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Maintenance Best Practice

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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


It May Be The Festive Season But Drugs And Alcohol Definitely Do Not Mix With Road And Workplace Safety The festive season brings heightened awareness of the need to ensure that anyone driving or operating machinery and process plant is not doing so under the influence of alcohol. As a senior police officer calls for the drink-drive limit to be reset to zero, Draeger Safety reminds employees and their employers of the dangers of drugs and drink driving during the Christmas and New Year festivities. Where drugs and alcohol are involved, the morning after the office party or a lunchtime meeting with a customer could mean the loss of a driving licence and be the cause of a serious accident. For a business it could lead to the loss of a valued employee or, depending on the work involved, even the loss of a hard earned corporate reputation. According to reports, Deputy Chief Constable Suzette Davenport, who is responsible for policing the roads of England and Wales, feels that a change to a zero limit would drastically reduce the number killed and seriously injured on the

4 November/December 2011

UK’s roads each year. The news came as the Association of Chief Police Officers launched its Christmas drink-driving campaign. It is expected that thousands of tests will be carried out on drivers in the run up to the Christmas break and that, in particular, breath-tests will be carried out in the morning in an effort to stop people from driving after a heavy night’s drinking. Ensuring easy, quick, non-invasive testing, Draeger offers a range of hygienic drug and alcohol measuring systems. Ideal for use in any breath alcohol measuring application, the Draeger Alcotest 6810 is simple to use.

Accurate and reliable, it can be operated within six seconds of start up and provides up to 1500 measurements with just one pair of AA batteries. For drugs testing, the Draeger DrugTest 5000 drug detection system detects six different substance categories and is ideal for use in screening, for cause and/or post incident applications in accordance with current health and safety legislation.

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


Reliability and Maintenance Management Current Best Practices Part 1 You have been told you that your maintenance cost as a percent of estimated replacement value (ERV) is 4.6% and that this is too high. Best performers, you are told, should have maintenance cost lower than 3% of ERV. (Our database shows that the average maintenance cost as percent of ERV in the process industry is 4.2%.) So, now what do you do about this?

COMPARING MAINTENANCE COSTS. Before we discuss what you can do, I would like to discuss the reliability of maintenance cost comparisons between plants. During the last year, I have worked with two companies that were competing in the same market segment with the same products. For years, cost comparisons, including maintenance costs, had been made between the two companies’ plants. One company’s plants always had the lowest maintenance cost per ton. Then, these companies merged and “overnight” the maintenance cost for the company with the lowest maintenance cost per product produced went up 50%! The reason for this increase was different guidelines for what maintenance to expense and what maintenance to capitalize. The company with the lowest maintenance cost per ton capitalized as much as they could, while the other company expensed as much as they could. When new guidelines were applied, the “low maintenance cost company” was told to follow the “high maintenance cost company’s” guidelines, so, instead of a maintenance cost of $60 per product produced, its cost was now close to $90 per product produced.

ESTABLISHING A RELIABLE ERV. A reliable ERV is equally difficult to establish. To make an attempt for getting it as close to right as possible, you need to go back to the original investment of the mill. Then, you have to decide what index to use for estimating current replacement value. After that, you need to cluster all investments and divestments, for example, in a three-year time period. When all this is done, you can calculate ERV. Well, I know that you will have to live with all these cost comparisons, and you will continue to argue over why they might be right or wrong. If the numbers are right and used for trending your own performance, they can be useful. The most important matter will still be to do something about improving your

competitiveness and your productivity. So, whatever way you have been measured and compared, you will have to develop an action plan and then execute this action plan to improve the numbers used to compare you.

DEFINING CURRENT BEST PRACTICES. You can name maintenance any three-letter acronym you want, but if you break the maintenance function down to its elements or practices, you will soon notice that they will all have to be done in an efficient manner to deliver better performance. So, what are these practices? Many years ago we defined all these practices and have used them to evaluate and identify maintenance improvement opportunities in hundreds of maintenance organizations all over the world. Recently, we sat down again with corporate management of a major international company to define all these practices. To no one’s surprise, these practices were the same as 30 years ago. It must be explained that these practices only describe WHAT the best practices are, the execution—or HOW—can vary between plants and also within plants. I think it can help many organizations to describe some of these practices. It can help you understand the complete maintenance process. You can also use it to educate others and to describe job responsibilities. We use it to uniformly evaluate essential reliability and maintenance processes. We call them current best practices (CBP) to indicate that this is the best way we know currently—the future will find better practices. If you want to develop your own CBPs, I advise you to start with structuring the whole concept into key processes, then sub-processes, and then elements of these sub-processes—elements that are the ones we call CBPs. When you perform this exercise down to the CBPs, you will soon notice that you are back to the very basics of maintenance such as alignment, balancing, filtration, operating practices, etc. It is still on this level that improvements need to be done in order to increase reliability and lower maintenance costs. November/December 2011


MAINTENANCEINDUSTRY BEST PRACTICE NEWS The key processes we identify include: leadership, support facilities, preventive maintenance, planning and scheduling, materials management, technical database, skills development, etc. For a copy of CBP material, please contact me. In the following columns, I will explain some of the CBPs in detail. To give an example of what could be included in a key process, I would like to describe how Part One of the Planning and Scheduling CBP is structured. The complete Planning and Scheduling CBP includes: 1.

Work request




Back log management



process is identified according



to the recognized maintenance




How the work affects the






CMMS tool


Workflow process is followed.

Contractor management


Known safety requirements are


Work request is validated.

identified. Together, these sub-processes comprise about 100 elements.

PLANNING AND SCHEDULING CBP: PART ONE. The following is an example for Part One of the Planning and Scheduling CBP, which is the work request. The minimum requirement for a work request includes: 1.

Work request is submitted in a computerized maintenance management system (CMMS) and has a work request ID number.



4. 5.

An accurate requested priority is

10. Work request can be entered by anyone in the plant. 11. Work requests are filtered and collected at a central point. Use the aforementioned elements to evaluate your own practice in this initial part of planning and scheduling. Make sure you focus on how well the above is actually executed and not just on how you had intended to execute it. Let me know if you score yourself better than 75 on a scale of 100. To score at least 75, you must be able to answer “yes” to all of the following questions: 1.

Documentation of process

assigned according to the existing

exists. It is communicated to all

guidelines for priorities.

involved in the process.

Equipment number, originator,


Process awareness is evident

description, and/or location is

at hourly workforce level and

assigned and verified.

among all requestors.

A good work description and/or


Process is understood and

observed symptoms are recorded.

viewed as value added at all

Preliminary work order type

levels of the organization.

should be defined as either corrective maintenance or system improvement (expense or capital work).


True execution of the process is occurring.

It is common to find that very little of the above is documented in a work request.

Above: Figure 1 It is more common to find “pump not working” followed by “fix immediately” as the only verbal or written information. It is also important to note that the beginning of a maintenance job is called a work request - not a work order. Such a designation suggests that there is no guarantee the work will be done just because someone initiated it. This is an obviously necessary procedure if you want to control costs and prioritize work in the best way. The chart above (figure 1) shows an example of scores for all planning and scheduling sub-processes.

Reliability and Maintenance Management Consultant Idhammar is vice president of IDCON, Raleigh, NC, a reliability and maintenance management consulting firm, specializing in education, training and implementation of improved operations, reliability, and maintenance management practices. Feedback on this reliability article is appreciated. Send to For plant maintenance consulting information. Please call: (919) 847 8764 Visit: November/December 2011



Belgravium Technologies And Key Computers Sign Joint Marketing Agreement To Promote Their Best Of Breed Solution To Service Management And Other Sectors

Gary Jones, Sales Director at Key Computers explained why the company

Panasonic Electric Works introduces a new SC-GU Series

Leigh, Manchester : 17th October 2011. Key Computers is pleased to announce the formation of a strategic marketing alliance with Belgravium Technologies, leading specialists within the mobile computing and wireless communication markets. Both companies have committed to providing a best-in-class IT solution for the service management industry and the formation of the alliance will see Key Computers promoting Belgravium’s hardware solutions to the field service market alongside their best of breed mobile workforce software solutions. The diversity and flexibility of both the Belgravium hardware and Key Computers software will allow the partnership to extend its reach into other applications such as field sales, general logistics, construction and healthcare.

Peter Marsh, Sales Director for Belgravium comments, “We are delighted to have formed a working relationship with an established company like Key Computers. This arrangement will enable users within the UK service management market access to a true end-to-end solution that will facilitate the efficient management of their business cycle, from lead opportunities, sales order processing and delivery through to invoicing. The wealth of experience, professionalism and extensive functionality of the solution will provide real benefits to all our customers”. Working closely with Belgravium, Key Computers will help develop joint commercial opportunities through their wide network of sales and industry contacts.

