVINGS OF MORE THAN 15% Switching its domestic hot water and heating from shelland-tube calorifiers to EasiHeat™ systems from Spirax Sarco has delivered energy savings of at least 15% at Aberdeen Royal Infirmary. Replacing the hospital’s ageing calorifiers has also saved up to three weeks of maintenance work each year, since the old systems had to be stripped down for regular insurance inspections.

used to store 2,100 gallons (9500 litres approx) of hot water, 24-7,” says Mr. Stirton. The removal of hot water storage also saves space and potentially helps eliminate problems associated with Legionella pneumophila contamination, which is a risk in any system that stores hot water. “We’ve been very pleased with the installation,” says Mr. Stirton.

“We made the decision to change because one of the calorifiers was nearing 55 years old,” says Aberdeen Royal Infirmary’s Estates Officer Mr. Trevor Stirton. “They were high maintenance and we knew that modern systems would be more energy efficient. We don’t have the new systems metered for steam consumption so we can’t say exactly what they’re saving, but it is estimated to be up to 15% overall for the heating and domestic hot water applications we have replaced.”

EasiHeat systems are compact, skid-mounted installations with a stainless steel plate heat exchanger at their heart. They use plant steam to deliver a heating capacity of up to 1800kW. With most of the engineering and quality checks carried out offsite, installation simply means connecting the system up to the appropriate utilities. Commissioning is also trouble-free.

EasiHeat systems use compact plate heat exchangers to provide hot water on demand. This eliminates the need for hot water storage and the resulting reduction in heat losses leads to greater energy efficiency. “We can’t afford to run out of hot water, so in one area alone we

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For more information: email: uk.enquiries@uk.spiraxsarco.com, call: 01242 535319 or alternatively visit: www.spiraxsarco.com/uk.

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FATIGUE TESTING

TESTING FOR WIND ENERGY AND AEROSPACE APPLICATIONS Instron Ltd and the National Composite Certification and Evaluation Facility (NCCEF) based at the University of Manchester have jointly set up the state of the art Instron Composite Laboratory.

This laboratory has UKAS accreditation for a wide range of mechanical tests on composites and is equipped with Instron fatigue test machines ranging from 100kN to 300kN capacity capable of performing biaxial and multiaxial testing at ambient or elevated temperatures. The test machines are all controlled by the latest WaveMatrix software and are able to perform high or low frequency testing.

This facility specialises in testing for wind energy and aerospace applications where the quality and precision of test results is critical. The aim of the fatigue test laboratory is to serve industry in obtaining a better understanding of the fatigue behaviour of composite materials, and develop new test standards to meet the design requirements for complex components and systems.

National Composite Certification and Evaluation Facility The University of Manchester, Paper Science Building Sackville Street, Manchester M139PL, United Kingdom Website: www.futurecomposites.org.uk Email: nccef@manchester.ac.uk Tel: +44 (0) 1612 758160 Instron European Headquarter Coronation Road, High Wycombe, Bucks HP12 3SY, United Kingdom Website: www.instron.com Email: web@instron.com Tel: +44 (0) 1494 464646

SENSORS

COMPACT CYLINDER SENSOR ifm electronic launches cylinder sensor with integrated connector Available now from ifm electronic Ltd are yet more sensors for pneumatic cylinders made in their trademark robust style, but this time featuring an integrated connector.

The MK range of cylinder sensors is characterised by the ease of installation and universal fitting. If it’s a T-slot, ifm’s MK will fit, otherwise there’s probably an adapter to suit.

The MK is offered as a DC PNP device or in a NPN version, complemented by two-wire and three-wire reed variants, and all feature a highly visible LED. The three-pin M8 connector conforms to the industry standard, and is complemented by a wide range of mating connectors from ifm’s EVC series, designed for perfect compatibility.

These IP67 rated units, from leading sensor supplier ifm electronic, offer yet another reason to standardise on one kind of sensor for all your pneumatic needs, instead of stocking all the different varieties from the pneumatic suppliers.

Like their predecessors the new MK’s from ifm electronic simply drop into the slot with a snug fit, can be positioned and then fastened easily and quickly. No special tools required, a normal terminal driver will do the job.

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ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.

For further information, contact Mel Lewis, ifm electronic Ltd., Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD. Telephone: 020 8213-0000. Fax: 020 8213-2228.

E-mail – marketing.gb@ifm.com or visit our website at: www.ifm.com/uk

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PRODUCT SPOTLIGHT – CORROSION MONITORING

DR. SHRINK’S VOLATILE CORROSION INHIBITING (VCI) SHRINK WRAP Dr. Shrink’s Volatile Corrosion Inhibiting (VCI) shrink wrap contains additives that will prevent corrosion on both ferrous and non-ferrous metals, and electrical connections, for periods up to 2 years. Available in a heavy duty 7 mil thickness.