Open Network Sensor Communication Unit from Panasonic

communication unit that allows a range of Panasonic sensors to interface to Open Networks that include CC-Link and DeviceNET

The SC-GU3 series Communication Units allows various Pansonic FibreOptic, Laser and Pressure sensor products to interface to the following open networks had decided to add Belgravium’s product to their existing hardware portfolio; “The past decade has seen Key Computers grow steadily and sensibly. Our strategic aim is to become the leading provider of bespoke mobile computing software solutions within a variety of sectors, in particular field service and logistics. These sectors are still yielding a significant number of new projects and, in order to capitalise fully upon these opportunities, we have to present potential customers with world class product offerings. We were aware of Belgravium’s standing in the AIDC marketplace and, after a closer evaluation of their hardware, decided to formally offer the range as our preferred hardware solution. The quality of the product is self-evident and we are confident that, when combined with our own exceptional software, end-users will be delighted with the overall data capture solution.”




Up to 16 individual sensors can be addressed by each communication units allowing •

Reading/monitoring of Digital and Analogue Values

Modification of sensor setup parameters

Reduction in wiring and installation time.

For more details on this product and the range of Panasonic Sensor Products please contact Panasonic Electric Works UK Ltd on:


01908 231 555


or email: November/December 2011


10 November/December 2011


New emergency device for safe load lowering in the event of mains power loss As part of an ongoing safety evaluation for all their products, J D Neuhaus have introduced an emergency lowering device for their EH range of air operated monorail hoists. With this feature JDN complies with the leading standards like NORSOK, specifying an emergency device for the safe lowering of loads in the event of a cut in the main power supply.

Ea Technology’s Switchgear Safety Conferences In Demand Due to unprecedented demand, EA Technology, technical authors of the Health & Safety Executive publication HSG 230 ‘Keeping Electrical Switchgear Safe’, will be hosting an additional switchgear safety conference on 6th December from its state-of-the-art facility in Chester.

Continuous vibration monitoring ifm electronic introduces vibration transmitter in stainless steel housing

Ideal for keeping an eye on things, the new VT stainlesssteel vibration transmitter from leading manufacturer ifm electronic Ltd monitors plant and machinery according to ISO 10816.

This new device supplements an existing fail-safe disc brake, which is activated in the immediate event of a mains power failure, ensuring that suspended loads are held safely and securely at their above-floor level until mains power is again made available. JDN monorail hoists with lift capacities from 25 to 60 tonnes can now be equipped with the latest safety development. This comprises an additional separate pressurised air reservoir tank (maintained at a mains air pressure of normally 6 bar), with a purpose built hand controller incorporating two additional pushbuttons. The controller provides positive two-handed lowering control, while eliminating the potential for unintended load movement. One button switches between normal and emergency lowering operations. The second button activates the integrated safety brake enabling the safe controlled lowering of a deadweight load. The air reservoir, which is protected by a check valve, is topped-up during normal hoist operations, and contains a sufficient air supply to complete a controlled lowering of a suspended load in the event of a loss of mains air pressure. Det Norske Veriras certification of the emergency device can be supplied where required. The NORSOK standard covers offshore cranes as well as power driven winches and hoists. JDN can supply handling equipment that has been purposed designed for BOP handling. Other essential machinery and even emergency escape products can also be safely and effectively handled, with the additional features of controlled load lowering even in the event of a total power failure. These JDN products are designed for working in hazardous areas and are supplied with Ex ratings for explosion risks. They are insensitive to humidity and dust while operating at temperatures from -20°C to +70°C. Instant starting, minimum maintenance and low air consumption are their positive features, coupled with compact low-headroom design. Standard features include lateral guide plates, emergency shut-off valve together with both anti-climb and anti-drop devices. Optional accessories include increased spark protection (and higher Ex rating), rack and pinion drive, overload protection, two speed trolley travel control and filter silencers. J D Neuhaus are a privately-owned company, founded in 1745, and for over 265 years they have been using their expertise and experience to manufacture the highest quality hoists, winches and cranes. Their products offer solutions to almost every material handling problem irrespective of the driving medium: from air, manual and hydraulic hoists up to complete crane installations with explosion proofness.

J D Neuhaus Ltd


Tel: 0044-2476-652500

Email: |

The Keeping Electrical Switchgear Safe (KESS) conferences have been designed to share best practice across the industry with industrial and commercial owners as well as distribution network operators and switchgear equipment suppliers. Over 1500 industry professionals have already attended these essential conferences, which cover switchgear safety in a detailed and easy to follow one-day structure. Delegates will gain a deeper understanding of how to apply best practices in the selection, operation and maintenance of electrical switchgear equipment, which will save companies time, money and potentially lives. The KESS conferences, which are regularly updated to ensure that all changes to legislation and standards are covered, focus on the complex issues surrounding HV switchgear maintenance and safety and the costly and potentially dangerous implications that poor switchgear management could have. Typically based around four key topics; legislation, day-to-day operation, maintenance and replacement or upgrade strategies, the extra conference promotes the application of best practice in relation to PAS 55 the emerging international standard for excellence in asset management.

The sensor measures the true rms velocity of non-rotating component surfaces, then transmits these values directly to the PLC as an analogue signal (4...20 mA). The unit is quick and easy to install. No extra parameter setting software is required, and to make life even easier, the VT is a two-wire looppowered device. With its robust design, high IP Rating as well as the maximum ambient temperature of 105 °C the sensor is suitable for use in harsh environments. Connection to the outside world is via an industrystandard M12 connector, with mating connectors in matching IP versions available from ifm. 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: Telephone: 020 8213-0000. Fax: 020 8213-2228. E-mail: or visit our website: November/December 2011



SIPOS software

Aids Sydney Water Filtration Scheme

Valve operation at an Australian Water Filtration Plant (WFP) at Nepean, 75km south of Sydney, will be supported by SIPOS Aktorik’s variable speed, electric actuators. Advanced actuation communication capability for SIPOS’ 5 Flash actuators was demonstrated to secure the contract for 60 units by local distributor, Barron GJM Pty Ltd. Located close to two dams, the Nepean WFP, owned by Sydney Water, incorporates a cluster of five filtration plants. Raw water is drawn from the Nepean dam and treated water is supplied to the townships of Bargo, Couridjah, Buxton, Thirlmere, Tahmoor, Picton and adjacent regions. An upgrade of the scheme’s 12 PLCs and SCADA system, comprising a primary and secondary server, is being implemented to enhance the speed of screen updates and reliability of the communication network. Commenting on how bus technology and software programming support for the plant’s SCADA control system addressed the technical considerations of the project, Weyand Magnaye, Water Products Manager for Barron GJM said: “Technical competency of the actuation solution demonstrated at the scheme also includes interlocking capability which, via Profibus, enables and disables the local push button functionality. Additionally, a failsafe function has been incorporated which ensures that, if a bus communication fault occurs, the actuation system defaults to an emergency position.” The order is the latest in a series of actuator commissions secured by Barron. Previous Sydney Water contracts for SIPOS actuators include a $150 million improvement programme at the North Head STP. SIPOS reports that any of its actuator installations for Sydney Water can be updated simply by uploading latest version firmware.