Color is opaque to reflect heat and minimize condensation.

Our Container Dri II bags absorb moisture vapor and reduce dew point temperature inside transport containers, boats, and other storage containers. By preventing condensation, Container Dri II eliminates corrosion, mildew, peeling labels, and other harmful effects of moisture-related damage during shipping and storage.

Dr. Shrink also offers Zerust Capsules that protect electrical and mechanical metal components against corrosion failures during storage. The capsules create an invisible corrosion inhibiting vapor shield on the metal surface. Various sizes are available.

For More Information Please Visit: www.dr-shrink.com

PRODUCT SPOTLIGHT – CORROSION MONITORING

INTRODUCING THE LIGHTWEIGHT BATTERY OPERATED CORROSION MONITOR Hydrosteel 7000 Transportable Light (TL) is a complete stand-alone battery 8 kg kit for real time monitoring of sour, HF and high temperature corrosion and hydrogen risk damage risk, non-intrusively.

Hydrosteel 7000TL provides the most sensitive, precise monitoring of hydrogen flux available. The tool monitors continuously, without any human intervention, and responds to corrosion changes within minutes. Target industries for Hydrosteel 7000TL include sour gas and oil production, refineries chemical plants. Monitoring spans of up to 9 months are possible.

The equipment can be used in Class 1, Divison 2 areas, requires no bespoke probe fittings, unlike many other corrosion monitors. Data can be downloaded to laptop or via 4-20 mA output.

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For more information visit: www.ionscience.com

PRODUCT SPOTLIGHT – CORROSION MONITORING

“ROLLING IN RESULTS” WITH THE NEW CORROSION MAPPING SCANNING SOLUTION FROM SONATEST LTD. Veo & Corrosion WheelProbe Scanning System Building on the proven success of Corrosion WheelProbe a new semi-automated solution for corrosion mapping applications has been developed by Sonatest Ltd; the Veo & Corrosion WheelProbe (CWP) Scanning system.

The CWP Scanner is a new enhancement in response to clients’ requests, providing an easier, semi-automated way of providing 100% coverage.

The system as a whole consists of the veo 16:64, a phased array flaw detector, a 64 element Corrosion WheelProbe and a CWP scanner. The Corrosion Wheel Probe is a tried and tested solution for corrosion mapping by many leading companies in the Pipeline and Oil & Gas sectors, hence the development of this system.

The scan width of a Corrosion WheelProbe (CWP) is close to 50mm in one pass and it can be used on pipe diameters from 4 - 42 inches. Importantly the conformable tyre allows excellent coupling to rough surfaces, and the design allows for consistent reliable

inspection in both depth and amplitude. This amplitude mode enhances the possibility of finding small pit type defects, which normally do not give a good ultrasonic response, however results show excellent indications of internal condition.

If you would like to know more about the CWP Scanning system or the up and coming exhibitions, please contact us via email - sales@sonatest.com - or via the Sonatest website wwww.sonatest.com.

PRODUCT SPOTLIGHT – DESCALING

ScaleWatcher Enigma Maintains Maximum Efficiency in Water Heating and Cooling Systems Hard water costs Industry £billions a year in lost production, early renewal of capital equipment, chemicals and increased energy costs.

Just 3mm of limescale reduces energy efficiency by a staggering 21%. Hard water has massive negative impacts on Sustainability. Additionally hard water results in increased Heath & Safety risk, including Legionella.

Since 1989, Scalewatcher ENiGMA has pioneered nonchemical treatment, introducing the world’s first patented electronic descaling system. Working with universities, water companies & industry, plus continuous investment in R&D, has given us specialist knowledge in the practical application of this technology.

Scalewatcher ENiGMA helps to maintain maximum efficiency in water heating and cooling systems. Satisfied customers include the John Lewis Partnership / Waitrose, MoD, St Thomas & Guys Hospital Trust, Southern Water, Barchester Care Homes.

Environmental Treatment Concepts Ltd 7 Funtley Court, Fareham PO16 7UY Tel: 01329 836960 www.electronicdescaler.com Email: info@electronicdescaler.com

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SELF CONTAINED LOW COST NON CONTACTING LEVEL MEASUREMENT Pulsar’s IMP range of level control devices are ideal where space is restricted or manual checks have traditionally been used.

They are compact and versatile and come complete with a combined transducer and controller in one self contained unit for reliable fit and forget measurement of virtually any liquid or slurry in tanks and containers from a few cm’s to 10 m deep. An analogue output is dedicated to level, it can be loop powered or 3 wire.

Digital readout provides instant and reliable continuous measurement and tank status data.