Green Gas International - Appointment Of New Chief Executive Officer Amsterdam, 14 October 2011: Green Gas International BV (Green Gas), an international leader in the production of clean energy and carbon credits from coal mine and landfill gas, announces that Joost Knoll will succeed Chris Norval as Chief Executive Officer (CEO) of the company, from 1 December 2011. The appointment will be formalized during the General Meeting of Shareholders, to be held on 2 November 2011. Joost brings to Green Gas 25 years of management experience, from a variety of industries. Over the past decade, he successfully lead the Hertel Group, first as an Executive Board Member and from 2003 as CEO, during which time the company achieved strong growth. Whilst at Hertel, a major contractor to the Oil & Gas and Energy industry, Joost gained valuable insight into the markets and customer requirements also faced by Green Gas. Before heading Hertel, Joost developed broad experience in waste management over a decade in various different roles at BFI, Waste Management and AVR. This included serving as a Director of several divisions of AVR, the undisputed waste management industry leader in the Netherlands. Derk Stikker, Chairman of the Board of Green Gas International B.V. said: “We are grateful for all the effort Chris has put into the company. Today Green Gas International is in a unique situation from where it has a very strong base from which to grow. During the past twelve months, we have restructured the company so that there are no barriers to benefitting from the existing platform and to taking the company to the next level. I am confident that Joost is the right CEO for this task.” Joost Knoll, CEO designate of Green Gas International B.V., added: “I look forward to building upon the strong foundations laid by Chris Norval. Green Gas already has a good track record in Europe, and is achieving strong growth in the Americas. I will be looking to build on this and to increase the overall scale of operations. Green Gas and its customers have enormous potential to benefit from the company’s unique propositon, namely: ‘Managing the entire methane to energy project: from the design, build and investment to successful operation.’ I’m very excited at the prospect of leading Green Gas and the business opportunities and potential the company has.” For further information, please contact: Marco van der Hijden | M: +31 (0) 6 233 69 005 | T: +31 (0) 20 570 2250 E: |

Mubadala Aerospace Takes Active Steps To Increase Emiratization At Najah 2011 18 October 2011, Abu Dhabi: Mubadala Aerospace is taking active steps to increase its Emiratization and is proud to be taking part in Najah 2011, the Education Training Exhibition and Career Fair taking place at ADNEC from 18th – 20th October. As part of the measures being taken by the UAE government to increase UAE National employment rates by creating an employment scheme which aims to ensure that 15% of positions in the private sector are filled by UAE Nationals, several of Mubadala Aerospace’s assets are taking part in the fair to announce their current job openings and career opportunities to encourage young Emiratis to consider a career in the aerospace industry. Committed to growing local Emirati talent and driving opportunity for the aerospace industry, Mubadala Aerospace’s assets form a global network of aerospace businesses that demonstrates world-class performance, creating innovative products, and delivering value-added services to its customers. The network of aerospace companies is offering many beginner and advanced roles in several different fields related to the industry and is able to provide local youth with a growing number of high-tech opportunities. Homaid Al Shemmari, Executive Director of Mubadala Aerospace, said that “We are delighted to be able to support Najah this year by having a presence at the fair. Our team at the stand will be on hand to explain the variety of the career opportunities across our portfolio of assets that are open to those attending; for entry-level job seekers, graduates and those with more experience in the aviation and aerospace industry.” For further information please contact:

SIPOS Aktorik GmbH Im Erlet 2, D-90518 Altdorf, Germany Tel. +49 (0) 9187 / 9227- 0 Fax +49 (0) 9187 / 9227-5111 Web:

12 November/December 2011

Maryam Imogen Ghouth Mubadala Aerospace Senior Communications Officer M: +971 55 700 7592

Alisdair Haythornthwaite Bell Pottinger Middle East M: +971 56 690 1725


Atlas Composites Ltd Achieves AS9100:2009 Rev C Accreditation The first stage was to determine Key Performance Indicators for all the required processes. This was followed by integrating a review process where performance was measured against

In August 2011, Ilkeston-based Atlas Composites Ltd became one of the first composite engineering companies in the UK to achieve AS9100:2009 Rev C, after a successful audit by SGS United Kingdom Ltd. The latest revision is now the established benchmark for any company in the composite engineering industry wishing to tender for new business in Aerospace and Defence. Compliance with it proves that a company’s Quality Management System relies on clearly defined business processes to measure its effectiveness in meeting customer requirements. Atlas Composites are industry leaders in the design and manufacture of carbon, glass, kevlar and aramid composite components and tooling for the Aerospace, Defence and Satellite Communications industry. Customer approvals include Airbus, Agusta Westland, BAE Systems, Bombardier Aerospace, Cooper Antennas, GKN Aerospace, Lockheed Martin, MBDA, Meggitt, Nordham and Thales. Work towards the revised standard began in 2010 using a gap analysis database designed by strategic partner TPT Consultancy, to verify the effectiveness of the management system and practices. The gap analysis identified the need for Atlas Composites to make the transition from its procedural-based quality management system, which satisfied the requirements of AS9100 Rev B, to the required new process-led approach.

planned targets and improvements made where targets were not being met. SGS conducted the successful audit in July 2011 and issued the AS9100:2009 accreditation with no non-conformities identified. As a result, Atlas Composites business objectives are now clearly defined, deployed and integrated into the company, supported by clearly defined KPIs. The business process interactions are defined using the process approach and process owners identified. The process performance is measured through the effective deployment of KPIs to support continual improvement. Delivery performance over the past 12 months stands at 100%, and Quality Performance 99.4%. “Making the transition from Rev B to Rev C was a key objective,” says Shaun Moloney, Managing Director, Atlas Composites Ltd. “Without this there was potential that business could be lost. Delivery and Quality was excellent, and the challenge was to measure how effective we were in achieving this.”

PULS UK’s New Website Streamlines Product Selection Leading Din Rail power supply manufacturer PULS UK has announced the launch of its new searchable website The new site gives customers detailed information about the full range of PULS UK’s products as well as important contact details and company information. Visitors to the site will be able to use a special search facility to find the most suitable product for their application simply by entering the specification requirements using a series of dropdown menus. PULS UK’s Managing Director Harry Moore said, “We now have well over 100 items in our product range covering an enormous number of applications and we wanted to make it really easy for our customers to find what they need. The new website has taken quite a while to develop but I am confident our customers will appreciate the improvements we’ve made and find the site useful.”

14 November/December 2011

For More Information Contact: PULS UK Ltd Unit 10 Ampthill Business Park, Station Road, Ampthill Bedfordshire, MK45 2QW Tel: +44 (0) 330 999 9988 Fax: +44 (0) 1525 841291 November/December 2011



Off The Shelf’ Format Makes Clixcoolers The Emergency Winter Choice Are your heat exchangers not working efficiently in the winter weather? Breakdowns and a long wait time for delivery? With their ‘off the shelf’ availability, Clixcoolers the new, unique, modular forced air heat exchangers from Forward Industrial Products can be delivered and installed in just 72 hours. With their patented design encompassing special aluminium multiport tubes and fins currently used in aerospace heat transfer, Clixcoolers are more efficient and cost effective than traditional copper tube aluminium finned coil type heat exchangers. And because they are UK designed and manufactured, they can be supplied quickly in an emergency, so minimising hourly and daily losses incurred during plant shut down. Individual sections of the system can be replaced rather than complete units, reducing cost, wastage and maintenance down-time for repairs. Speed of installation in most locations can also be guaranteed thanks to the Clixcooler’s modular system which is delivered in virtually ‘flat pack’ format. The modular construction means less need for heavy lifting gear during initial assembly as well as on-going servicing and repairs, so

giving further cost savings. Martin Cleaver, Managing Director of Forward Industrial Products explains: “It is in the winter months when the ambient temperature has dropped that many businesses experience the inefficiencies of their existing copper tube heat exchangers. As well as being costly to run, complete breakdown due to freezing is not unusual and sourcing replacements can take months during which time down-time costs can escalate. Clixcoolers have a small carbon footprint so can be easily installed, are operationally cheap to run and most importantly, when it is an emergency, can be delivered and installed in a 72hour period.” Once installed, Forward Industrial’s team of experienced engineers will also maintain the Clix Cooler unit, with servicing and cleaning every 12 months

to ensure maximum efficiency, particularly suitable for those businesses which do not have staff available to undertake maintenance. Forward Industrial is offering Clix Cooler with five years on site warranty cover on the matrix and three years cover on the system motors, giving customers additional reassurance. For more information on Clix Cooler contact Forward Industrial on: 0121 708 3070. Email: Website:


Bradford Hospitals To Save Over £26,000 On Air Handling Energy Costs Variable-speed drives from ABB are delivering expected savings of more than £26,000 a year at a leading NHS Foundation Trust. Bradford Teaching Hospitals NHS Foundation Trust has fitted the drives to 28 air handling units. The ABB standard drives for HVAC are installed in critical areas such as theatres and infection control zones, where the air flow is controlled to promote both safety and comfort. The load on the air handling units varies with the outside temperature, but the biggest difference is between day and night. The fans typically run at half speed at night to conserve energy, reduce noise and minimise wear. The new drives are rated from 0.75 kW to 30 kW. Together they are expected to save more than 200,000 kWh and 110 tonnes of CO2 per year. The drives are supplied and commissioned by ABB’s Drives Alliance member, Halcyon Drives. Halcyon Drives,, carried out the two-month project in four phases.