I.S. to ATEX and IECEx option available.

Can be easily retrofitted or integrated into older installations via simple keypad instructions.

Pulsar Process Measurement Ltd., info@pulsar-pm.com | www.pulsar-pm.com Tel: +44 (0)1684 891 371

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CONDENSATE MANAGEMENT

BEKO TECHNOLOGIES RANGE OF

SPECIAL CONDENSATE DRAINS BEKO Technologies are world leaders in condensate management, beyond our standard range of BEKOMAT’S BEKO Technologies offer a number of special condensate drains to suit applications that are not adequately covered by the other products in the market.

BEKOMAT explosion proof models with ATEX approval are designed for use in explosive, hazardous locations such as off shore, chemical plants and power plants to name a few.

The vacuum version of our BEKOMAT condensate drains have been designed specifically for the discharge of condensate or other fluids from vacuum systems. Additionally, these condensate drains can also be used for technical processes under standard atmospheric conditions. They extend the scope of application of BEKOMAT devices to include pressure from 0.1 to 1.8 bar (abs).

In the case of multistage rotary compressors, the condensate from intercoolers must be reliably removed otherwise it will get into the next compressor stage. The consequence: a slug of liquid hitting the impeller. With the BEKOMAT LA/ LALP range damage to the later compressor stages can be prevented.

The BEKOMAT 8 and 9 condensate drains are for large volume compressors. They are particularly used in crude oil installations and refineries, the petrochemical industry and the chemical engineering sector.

High pressure BEKOMAT’S up to 63 bar can also be supplied be BEKO to suit applications in many industries using high pressure compressed air.

For more information please call our technical team on: 01527 575778 or visit our website at www.bekotechnologies.com.

NON CONTACT MEASUREMENT

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PRODUCT SPOTLIGHT – INDUSTRIAL MAINTENANCE BOOKS

PRODUCT SPOTLIGHT – CENTRIFUGAL PUMPS

“SWEET” SUCCESS Three new Gorman-Rupp Super T Series Self priming Pumps have been installed at a confectionary production factory.

UK Distributors of Gorman-Rupp Pumps, Hydromarque Ltd, have supplied three pumps to replace existing pumps that were fitted with external priming devices.

The Gorman-Rupp Super T Series Self Priming pump has an integral priming chamber that removes the need for external priming devices, thus reducing maintenance and running costs.

The pumps have been installed in stages, doing one at a time and are all now pumping chocolate effluent from a sump approximately 4 metres deep.

Initially the client was sceptical about using this type of pump, however, following various visits to Anglian Water sites where there are hundred’s of these pumps in operation and on a lot more arduous duties that they required, they agreed to try the first pump and have never looked back since.

The Gorman-Rupp self priming Super T Series pump is designed for trouble free operation and has superior

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solids handling capabilities, which makes them suitable for a variety of applications. The large volute design allows automatic re-prime in a completely open system without the need for suction and discharge check valves.

Maintenance has been greatly improved at this site due to the ease of servicing this type of pump. Servicing can be carried out using common hand tools without disconnecting any pipework. The Impeller, seal, wearplate and flap valve can all be accessed through the shimless coverplate opening, easily removed with a grip handle and pusher bolts.

For more details contact: tellott@hydromarque.com or visit our website at www.hydromarque.com

PRODUCT SPOTLIGHT – CENTRIFUGAL PUMPS

STERLING-SIHI HAVE THE POWER… …TO SAVE YOUR ENERGY the gains to be had, many manufacturing sites do not adopt

Somebody recently suggested that

energy saving practices. Why? Resources!

Pumps typically account for 20%

components all takes time – not to mention capital expenditure

of a manufacturing plant’s total

already working with a number of manufacturing sites, gathering

energy costs, though it could be argued that this percentage is likely to vary (depending on the nature of manufacturing involved). However, most people will agree, that RotaDynamic (Centrifugal) Pumps are a MAJOR power consumer.

Researching the plant history, designing a system and selecting (which needs to be justified). This is exactly why Sterling-SIHI are data, taking a joint approach to Whole-System-Savings (WSS) and measuring Key Performance Indicators (KPI’s).

Sterling-SIHI’s dedicated team work to the following principles: •

Define the pumping system’s present duty

•

Establish the real need

•

Investigate where the main points of energy losses exist

•

Reduce energy losses accordingly

•

Fit the supply (pump-and-system) to demand (process)

Underpinned by the Department of Energy in the US, the system approach has proved successful for many years. Here in the UK, The British Pump Manufacturers Association (BPMA) is working

Sterling-SIHI has invested into an understanding of exactly

with the same model in which to deliver concrete results – which

where power is (a) useful - as in 100% efficient, (b) consumed,

means site savings.

and (c) wasted through system absorption.

Collaborating with Sterling-SIHI not only enables staff to focus on Pump efficiency is a conventional element of Research &

their core duties, it also ensures that investments can be justified

Development, but significant improvements in hydraulic design

by real and reliable data. Moreover, an accurate calculation

will still only save a manufacturing site a fraction of its energy

of ROI (Return on Investment) is made possible, and simple,

bill. A full system approach must be utilised in order to conserve

because all Sterling-SIHI data is supported by time-scales.

energy.

Evidence can be seen within the Sankey diagram,

below.

Additionally, not only does the WSS approach give a pump-using facility the ability to save energy, Sterling-SIHI can demonstrate

Sounds easy, doesn’t it? Adopt a full system approach and

that it will also improve machine reliability, inventory levels, and

reap the benefits (efficiency and savings)… However, despite

overall process efficiency.

Please contact Sterling-SIHI for more details.

Sterling Fluid Systems (UK) Ltd Telephone: 0161 928 6371 Email: uksales@sterlingfluid.com

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LEAK REPAIRS

BELZONA PROVIDES AN INNOVATIVE SOLUTION TO TRANSFORMER LEAK REPAIRS Belzona Polymerics Limited, providing solutions to industry for over 59 years through the design and manufacturer of polymer repair composites and industrial protective coatings has demonstrated a solution to repair transformer leaks.

Authorised contractor of Belzona, C & D Environmental Co. Ltd was recently looking for a reliable leak repair solution for a Power Station in the UK. One of the Power Stations major transformers on an aluminum smelter plant had an oil leak. The transformer was critical to the overall smelter plant and should it unexpectedly fail, the production area would come to a standstill resulting in lost production and downtime.

On further inspection it was found that the base of the transformer was heavily corroded in one corner. Before determining the best solution, there were some major obstacles to overcome, firstly due to time constraints the oil could not be drained from the transformer during the application. Secondly conventional methods of surface preparation could not be used as to the walls of the transformer were thin and have suffered considerable corrosion.

Taking this into consideration, Belzona’s engineers decided the best solution would be to fabricate a tray that could be bonded to the corroded area on the underside of the transformer creating total encapsulation of the fins preventing future corrosion.

The internal surfaces and edges of the tray were prepared using an MBX Bristle Blaster. The pin hole leak on the corroded transformer base was plugged to stem leak using Belzona 1291(ES-Metal) a rapid curing, emergency live leak sealing putty stick. The bottom vertical edges and base of the transformer where thoroughly cleaned and

degreased using Belzona 9111 (Cleaner/Degreaser).

The tray and transformer edges were then wetted out using Belzona 1831 (Super UW Metal), a surface tolerant product which can be applied to wet and oily surfaces.

The product was mixed and a 30mm fillet was applied around the internal 90 degree edge of the tray. The tray was offered up to the base of the transformer and held into position using ratcheted straps allowing the fillet of Belzona 1831 (Super UW Metal) to seal the base.

The top lip of the bonding plate and top edge of the transformer base was then finished off with Belzona 1831(Super UW Metal).

Finally a corrosion resistant coating, Belzona 5831 (ST Barrier) was applied to the underside of the tray, the edges and transformer lip to protect repair from environmental damage and further degradation.

www.belzona.com Belzona Polymerics Limited Claro Road, Harrogate, HG1 4DS e: lsmith@belzona.com t: 01423 567641 | f: 01423 505967

PRODUCT SPOTLIGHT - DRY LUBRICATION

PRINCES GATE SPRING WATER – NATURALLY RESPONSIBLE! “I have never seen such a large improvement on a production line with just one single counter measure. Dry lube has been like flicking a switch on our lines and has had an immediate impact on our efficiencies. We are probably yet to realise them all as we have further improvements to make but this has been tremendous.”

Endaf Edwards, Operational Manager at Princes Gate Spring Water Ltd The award-winning Princes Gate Spring Ltd supplies its natural water sourced from organic land to major UK retailers such as Tesco, Asda and Waitrose. Located alongside a modern state of the art bottling plant the spring provides the ideal source for producing still or sparkling spring water.

Since a product relaunch in 2007 Princes Gate’s sales have grown significantly year on year gaining new markets around the UK. Accompanying the growth of the business has been the on-going environmental improvement program which has resulted in reduced electricity usage by 30%, oil use by 10% and carbon emissions by 45%.

Dry Lube Ltd is pleased to help Princes Gate to achieve these results. The state of the art dry lubrication system on site has dramatically improved bottle stability and increased

line performance. In addition Princes Gate has been able to achieve a considerable improvement in energy savings and extended belt life expectation.