16 November/December 2011

Installation and commissioning had to be carried out without disrupting critical air handling operations. This was possible because of the redundancy already built into the hospital’s systems. Halcyon specialists installed, set up and commissioned all the drives. Each one is connected into the wider building management system (BMS) arranged by the onsite BMS systems company to communicate using the ABB HVAC drives standard protocol BACnet. The project was part of a wider initiative by the Trust to save energy as part of its preparations for the introduction of the CRC Energy Efficiency Scheme. This includes the on-going development of a long-term policy, which is designed to conserve energy and minimise

investment costs by optimising the phased replacement of older motors throughout BRI and St Luke’s. The draft policy includes specifying variable-speed drives on all future motors. In 2009 the Trust was awarded the Carbon Trust Standard for its commitment to managing and reducing its carbon footprint. In the recently published Carbon Reduction Commitment league table Bradford Royal Infirmary were listed 50th out of 2,000.

Visit: November/December 2011



Mutech Pledges Support For National Coal Mining Museum For England Mutech Ltd, one of the UK’s leading electronics design and manufacturing companies, has pledged its charitable support to the National Coal Mining Museum for England (NCM) based in Overton, near Wakefield. The National Coal Mining Museum, formerly Caphouse Colliery working mine, which ceased production in 1985, preserves the heritage of coal mining in England, attracting thousands of visitors annually from the UK and overseas. Liz Orme, Development Officer for the NCM, explains: “With Mutech’s help we will continue to raise awareness of our exciting exhibitions and events as well as spread the word about the Museum’s educational value for both children and adults. We are delighted that Mutech has chosen to support our work and we look forward to building a long term relationship with them in the future.” Sarah Varney, Mutech Operations Director, comments: “As part of our corporate social responsibility (CSR) we wanted to support a charity that would be relevant to our expertise in intrinsically safe mining equipment and therefore close to our hearts. “In line with other sponsored Museums, NCM’s funding will be reduced over the next four years, so the Museum needs to attract donations, sponsorship, legacies and grants to continue to develop and expand. We are committed to helping the organisation keep the history of coal mining alive for future generations.

”Mutech is also looking forward to welcoming NCM personnel as guests of honour at our Christmas Open Day in December, and Mutech representatives will be visiting the Museum in 2012.” Mutech Ltd designs, builds and tests ATEX and MSHA approved products for its customers in the fields of mining and other hazardous areas. A member of the Association of British Mining Equipment Companies (ABMEC), Mutech has 25 years experience in electronics design and manufacture of intrinsic safety equipment for leading worldwide companies. More information is available from Mutech Ltd, tel: 0161 872 0400, email: Website:


JUMO Wtrans B Programmable and cordless head transmitter with wireless transmission. The radio transmitter is equipped with a universal measuring input for RTD temperature probes, RTD potentiometers, thermo-couples as well as mV signals; it measures both temperature and further process signals. The compact design of the aerial battery case allows for simple installation at the form B DIN connection head. • Transmission frequency: 868.4 MHz • Outdoor range up to 300 m • Universal measuring input • Customized linearization (40 pairs of values or polynom of the 4th order) • Li battery 3.6 V / 2.1 Ah in the AA format • Operating temperatures from –30 °C to +85 °C • Comfortable setup program incl. online chart (optional) • German engineering and design

18 November/December 2011

For further information please contact: JUMO Instrument Co. Ltd Temple Bank, Riverway Harlow, Essex, CM20 2DY Phone: +44 1279 635533 Fax: +44 1279 635262 e-mail:

20 November/December 2011


Thermal Imaging Identifies Energy Loss And Deepens Public Awareness The carbon emission and energy consumption targets set by the London Borough of Camden are indeed ambitious. By 2015 it wants cuts of 21% and by 2020, 40%. Thanks to its investment in thermal imaging however, the efficient identification of problem areas and the creation of public awareness through specially designed tags, is well underway.

Above: Standard Photograph

Last year Camden Council purchased a FLIR B620, top of the range, thermal imaging camera. And in the opinion of The Local Authority’s Energy Management Officer, Danny Hunt, it was a significant move. “There is surely no quicker, non-invasive way to identify heat loss and gains. A thermal image is easy to explain, provided the operator is trained, and a good quality image is a very powerful means of raising awareness.” To support its energy saving initiative, Camden Council had been planning significant investment in carbon reduction measures and needed a method to assist scheme evaluation and verification. Having seen the benefit a colleague derived from FLIR thermal imaging, Danny Hunt proposed the FLIR B620 as the best tool for the job. The camera was purchased in 2010 and has become an essential part of Danny Hunt’s work. He is responsible for collating and analysing energy data from council buildings with a view to identifying energy saving measures which can be used to lower Camden Council’s emissions. And this, in turn, will also cut costs. “It allows me to conduct this detection work while auditing our building portfolio. I can see any anomalies quickly, easily and safely,” Danny Hunt adds. “And for these reasons we chose the best possible camera for the money that was budgeted to obtain the quality and functionality needed.” The FLIR B620 has a 640 x 480 pixels detector, the largest detector that is commercially available. This provides up to 307,000 measurement points, a resolution that is particularly important in the building industry as it allows smaller targets to be spotted and measured accurately at greater distances. The camera’s field of view is also larger and therefore fewer

Above: Thermal Image

images need to be taken. On average 25% fewer images are required on a typical survey, allowing the camera user to get the job done quicker and more efficiently. Danny Hunt continues: “It produces crisp and clean images which lower specification models can’t match. The difference in quality is amazing.” The camera’s quick refresh rate was also a factor in its purchase as was the viewfinder’s elimination of glare in sunny conditions. Although no startling discoveries have yet been made with the camera it has led to the introduction of a tagging system, the reaction to which has been extremely positive. The tag is, in effect, a calling card whose principal purpose is to enable the Authority’s maintenance department and contractors to pinpoint the problems identified by the FLIR B620. Created and designed by Camden Council, the tag is totally biodegradable and has a visual element that highlights the

Continues On Next Page November/December 2011


IR exact position of the area surveyed through the camera.

wall insulation in private dwellings in Camden.

“The tag helps raise awareness with the building users too as it contains the clear message ‘this area has been thermal imaged’ and on its reverse explains we’ve identified that this area could be more energy efficient.”

The camera is also helping in preventive maintenance work, for example, in applications such as identifying heating mains leaks. As Danny’s familiarity and experience with the camera increases so does the scope of his investigations, resulting in further cost benefits to the Council.

The next goal for Danny Hunt is to take advantage of the advanced, dedicated software that is available for the FLIR B620. FLIR BuildIR visualises and quantifies building related problems such as structural and insulation defects, thermal bridges and moisture ingress. It includes ten pre-designed report templates for easy report creation. One of the reports which will prove of great benefit to Camden is the energy cost comparison report that allows the easy calculation of achievable cost savings when the identified structural problems are fixed. FLIR BuildIR also includes a humidity report for calculating

22 November/December 2011

dew points and an air tightness report. Whilst the principal use for Camden Council’s FLIR B620 is in the identification of energy management measures in Authority-owned buildings its potential application scope is, of course, much wider. For example, it has recently been used to check insulation consistency after a major work programme to install cavity


Global Steel Company Saves Energy, Replacement Steam Traps And Maintenance With Thermal Energy International’s Gem Steam Traps A major global steel company, based in India, is saving on energy, replacement steam traps and maintenance after replacing its thermodynamic traps with Thermal Energy International’s GEM venturi orifice design. Following successful bucket tests on drip legs, Thermal Energy International’s Indian agent, Hyderabad based Zenith Marketing & Consultants, has installed 400 GEM traps throughout the plant. The steel plant, based in India’s eastern region, has a very long steam network measuring approximately 16km. Comprised of a high pressure system with a pressure rate of 63 bar and temperatures of 480°C and a low pressure system with a pressure rate of 15 bar and temperatures of 300°C, the network has approximately 500 steam traps fitted along the length of the pipework. Despite having tried thermodynamic traps, and in some places inverted bucket traps, from all of India’s five steam trap manufacturers, it was found that none lasted longer than six months. The plant then imported traps from Germany and Japan, and although the life of the mechanical trap increased, they still only lasted between 6 months and a year. Looking for a steam trap with longevity, the plant contacted Zenith Marketing & Consultants, a company specialising in industrial energy saving products, about the award winning GEM venturi orifice steam trap. Following a number of meetings a bucket test was carried out on the steam line to evaluate the GEM trap’s performance. The evaluation was carried out over a 30-month period and after the protracted trial it was found that the GEM traps were still working well. This provided the plant with conclusive proof that the GEM venturi orifice steam trap offers ultimate reliability. Fitting GEM steam traps has resulted in the plant achieving energy savings by preventing steam leaks from failed traps and providing added efficiency. In addition the plant has also saved costs on replacement traps

and maintenance, eliminated trap inspections, prevented pipe damage that destabilises the steam distribution system and improved the safety characteristics of the steam network. Commenting on the installation Subhas Naik, Director of Zenith Marketing & Consultants said: “We have installed 15mm and 20mm sized traps, which have helped solve the steam network’s many problems. The plant is delighted with the GEM trap and has made it its steam trap of choice”. Instead of utilising a valve mechanism to close off steam for maximum energy and water conservation, the highly efficient GEM steam traps use the venturi orifice design to effectively drain condensate from the steam system. GEM steam traps are 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 costs associated with regular repair or replacement of other types of traps. For More Details Contact: Thermal Energy International Inc, 1 John Street, Bristol, BS1 2HR Tel: 0117 917 7010 | Fax: 0117 917 7011 November/December 2011



Steam Trap Surveys Reveal £28,000 In Potential Energy Savings Per Site Drastic increases in fuel prices and increased concern about carbon footprints means the pressure is on to reduce energy use and cut fuel bills. Paul Mayoh, Technical Manager for Spirax Sarco explains how a focus on steam traps can raise the energy efficiency of steam systems.

A survey will also give an estimate of the potential financial gains through upgrades – providing information to help justify maintenance expenditure. For example, an analysis of 50 recent Spirax Sarco steam trap surveys revealed potential annual energy savings of £28,400 per survey on average. The average payback time, including the cost of replacement products and their installation, is about two months. A survey will encompass the location and tagging of all steam taps in the system, an inspection of each steam trap’s installation and suitability,

Steam systems are highly reliable and can drop down the list of priorities

and ultrasonic and temperature

when it comes to applying finite maintenance resources. This can mean

testing. An evaluation report will be

that steam systems do not always run at their full potential. For many steam

written, detailing a plan of work and

system operators, a new focus on their steam trap population is all that is

equipment specification for replacing

needed to create substantial energy efficiency gains with short payback times.

inappropriate and failed components,

A steam trap survey will help to keep a system running smoothly and will

correcting faulty installation and

almost certainly reveal impressive savings through reduced fuel consumption,

adding new equipment to improve

fuel emissions, water and effluent charges.

the system’s performance. The proposal should include full costings, scope and schedule of work and payback calculations.

Achieving the savings One site that has benefited from a survey is the Heinz factory in Wigan, the largest food factory in Europe. The 55-acre site produces canned soups, baked beans, pasta and puddings for the UK and continental European market, and its on-site energy centre generates up to 140 tonnes of steam per hour to keep the canning lines running.

24 November/December 2011

STEAM TRAPS Thermostatic traps sense a temperature difference between steam and sub-cooled condensate or air/steam mixtures. For example bimetallic traps and balanced pressure traps. Mechanical traps sense a density difference between condensate and gases. Examples include float traps and inverted-bucket traps. Thermodynamic traps sense the difference between the dynamic pressures of condensate at lower velocities and high-velocity flash steam.

Energy savings have enabled Heinz to realise a payback of less than nine months after investing in a steam trap survey and undertaking the resulting remedial work. The site has more than 550 steam traps, but there hadn’t been a systematic trap survey for over five years. “We decided to have a full survey in light of our commitment to energy efficiencies and improvements,” says the site’s environmental compliance manager. “We decided to buy in the necessary steam system expertise.” Engineers were on site for 10 days. They surveyed 559 traps, of which 75 were found to need maintenance to improve their energy efficiency. According to the environmental compliance manager, Heinz intends to prevent possible future losses by adopting a planned approach to steam trap maintenance, including bringing in experts to carry out annual surveys from now on.

The right trap for the job Ensuring correctly specified steam traps is vital for maximising the effective heat transfer and energy efficiency of any steam system. Around 98% of steam applications place varying loads on traps. They may involve a fluctuating steam demand, for instance, or changing external factors such

In systems with continuous demand a user may also consider fixed-orifice traps as a further option, although these may struggle to cope with variable load conditions. Picking the right trap for the job is not always straightforward and it’s often worth asking the opinion of a reputable supplier. For example, for batch processing applications which involve a lot of starting and stopping there is likely to be a lot of air in the steam space. A balanced pressure thermostatic trap would be a good choice in this instance because it will discharge air freely, whereas an inverted-bucket trap might struggle to cope because bucket traps have only a limited capacity for air venting. For more information

as ambient temperature. The condition of the steam itself may also vary,


and even a process that normally demands a fairly steady load will result in,

a range of flow rates, temperatures and pressures, depending on whether the equipment is starting up, operating normally or going through a cycle of operations.

call: 01242 535319 or alternatively visit:

There are a variety of steam traps available for such variable applications,

which can generally be divided into three groups. November/December 2011


HAZEZ Show – The New Exhibition

New Hazardous Area Event Launched At Maintec 2012 MAINTEC 2012 will now house a new specialist hazardous area event called ‘HAZEX’, in association with Hazardous Engineering Solutions. The new area is being introduced at the show for the first time next February to reflect the growing responsibilities of engineering professionals and the growing concerns and tighter legislation over the health and safety of industrial, commercial and government sites and facilities. Commenting on the new element of the show, Matt Benyon, Managing Director at easyFairs UK & Ireland , says: “HAZEX will offer visitors the opportunity to discover the latest products, legislation, case studies and latest techniques applicable to engineers working within hazardous areas and handling hazardous materials.” He continues: “One of the new minefields for engineering and operations professionals is the mandatory European Community directive ATEX 94/9/EC. ATEX stands for atmosphere explosive and it is the law in the EU. HAZEX will offer ATEX-approved companies the ideal platform in which to showcase their products and services. Additionally, it provides a forum for companies supplying products to those working in hazardous environments.” Indeed, but it’s not just ATEX that has prompted easyFairs to host the new hazardous area. Health and safety has always been a key theme within MAINTEC, and an important issue that is covered by the exhibition. Earlier in the year a recent report by the Health & Safety Executive found that around 8,000 people die each year from occupational cancers and around 14,000 new cases are reported each year. Many of these tragedies are caused by hazardous substances at work and, therefore, are entirely preventable. Matt Benyon continues: “The Control of Substances Hazardous to Health (COSHH) Regulations 2002 provide legislation that must be complied with by all companies throughout the EU. However, to really deal with the problem often means taking action over and above legal requirements. As organisers of MAINTEC that is where we can help, by bringing together the leading hazard prevention experts under one roof, so that visitors can witness firsthand the very latest in hazard prevention training services and products.” Michael Dominguez, Publisher at Hazardous Engineering Solutions, adds: “HAZEX will be a one stop shop for

26 November/December 2011

engineers looking to comply with the latest health & safety legislation. Over recent months there have been a few high profiled incidents that have resulted in deaths within the industrial workplace. It is our intention to help engineers and health & safety professionals alike implement the best safety practices available and minimise the risks associated with working within hazardous areas.” Michael continues: “HAZEX will be the ideal platform in which to give engineers the knowledge to all the current tools, services and best practice associated with hazardous engineering. With the extensive combined knowledge of the MAINTEC team and Hazardous Engineering Solutions magazine we are confident that we can deliver a well prepared and needed event that not only enables equipment suppliers to showcase their latest products but also offers engineers the latest legislative and legal trends.” As well as a strong line-up of exhibitors, accompanying the exhibition will be a comprehensive seminar programme covering a variety of topics relating to working with and within hazardous areas.

MAINTEC 2012 takes place from Tuesday 28 February to Thursday 1 March 2012 at the NEC, Birmingham. To find out more information about HAZEX or the main show visit MAINTECUK, and for stand bookings and exhibiting enquiries contact Jerry Dawson on: +44 (0)20 8843 8823 or email:


Ensure Compliance with PPG26 Pollution Prevention Guidelines Fentex Ltd have consolidated their spill trays and absorption materials providing a range of products to achieve compliance with the national Pollution Prevention Guidelines (PPG26). Spill trays can be supplied for use with single or multiple primary containers of 1, 5, 20 and 25 litres capacity together with drums up to 205 litres. These provide the necessary secondary containment facilities during the storage or decanting of liquids, ensuring that drips, leaks and accidental spills can be successfully contained. They help maintain a clean, safe work area environment while preventing pollution or contamination of land, surface waters and groundwater from the run-off of inks, oils, solvents and a wide range of potentially harmful or noxious fluids. In general workshop conditions, spill trays can be used to provide a contained cleaning/dispensing area and can also deal with machinery leaks or the storage of oil contaminated components during breakdowns/servicing of machinery. They help to reduce floor contamination

leading to better, safer working conditions, while leaked fluids that would have been lost can be recovered for recycling or re use. The spill trays are manufactured from durable, lightweight rigid plastic, in a wide range of rectangular and square sizes and various depth configurations. They incorporate an all-around moulded lip, some featuring a pouring spout, which ensures extra rigidity and good lifting control for trays during moving when they are full with their spill contents. Trays can also be supplied with moulded ridges on the base to allow for airflow under stored containers. Mini spill trays from 35 to 76cm in length can be supplied, suitable for small bottles and containers, or as convenient machine drip trays. Larger trays from 40 to 60cm in width and 56

to 120cm in length provide fluid spill retention capacities from 2 - 28 litres. These are complemented by larger capacity drip pans and extra deep trays with spill retention capacities up to 120 litres. Handy trays for general maintenance operations or use as drip trays underneath mobile plant or other vehicles include a 41 x 31cm size tray together with an 85cm octagonal tray which covers a large floor area. Contact: Mr Chris Lunn Company: Fentex Ltd Website: Tel: +44(0)1480 890104 November/December 2011