For more information please contact: Julia Heyse Marketing Executive at Dry Lube Ltd Jheyse@drylube.co.uk 0044 131 240 1292

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PRODUCT SPOTLIGHT – FLOW METERS

ENGINEERED VALVE SOLUTION FROM AQUAFLOW A framework contractor working on behalf of United Utilities contacted T-T’s division Aquaflow to help them solve a problem of four persistently problematic valves which had become costly to maintain.

The four DN800 tilting disc check valves, manufactured by a nominated framework valve holder, had been installed within a critical pump house which serves the regions water supply. Aquaflow worked closely with the site representatives and, a number of serious installation issues were identified including incorrect valve sizing and poor valve design which had lead to increased wear and a reduced lifespan.

Following a consultation and reappraisal of the hydraulic parameters Aquaflow supplied four engineered replacement DN600 slanted seat check valves. These chosen valves had slanted seats for improved performance characteristics and to reduce the negative effects associated with slamming, each valve is fitted with a fully maintainable stainless steel integral damper mechanism. The design of such allowed for the disassembly of the damper mechanism without the costly removal of the valve from the line.

Being the manufacturer Aquaflow,had full control over the design, therefore was able ensure that all materials were

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carefully selected and suitable for the application and a trouble-free operation, with a long efficient lifespan. The work ran very smoothly and to schedule and, the water company were left extremely satisfied.

Aquaflow supply a wide range of waterworks valves with many ranges having third-party WRAS approval for potable water networks. As part of T-T we are also able to offer complete actuated valve packages including bespoke electric control panels and monitoring systems. Visit our website, www.ttpumps.com to discover our diverse product range, and to see what we can do for you.

For further information please contact our sales team Tel: 01630 647111 e-mail: response@ttpumps.com Website: www.ttpumps.com T-T Pumps Ltd, Onneley Works, Newcastle Road, Woore, Cheshire, CW3 9RU

PRODUCT SPOTLIGHT – FLOWMETERS

INSPIRING FLOW SENSOR TECHNOLOGY Sensirion CMOSens® flow sensor technology is most effective at the lowest flow rates.

Based on a thermal principle, Sensirion’s liquid flow products benefit from digital microsensor technology which offers totally media isolated flow sensing down to nanolitres per minute.

The SLG1430/ALS1600 family offer extremely sensitive and fast measurement of liquid flows down to nanolitres, with a typical repeatability of 1% of reading. Over pressure ratings of up to 350 bars are also available. All flow meters measure non-invasively with exceptionally short response times in the millisecond range. The integrated straight flow channels are made of 100% glass to ensure excellent chemical resistance and biocompatibility. The absence of any moving parts ensures maximum reliability.

For hydrocarbon based liquids the SLQ-HC60 with its IP65 rating is an ideal choice for industrial process applications.

It can also be used to detect clogging, leaks and bubbles.

The 0-10V output signal corresponds to flow rates up to 100ml/min.

Sensirion products are available in the UK from APC Hero.

For more information on Sensirion products contact; John Kain APC Hero, Phoenix House, 2 Phoenix Park Eaton Socon, St Neots, Cambs PE9 8EP Tel; 01480 226656 | Fax; 01480 218752 johnk@apc-hero.co.uk | www.apc-hero.co.uk

PRODUCT SPOTLIGHT – GAS TURBINES

LEARN FROM THE GAS TURBINE EXPERT DR. MEHERWAN P. BOYCE, PHD, P.E., C.ENG (UK) DR. BOYCE, BEST-SELLING AUTHOR, CONSULTANT, AND DEVELOPER OF THE FIRST TOTAL CONDITION MONITORING SYSTEM (MECHANICAL & AEROTHERMAL), WILL PRESENT TWO LIMITED ENGAGEMENTS IN LONDON IN 2011.

Improving Efficiency, Productivity and Reliability of Centrifugal Compressors and Gas Turbines July11-13, 2011 Advanced Technology Gas Turbines & Planned Optimization of Combined Cycle Power Plants November 22-24, 2011

A world recognized expert in gas turbines, centrifugal compressors, and combined cycle power plant systems, Dr. Boyce has designed systems for offshore platforms, refineries, natural gas facilities, pipelines, and power plants. Major corporations, the EPRI, and the U.S. Department of Energy consult with Dr. Boyce on designing and recommending systems.

Dr. Boyce’s short courses are interactive and provide practical information with minimal theory. Participants are encouraged to bring challenges specific to their environment for Dr. Boyce to solve. Total Condition Monitoring and turbine and compressor characteristics are discussed in-depth.