SKF Bearings Take The Load On Pont Y Werin Bridge Advanced spherical roller bearings, developed and manufactured by SKF, the knowledge engineering company, are playing a vital role in supporting a 40 tonne, 30m opening deck on the Pont Y Werin bridge in South Wales. The bearing units form part of a powerful hydraulic system that is capable of lifting the bridge deck safely and efficiently in just two minutes to a vertical position of 75 degrees, while withstanding wind speeds of up to 25m/sec. Pont Y Werin or ‘The people’s bridge’ has provided a much needed pedestrian and cyclists’ link from the city of Cardiff to Penarth, across the newly developed Cardiff Bay area, spanning the river Ely and just a stones throw away from the iconic Welsh Assembly. The bridge opens and closes to allow river traffic to pass and was built thanks to a large lottery grant in 2007. It took three years from planning to construction and is one of the key strategic development projects being carried out as part of the on-going regeneration of the Cardiff Bay and surrounding region. The design and construction contract, awarded to civil engineering group Dean and Dyball Civil Engineering, was for a 130m bridge, comprising four equal sections, one of which is a lifting span that maintains a clear 20m navigational channel below, and opens to 15 degrees from the vertical position. The company worked closely with engineering consultants KGAL to design sophisticated and reliable mechanisms to control the movement of the lifting span. Dr Arash Farahani of KGAL explains that, “We developed a system that allows the lifting span to be controlled by two hydraulic rams, with its base end being hinged by means of pairs of 440mm diameter SKF spherical roller bearings, set into a specially engineered deck trunnion. Additional bearings are fitted at the top of the hydraulic rams to enable them to pivot smoothly as the span opens and closes”. Dr Farahani adds, “The bearing units are key to the efficiency and safety with which the span moves, as they have to take almost the entire load of the span, which is around 40 tonnes, and withstand the effects of wind forces; these can be particularly high when the span is fully opened and can gust from any direction. Additionally, the bearing units have to resist

extremes of temperature and the effects of both rain and salt water”. The SKF spherical roller bearings have been designed to provide extremely high load carrying capacities, while being robust, easy to fit and inspect, with little or no maintenance under these operating conditions. Highly efficient contact seals on both sides of each bearing unit retain the grease inside, while reliably excluding moisture and other contaminants. The SKF bearings used for the Pont Y Werin Bridge were of CC design type, with symmetrical rollers, two window-type steel cages and an inner ring centred via a floating ring between the two rows of rollers. Neil Chambers, Project Manager at Dean and Dyball, is delighted with the performance of the system, “Although the bridge has only been open for a short period of time, it has already had extensive use, with a large number of shipping movements requiring the lifting section to be raised and lowered at regular intervals. This takes a maximum of 11 minutes, from the sounding of pedestrian alarms to the final release of the safety barriers. The actual open and close time of the bridge span itself is just four minutes which, given its length and weight is relatively fast, and could not have been achieved without the performance, precision and reliability of the bearing units.” A large number of bascule bridges across the world now rely on SKF spherical roller bearings thanks to their outstanding inbuilt features and proven reliability. The cyclists and pedestrians of Cardiff and the surrounding area can be confident that their bridge will stand the test of time, providing a much needed link for many years to come. For further information, please contact: Phil Burge, Communication Manager, SKF (U.K.) Limited T: +44 (0)1582 496433 M: +44 (0)7770 647591 E: November/December 2011


PULS Power Supplies Survive Lightning Strike Test DIN-rail power supply manufacturer PULS has carried out extreme testing of its QT40 3-phase units by subjecting them to simulated lightning strikes. The lightning test is one of several procedures devised by PULS to prove the durability and functionality of its power supplies in the harshest conditions. The test was carried out using a Marx generator producing a voltage of 500kV over a distance of 0.5 metres. This generated a series of manmade lightning bolts of up to 4kA which hit the power supplies in two separate tests. The first strike was directed into the housing of the unit while the second strike hit the input (L1 – L3) of the QT40. Despite being subjected to such extreme conditions the power supplies continued to work normally. Harry Moore, Managing Director of PULS UK commented, “Our customers rely on our power supplies to keep their production lines running, so it’s important we do everything we can to make sure they can cope with even the most extreme circumstances. Lightning strikes are a potential cause of failure but these tests prove our power supplies can withstand them.” The PULS QT 40 is ideally suited to industrial bulk power applications such as control systems for large electric motors powering production equipment, conveyors, machine tools, etc. It is also ideal for outdoor applications where the ability to operate at low temperatures is important - ambient temperatures as low as -25˚C can be tolerated without difficulty.

All business enquires to: PULS UK Ltd Unit 10 Ampthill Business Park Station Road, Ampthill Bedfordshire, MK45 2QW

Tel: +44 (0) 330 999 9988 Fax: +44 (0) 1525 841291

Vent Dryers Protect Against Humidity In Tanks Brownell has developed a range of Vent Dryers to protect the contents of liquid storage vessels against moisture contamination. They are available in two sizes both standard and heavy duty variants. These rechargeable units also minimise pressure differential build up and odour emissions. The design of the dryer incorporates excellent weather protection, making it suitable for external applications. An active desiccant bed retains any moisture before it can enter the vessel. Field trials have proven that most existing moisture vapour contained within a vessel is quickly removed when these vent dryers are fitted. Vent dryers will maintain the moisture concentration to acceptable levels. A colour change indicator within the desiccant is fully visible. This tells users when to change the beaded silica gel. Re-charging is quick and easy to undertake, simply by removing an access port plug, empty-out and pour in the new material. This ensures full protection at all times. Visit: Telephone: +44(0)20 8965 9281 Email:

Ultrasonic Cleaners for Intercoolers and Heat Exchangers Hilsonic announces a Bumper year for their range of Ultrasonic Cleaners specifically aimed for the cleaning of large scale Intercoolers, and Heat Exchangers. we are prowd to announce that our range of ultrasonic cleaners have proved to be a very popular solution to the problem of dirty heat exchangers and intercoolers, this interest has been increased significantly with our unique ability to offer custom built cleaners to meet specific requirements. Traditionally the approach was to replace a Heat Exchanger and Intercooler as there was no effective method of cleaning them. Our range offers a solution to this, effectively allowing our customers to clean and reuse existing Heat Exchangers and Intercoolers as opposed to replacing them. This offers a significant cost saving to the client as well as the obvious environmental benefit. Furthermore all our Equipment is built to last with an estimated twenty year life span and has easily serviceable components which we can provide as required. Since our launch we have received orders from as far afield as Brazil, Tahiti, South Africa, as well as Europe and of course the UK.

30 November/December 2011

Industries that have been particular interested in this range include the Shipping Industry, Dry-docks, Shipyards, Power Stations, and Engine Refurbishes.”