Secure your spot today! www.boyceconsultancy.com 2121 Kirby Drive, Houston, TX, 77019, USA 1-713-807-0888 zmboyce@boycepower.com

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INSULATION AND CONTINUITY TESTERS

MEGGER MAKES INSULATION TESTING SAFE FOR INDUSTRY In industrial applications where high-energy transients in electrical supply systems are by no means uncommon, Megger’s new MIT400-range of insulation testers with their Category IV 600V rating in line with IEC61010, provide users with and invaluable extra level of safety.

Safe to use in all normal service and maintenance operations, even close to the source of supply where transient levels are highest, MIT400 testers feature exceptionally rugged construction that ensure long reliable service even in demanding industrial environments.

Despite their tough construction, the testers are sufficiently compact to allow easy one-handed operation with either hand. Designed from the outset to be fast and easy to use, all models incorporate a convenient dual digital display, plus an analogue arc.

The main display shows the principal parameter being measured – for example, insulation resistance – in both digital format and as an analogue arc, while the smaller secondary display shows a related parameter – for example, insulation test voltage – as a digital value. Users therefore save valuable time by measuring two parameters with a single test.

In addition to versatile insulation testing facilities, MIT400 insulation testers also offer timesaving fast-response continuity testing and true RMS voltage measurement that provides accurate results even when the supply waveform is non-sinusoidal.

For industrial applications, Megger offers its new MIT400 testers in four versions.

The entry level MIT400 provides insulation testing at 250V, 500V and 1,000V, together with continuity testing and voltage measurement. The MIT410 adds 50V and 100 V insulation tests, as well as fully automatic measurement of dielectric absorption (DAR) and polarisation index (PI), while the MIT420 provides all of the facilities of the MIT420

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plus internal storage for test results. Stored results can subsequently be recalled to the screen to allow easy recording.

At the top of the range is the versatile MIT430, which not only stores test results but also allows them to be transferred to a PC via a Bluetooth wireless connection.

This arrangement completely eliminates the need for data cables, and also guarantees total electrical isolation between the instrument and the PC to which the data is being transferred.

Special-purpose MIT400 models are also available for insulation testing at low voltages, for example on sensitive IT systems, and for applications in telecommunications systems.

For further information: Mark Johnson, Megger Archcliffe Road, Dover, Kent, CT17 9EN Tel: +44 (0) 1304 502100 Email: mark.johnson@megger.com Web: www.megger.com

A BOLT TENSION SOLUTION THAT CAN REPLACE TORQUE The industry has recently recognized the importance of the tension of fasteners and this will challenge some of the torque tightening practices that exists today as the industry matures and adopts more sophisticated technology to both improve reliability and reduce maintenance costs thus improving the economies of electricity production from wind turbines.

Bolts can be installed in one of two ways: By torque tightening or by hydraulic tension tightening.

Torque tightening Torque is the rotational force applied to a lever, multiplied by its distance from the centre of the tightening end (fulcrum). The force is measured in Nm or lbs/ft. Torque tightening rotates the bolt head or nut to tighten and stretch the bolt to clamp two surfaces together. Hydraulic torque wrenches allow the operator to control the torque applied and are used extensively to tighten wind turbine bolting.

It is simple to use, however, this technique suffers from inaccuracy due to inconsistent friction. Even on lubricated threads and nuts, the level of friction is uncontrollable. This means there is a critical lack of tension control that can lead to bolt failure, and ultimately, joint integrity being compromised.

Hydraulic tensioner tightening Hydraulic tension tightening is also used to tighten (large diameter bolts on) wind turbine boltings. The tightener pulls the bolt axially by means of a hydraulic piston. When the bolt is stretched by a specified amount, the nut inside the tensioner becomes raised off the flange creating a gap between the flange faces. The gap is closed by tightening the nut and when the hydraulic pressure is released, the tension is transferred to the bolt and the flange.

During this process tension loss occurs (“load transfer relaxation”). To compensate for this loss, the hydraulic

pressure originally applied is increased (“hydraulic overload value”). However, the amount of load transfer relaxation cannot accurately be predicted and varies from one bolt to another. Hydraulic tensioners are therefore unable to control, or measure the tension, that has been achieved for each bolt and also unable to provide an in-service reliability check.

A bolt tension solution Innovative engineering has come up with a bolt that indicates when the specified load/tension has been achieved during tightening. James Walker RotaBolt developed the RotaBolt® system to provide a simple and effective measure of the real load/tension in a bolt. The RotaBolt® can be used in either torque or tension tightening. When a RotaBolt® is tightened, the cap locks at exactly the right amount of preload in the bolt. This allows for more control during tightening whilst ensuring that the customer’s design criteria are met independently of the tightening system. It also enables bolt reliability status to be instantly checked in service; something that the traditional bolt retightening checks are unable to achieve.