For further information contact: Darren Pyke - Technical Director, Hilsonic Tel: +44(0)151 639 6020 Fax: +44(0)151 334 7407 Email:

32 November/December 2011


New Brad HarshIO Ethernet I/O Modules from Molex Integrate QuickConnect and Fast Start-up Technology Easy, reliable, IP67-rated connection for sensors and actuators over EtherNet/IP and PROFINET WALLDORF, Germany – 13 December, 2011 – Molex Incorporated introduces the new Brad® HarshIO Ethernet I/O Modules with QuickConnect and Fast Start-up technology to provide a reliable solution for connecting industrial controllers to I/O devices in harsh environments where liquids or vibrations may be present. “As Ethernet flows from the office management level down to the factory floor, automation device manufacturers need to adapt their products to the constraints of industrial applications,” says Eric Gory, global product manager,

Molex. “When Ethernet is used to control the sensors/actuators on the robot tooling – such as on a welding robot – it is sometimes necessary to perform quick change of tools. In the automotive industry, for example, this tool change period is defined by manufacturers that the swapped Ethernet field devices must be able to start and operate in less than 500ms.” With the introduction of the QuickConnect (QC) technology for the EtherNet/IP and Fast Start-Up (FSU) technology for PROFINET, the Brad HarshIO Ethernet I/O Modules from Molex bring exceptional speed to the market and versatility to all industries using robots for repetitive tasks with precision. QC and FSU enable to start and operate the module in less than 500ms to meet the requirements for industrial applications in factory automation such as all type of body shop in automotive industry using robot tool changers. Delivering significant operational advantages over conventional I/O modules, the Brad HarshIO Ethernet

I/O Modules have been successfully tested with Rockwell and Siemenscompatible PLCs (i.e. for EtherNet/ IP the module is conforming to QuickConnect Class A device requirements to start and operate in less than 250ms). Additionally the Brad HarshIO Ethernet I/O Modules support safety automation architectures using separate power supplies to power the inputs (sensors) and the outputs (actuators). The HarshIO Ethernet power connector includes separate grounding isolation between the input/logic ground and the output ground. This feature allows powering the module with 2 distinct power supplies that is commonly used in safety applications. “Often, system designers are using safety relays that regularly perform pulse tests to be able to detect short-circuit, ground fault or an earth fault,” explains Gory. “If an error is detected, the safety function is triggered and unwanted and dangerous plant conditions are therefore avoided. However, if the separate grounding for safety is not required by the system designer, the HarshIO modules can operate using a single power supply where the ground of both logic/input and output is identical.” The Brad HarshIO modules are complemented by a wide range of Molex products, including cordsets, receptacles, field-attachable connectors, Ethernet switches, PC interfaces, gateways, diagnostic tools and simulations software. For additional information, please visit: html. To receive information on other Molex products and industry solutions, please sign up for our e-nouncement newsletter at: November/December 2011



Bespoke Halifax Fans Help Pet-Food Manufacture Reduce Its Carbon Footprint A major pet-food manufacturer has put efficiency ahead of first cost and selected 6 high-efficiency bespoke engineered Halifax Fan ‘Beaufort’ high volume, low speed fans paired with IE3 motors to extract and filter half-a-million cubic metres of process fumes and air per hour as part of a substantial expansion project. Despite the recession, the pet-food

diversification enterprise and

industry seems bomb-proof and

maintains a strong environmental

Golden Acres Petfoods (GA) is in the


process of expanding production of dry extruded pet-foods, from

Pet-food manufacture can be a

1,500 tonnes per week, to 2,500

smelly process and GA is going to

tonnes. Half of the multi-million cost

incredible lengths to ensure that the

of the expansion is being incurred in

cooking smells don’t trouble their

sustainable environmental aspects of

neighbours and this means installing

the project, meeting and exceeding

a powerful ventilation system with

rigorous DEFRA regulations and ensuring the comfort of GA’s close neighbours in the nearby town. GA, based on a 2500 acre site near Bretherton, Lancashire, is Europe’s largest manufacturer of premium dried pet-foods and is the largest pet-food manufacturer you’ve never heard of. This is because some 5,000 product lines are all branded under others’ names, many of them instantly recognisable. The company was founded as a farming 110kW scrubber fans feeding the bio-filters.

34 November/December 2011

Overhead view showing the bioscrubbers below and the new fan house under construction, top left.

multi-stage scrubbing and filtering of the process fumes and factory air. The factory air will be changed 10 times per hour, and along with


Main vent fan with the new fan house under construction.

conducting bearings and insulation properties which will ensure longer service life when inverter driven. GA accepted there was a premium price for the six motors but their enhanced efficiency will save an estimated £26,000 per year, paying back the price premium within 3 years and will help to reduce Golden Acre’s carbon footprint. The fan and motor assemblies were fully tested in-house at Halifax Fan’s factory in Brighouse before despatch to site where the three extract fans the process fumes will be passed

system. “We chose Halifax Fan for

through filters and wet scrubbers to

a number of reasons”, explained Ian

remove particulates and then to a

Barnes, GA’s Project Manager. “We

huge bio-filter to cleanse the air of

recognised Halifax as a reliable global

any odours before exhausting it to

player in the business and the fact

the environment.

that it was based more or less locally was a bonus. It was decisive that

will be housed in a purpose built fan room which is being built around them. Halifax Fan will also provide engineering assistance during final installation and commissioning. Ian Barnes again “Halifax Fan stood out from its competitors. The sales

Pushing 500,000 m3 of air per

the fans were correctly sized for our

hour takes an immense amount of

application and bespoke engineered

power and GA has purchased 6

for optimum efficiency, which helped

new Beaufort fans from Halifax Fan

reduce motor ratings in one instance

of Brighouse for the job. The two

and will save a great deal of energy

process gas extraction fans are rated

and carbon emissions in the long

at 250kW and 185kW and have

run. The point-of-sale consultancy

been constructed with stainless steel

the Halifax team provided was

impellers. These push the process

invaluable and they worked closely

gases through an air filter before

with us to engineer a complete

Ian Crum

the cleaned gases merge with the

solution that included monitoring

Halifax Fan Ltd

building ventilation air, powered by

airflows and duct pressures and

Mistral Works

a 250kW FD fan. This air passes

ensured selection of the right

Brookfoot Business Park

through wet scrubbers, pulled by

materials for the fan impellers and

the three 110kW boost fans, which


Elland Road

then push the air through the bio filters, to be finally exhausted to the

The fans will be speed controlled by

environment, smelling sweetly.

inverter drives and Halifax supplied 6 ABB IE3 cage induction motors.

and engineering team’s expertise from the outset has enabled us to obtain a custom designed, efficient and reliable fan solution, at the right price, and we’re confident we can rely on their local back-up as and when we need it.”

Brighouse, W Yorks HD6 2SD Tel 01484 475123 Fax 01484 475122

Having such a strong environmental

These high efficiency motors are


stance, GA placed a high priority

of a much higher build quality than


on the efficiency of the whole fan

standard machines, with non- November/December 2011


36 November/December 2011


Archco-Rigidon Protects Petroplus Caustic Tank Contractors E.G.Lewis were recently contacted by Petroplus at its Coryton refinery to apply a new protective coating to a caustic soda tank, which is part of the process in the refinery’s cracking plant. Because of the highly corrosive conditions, which are aggravated by the high temperature of the cracking process, E.G.Lewis approached Winn & Coales (Denso) Ltd for it recommendation of the most suitable protective coating. Winn & Coales’ Archco-Rigidon 423D coating system was chosen, which is based on glass flake vinyl ester. In order to remove the 15-year-old former coating and to give good mechanical key for the Archco-Rigidon coating, the caustic soda tank interior was first shotblasted to Swedish Standard S.A.2.5 near white metal to achieve a minimum profile depth of 70 microns. The tank was then tested for chlorides before applying Archco Ridgidon PD2 primer Petroplus is Europe’s leading independent refiner of petroleum products, with five refineries in Europe of which

Above: Caustic soda tank at Coryton refinery after protection with Winn & Coales Archco-Rigidon coating

Coryton is the flagship and largest, E.G.Lewis & Co are a South Wales based company and are the resident painting contractors for the refinery and have been for the past eight years.

Winn & Coales (Denso) Ltd Chapel Road London SE27 OTR Tel: 0208 670 7511. Fax: 0208 761 2456 e-mail: Web: SPARE MANAGEMENT SOFTWARE

Solutions for Parts and Service Information Use PARTS-PUBLISHER to automate parts catalogue creation, improve parts identification, streamline parts ordering and reduce mis-orders PARTS-PUBLISHER is a customisable standard software that enables equipment manufacturers and operators to assemble, distribute and automatically update parts and service information. The application delivers all parts and service data – such as parts catalogues, maintenance

description, service bulletins etc. Built using industry

manuals, technical specs and sales collateral – pre-

standards, the product integrates seamless with key

filtered according to serial number, product line or

business applications such as ERP, PLM or CAD.

configuration/trim package. PARTS-PUBLISHER catalogues employ an intuitive user interface

For more information please visit:

that provides a synchronised view of assembly

drawings or 3D models and associated parts lists,

Demo catalogues and videos online!

including detailed information such as pricing, part November/December 2011


38 November/December 2011


Robotic Pipe Maintenance The prototype of a robot which can inspect, remove coatings and apply a fast cure coating on a variety of pipes is currently being developed by Tube Tech International. The Robotic Maintenance Vehicle

inspect the surface once again.