All RotaBolt® fasteners are guaranteed (consistently) to indicate within ±5% of the specified (selected) load regardless of environmental influences. Its accuracy is not affected by friction, as in torque control, or by load transfer errors, as in hydraulic tensioners.

This bolt tension solution can ensure joint integrity on wind turbines. Joint integrity, in turn, allows for greater reliability and the more efficient production of renewable energy for the future.

For More Information: James Walker SPS Ltd Tel: +44 (0) 7595 202 928 E: nigel.stansfield@jameswalker.biz Website: www.jameswalker.biz/windenergy

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PRODUCT SPOTLIGHT – ONLINE CONDITION MONITORING

CONDITION MONITORING SYSTEM DEDICATED FOR WIND TURBINES 01dB-Metravib have been in the field of condition monitoring for over 20 years, OneProd solutions deliver reliability for wind energy from a GL-certified CMS, to project management, and up to 24/7 monitoring.

Condition Monitoring System dedicated for wind turbines • OneProd Wind System puts vibration analysis at play to monitor the health of wind turbines and establish diagnostics to anticipate failures.

• Its specific methodologies and algorithms are combined with the unique parameter ShockFinder to get reliable and easy-to-read information.

• Its power of analysis make OneProd Wind System a powerful diagnostic tool with remote access to all data.

• The system architecture can be adapted to all wind farms with reliable wired or wireless communication.

Scalable services If you are looking for quick results, scalable services can be proposed : • Management of the monitoring engineering, set up

• • •

and commissioning Training, expertise, monitoring and analysis services to boost to results Performance-based contracts gauged upon your operations indicators.

LiveProd offer covering equipment and monitoring services for a monthly fee Web site: www.oneprod-system.com General info Email : OneProd@areva.com Telephone: +33 (0) 4 72 52 48 00 Fax number: +33 (0) 4 72 52 47 47

ON-LINE PARTIAL DISCHARGE SOLUTIONS Protect Your High Voltage Assets and Ensure Employee Safety

**New** the PDSurveyor™ Handheld Product Benefits PD Test Family, designed for rapid, on• Simple-to-use, 10-second test line insulation condition assessment • Economical, handheld ‘PD of medium voltage assets, providing ‘First-Line-of-Defence’ against MV Screening’ tool insulation faults.

• Assists in the efficient direction Suitable for the rapid ‘PD screening’ of large numbers of MV assets, including • switchgear, cables, transformers and rotating machines).

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of MV plant maintenance Focuses resources to the plant with the highest failure risk.

HVPD specialise in on-line PD test and monitoring technology and provide PD test services to our global client base. E-mail us to discuss your requirements: info@hvpd.co.uk HVPD Ltd Manchester, UK www.hvpd.co.uk Tel: 0161 877 6142

PRODUCT SPOTLIGHT – ONLINE CONDITION MONITORING

MONITORING SYSTEMS With Optional Internet Connection

iBOX datalogger system with very powerfull features: • • • • • • • • • • • • • •

Ethernet/Internet connection Embedded webserver Customised systems Up to 32 inputs/outputs (16 bits) Counters, Analog, Status etc. inputs Remote Controlable Switches Alarms (contact/email) Local connection: Wired or WiFi Remote Wireless Access via GPRS/3G/VPN Optional online graphs and webdisplays Data automatically via FTP to server SD Card for data collection Ultra low power Field versions for remote sites Export to 90 countries, since 1983.

See our website for additional information: http://www.ekopower.nl engineeringmaintenance.info August 2011

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PRODUCT SPOTLIGHT - HEAT TRANSFER

97% OF PHE GASKETS FROM STOCK WITH NEXT Thanks to a reorganisation of their Parts & DAY DELIVERY Service division, heat transfer specialists Alfa Laval Limited are now able to offer ex-stock, next day delivery of 97% of their Plate Heat Exchanger (PHE) gasket range – a promise that no other UK- based supplier can match.

Alfa Laval are by far the largest supplier of gasketted heat exchangers to industry in the UK & Ireland. Covering 6000 square metres of their Camberley Headquarters, their workshops have the capacity to re-gasket and recondition 54,000 large PHE plates every year.

Recently, Alfa Laval have upgraded their inventory replenishment systems to match the quality of their product and service offering.

“Speed is vitally important to our customers because a

leaking PHE can mean product losses running into the thousands.” says Julie Knight, Parts & Service Divisional Manager at Alfa Laval. “That is why we have worked hard to make sure our gasket delivery service matches our products in terms of quality. As an OEM, we identify every PHE and gasket instantly by its serial number and can confirm at once whether or not it is in stock. Any item that has been picked more than three times in the preceding 12 months automatically becomes available for delivery from . Consequently, 97% of our gaskets are now available for next-day delivery.”

Alfa Laval Ltd, 7 Doman Road, Camberley, Surrey, GU15 3DN, United Kingdom Tel +44 1276 633 83 Fax +44 1276 6850 35 www.alfalaval.com | general.uk@alfalaval.com

PRODUCT SPOTLIGHT – HEAT EXCHANGERS

ALLEGHENY BRADFORD SHELL AND TUBE HEAT EXCHANGERS WE SET THE INDUSTRY STANDARD! Allegheny Bradford is the world leader in manufacturing sanitary shell and tube heat exchangers. They are the most innovative and best in the market.

ABC custom designs every heat exchanger to meet your exact application requirements. We design straight-tube, U-tube and coil heat exchangers. Our state-of-the-art fabrication technology uses high-pressure hydraulic expansion to seal the tube-to-tube sheet joints. This reduces the risk of roller expansion damage, as well as work-hardening effects and excessive thinning of the tubing. In addition, our proprietary integrated double tube sheet virtually eliminates tube-to-tube sheet joint stress.

The result is consistent performance, reduced maintenance and extended equipment life. ABC heat exchangers are 100% ASME BPE compliant. Prior to shipment, every heat exchanger undergoes rigorous QA/QC stringent testing and we provide comprehensive documentation and turn-over packages.

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Please Contact ABC for a quote Allegheny Bradford Corporation 16 Valley Hunt Drive, Lewis Run, PA 16738, U.S.A Toll Free: 800-542-0650 | Phone: 814-362-2590 Fax: 814-362-4674 sales@alleghenybradford.com www.alleghenybradford.com

PRODUCT SPOTLIGHT – HEAT EXCHANGERS

SMALLER-DIAMETER MICROGROOVE COPPER TUBES YIELD MAJOR ADVANTAGES The use of smaller diameter copper tubes is yielding major benefits to the end users of air-conditioning and refrigeration products. Less tube volume reduces the refrigerant in the system. Reduced tube wall thickness results in weight savings.

Improved heat transfer results in higher local heat transfer coefficients, allowing the same performance to be realized with less surface area; hence less tube, less fin and less refrigerant; and also less coil size and weight.

The MicroGrooveTM advantage could be summed up as follows: • Higher performance can be obtained using the same weight of fin and tube materials and less refrigerant volume.

• Equivalent performance can be obtained using less tube material, less fin material, less refrigerant and hence less overall system size and weight.

Visit www.microgroove.net for information about the advantages of smaller diameter, inner grooved copper tubes in ACR applications.

PRODUCT SPOTLIGHT – CNC BOOKS

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PRODUCT SPOTLIGHT – INDUSTRIAL FANS

RECORD BREAKING FAN NOISE CONTROL Faster, cheaper and more effective than silencers...

Conventional silencing seemed slow and inefficient to Formula One’s Red Bull. They found an alternative in our award winning aerodynamic noise control technology. Installed within a pitstop window of a few hours, it eliminated the problem at source (30dB) for the lifetime of the fan, without maintenance and without affecting fan efficiency.

“The INVC technique not only produced a fantastic result, but it’s also very satisfying as an elegant engineering solution” said Terry Brice of Red Bull Technology.

This is best available technology for a wide range of fan noise problems - faster fitting, lower cost and efficiency gains from reduced energy use compared with conventional silencing.

INDUSTRIAL CONVEYOR MAINTENANCE

EXCELLENCE EVERY INCH OF THE WAY Cooper Roller Bearings is the inventor and world leader in the design, manufacture and development of split roller bearings and has been leading the market for over 100 years.

With worldwide representation, vast experience and unbeatable know-how, Cooper is a full-service provider from bearing selection through installation, training to maintenance and repair.

Our manufacturing plant is in King’s Lynn where the reliability of Cooper products and business processes is underlined by ISO 9001, 14001 and 18001 accreditations as well as registration with Lloyds and BSI. The Cooper split roller bearing is a simple product that can save you huge amounts of money by reducing downtime and increasing productivity. The split feature means inspection and maintenance is cut to a minimum while the superior sealing promotes longer bearing life. As a result, your business profitability is increased.

When placing an order, engineeringmaintenance2011

please

Cooper Bearings Group Wisbech Road, King’s Lynn Norfolk PE30 5JX, England Tel.: +44 (0)1553 763 447 Fax: +44 (0)1553 660 494 Website: www.cooperbearings.com

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quote

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code:

Peter Wilson Industrial Noise & Vibration Centre 889 Plymouth Road, Slough Berkshire, SL1 4LP Tel: 01753 698800 | email: consult@invc.co.uk web: www.invc.co.uk

BUYERS GUIDE 2011

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BUYERS GUIDE 2011

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