(RMV) is an all-in-one solution for

The robot can then apply a fast

the main challenges presented by

cure coating, exclusively available

pipes. The robot can provide an

to Tube Tech International. All

initial inspection of the pipe surface.

these activities are completed by

It can then blast off the coating and

the remote controlled RMV while

the operator is on the ground away from the hazards of confined space working and the fumes generated by coating materials. Tube Tech International is a world leading specialist industrial cleaning contractor which constantly challenges traditional cleaning and inspection methods within the heavy industrial sector across the globe. For further information regarding the RMV please call: +44 (0)1268 786999.


Belzona Repairs Badly Corroded Chemical Containment Area Chemical containment areas are susceptible to deterioration through chemical attack. If the deterioration is not addressed early, the structural integrity of the concrete will suffer from serious long term damage causing potential chemical leakage and structural failure resulting in environmental damage and impact. Belzona has developed a solution to repair and protect against the detrimental effects of chemical attack within chemical containment areas. By way of example, Application Services Division, Belzona Technosol Limited recently completed an application for a premium spirits distiller in Scotland. The application was to provide a repair and protective system for a caustic chemical containment area.

The existing protective system had failed resulting in the chemical containment area offering no guarantees that it would successfully contain the products if the vessel was to fail. On preparing the surface and removing the fibre glass lining it became evident that the concrete substrate had badly degraded and required extensive repair. Belzona 4131 (Magma screed) and Belzona 4141 (Magma Build) were used to repair the degraded sections of the walls to bring the bunded area back to original state. The concrete floor surface was skimmed to a depth of 6mm and 50mm x 50mm fillets were installed to all horizontal and vertical corners of the bund with Belzona 4131 (Magma Screed) and Belzona 4141 (Magma Build).

A two coat system of Belzona 5811 (Immersion Grade), high performance barrier coating which is ideally suited to this application providing protection, from the effects of the disclosed chemicals, was then applied to the internal and external walls of the bund along with the floor. By utilizing this Belzona solution, chemical attack of concrete can be prevented reducing environmental impact and expensive operational downtime. Website: November/December 2011



New temperature and flow controller for Techne’s SBL series Fluidised Baths The new TC-9D control unit incorporates a flow meter plus thermocouple for more accurate and reproducible operation of the Techne SBL range of fluidised sand baths. With push fit connectors for convenient set-up, the self-contained TC-9D controller enhances temperature accuracy and stability of SBL Fluidised Baths.A traceable calibration certificate is available when supplied with an SBL unit. Techne has pioneered the development of fluidised bath technology and now offers a wide range of products capable of covering the temperature range –100ºC to 1100ºC. The SBL series of precision temperature fluidised baths provide a safer alternative to high temperature oil or salt baths and are widely used in the petrochemical and aerospace industries as well as for heat treatment of samples in engineering applications. BEARINGS

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An application video showing the new TC-9D temperature and flow controller in operation is available at


Setting the standard for Process Safety Management The National Skills Academy for Process Industries and Cogent SSC has developed a Process Safety for Senior Executives course.

One of the first businesses to undertake the training was Pentagon Chemicals Ltd,

The course was launched in September 2011

Allan Laing, CEO says, ‘feedback can be

and a number of businesses have successfully

summarised in one word – excellent’.

completed it and are now working on their action plan, which will see them move up a gear in health and safety.

To find out how you can get involved contact us on 0845 6070140. OFFSHORE

Santos Engineering Services Ltd Santos Engineering are a Technical Services and Manpower company operating in the Oil & Gas and Power sectors. We specialise in power generation plant and large to small compression plant for installation, commissioning and maintenance, we supply all disciplines - management through to technician level. We provide close support to our customers 7 x 24 on a personal basis and guarantee quality service. Santos operate on a worldwide basis and can mobilise quickly and effectively. We also require on an ongoing basis top class Managers, Project Engineers, Mechanical, Controls and Electrical support.

5 Clanwilliam Square , Dublin 2, Ireland Tel: + 353 1 661 9911 | Fax: + 353 1 647 57 05 E-mail: | Web: November/December 2011



The HS-620 Vibration Meter Kit From Hansford Sensors Ltd The HS-620 vibration meter kit from Hansford Sensors Ltd, is both entry level and a comprehensive vibration monitoring instrument for maintenance engineers across all types of industry. The kit consists of the compact vibration meter, a hand-held probe, a magnetic mount for more permanent installations, a protective carry case, an instruction manual and battery chargers for both mains and in-car use. The meter’s portability means that measurements can be taken in remote parts of the factory helping to find potential problems and avoid future plant failure. Conforming to ISO10816-3 and ISO2954, the unit can measure bearing condition and levels of velocity, acceleration and displacement. Operating from an internal rechargeable Lithium battery, the meter offers 48 hours continuous operation. From flat, the unit can be recharged in 3 hours.

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The HS-630 model has all the facilities of the HS-620 but also offers a fast and reliable way to measure non-contact temperature which is another useful parameter for monitoring the health of rotating machinery. Hansford Sensors Ltd specialise in the design and manufacture of accelerometers for monitoring vibration and temperature levels of industrial machinery, playing a key part in the role of predictive maintenance. Products include intrinsically safe models for approved use in Group I (Mining) and Group II (Petrochemical). Hansford Sensors Ltd also supply multi-sensor switch boxes, vibration sensor modules, portable vibration meters, accessories for

sensors, vibration condition monitoring protection systems and custom built vibration sensors. For more information on the extensive range of Hansford Sensors products, please visit:


Alicat Mass Flow and Pressure Devices ATEX Approved -X option for use in environments where ignitable gases are present Tucson, Arizona (October 28, 2011) – Alicat Scientific, Inc. offers its Mass Flow Meters, Mass Flow Controllers, and Pressure Equipment with an ATEX approved -X option. With this ATEX rating, Alicat’s precision devices are even easier to integrate into a wide range of hazardous settings or applications, without sacrificing functionality. Alicat devices can be ordered in the ATEX approved configuration with no extension of fast 7 business day lead times. All Alicat ATEX approved mass flow devices have 30 user selectable gas calibrations installed for gases like Acetylene, Oxygen, Hydrogen, and Propane, as well as 16 other gases and 10 gas mixes. Alicat ATEX approved devices also include a NIST traceable calibration and certificate. Other ATEX approved devices are often stripped of functionality to reduce power consumption and heat generation. Alicat devices, by design, consume very little power and generate very little heat, requiring few modifications to the Alicat ATEX device. It includes all of the benefits and features of its non-ATEX counterpart including the major functional advantage, the digital

display. Users in hazardous environments reap the flexibility of having an on-board display for quick visual verification of mass flow meter or mass flow controller operation. To learn more about Alicat’s ATEX approved devices, visit, or call +1 520 290-6060.


Doppler Radar Non-Contact Speed Sensor The Perfect Solution To A Wide Variety Of Speed Measurement Applications Typical applications are: •

Conveyor Speed

Distance Measurement

Product Speed

Vehicle Speed

Length Measurement

Traffic Monitoring

The output of the sensor is a pulse with a frequency proportional to the measured speed.   The cumulative number of pulses may be used to determine distance traveled or the length of a moving surface. Accuracy is ±0.34% at 0.5 m/sec. Speed measurement range is 0.8 km/h to 480 km/h. No gears, belts, pulleys or moving parts to jam or to break.

Delta DRS1000 Non-contact Speed Sensor with optional RM200 Magnetic Base Mounting Bracket.

Contact GMH Engineering: Website: Email: November/December 2011



NEW 9100D PORTABLE CALIBRATION SYSTEM The new 9100D is ideal for checking accelerometers, velocity and proximity probes on site. Packaged in a tough transit case, the 9100D is ready for travel. With calibration capabilities from 7Hz to 10kHz up to 20g, using the 9100D is simplicity itself. Merely attach the sensor, set the frequency and amplitude and record the results. The 9100D has a built-in sine generator and shaker, with a quartz reference accelerometer for stability, plus digital electronics. Has a battery life of 18hrs and closed loop control for added convenience. Contact PCB Piezotronics Ltd Call on: 01462 429710 or email: for more information.


The New HygroGen Calibrator Rapid, precise, transportable and user-friendly HygroGen2 is a selfcontained, portable generator of humidity and temperature based on AirChip3000 technology. It features a user friendly and responsive colour touch screen and advanced functions that significantly reduce the time to calibrate. Up to five probes from any manufacturer can be calibrated simultaneously and within minutes, at multiple %rh / °C points across wide ranges to match the application conditions. Unattended and out-of-hours programmed calibrations are easily performed, ensuring

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the HygroGen provides fast calibration turnaround times and a rapid return on investment. Integrated HW4 software enables measurements from Rotronic HygroClip2 probes to be recorded to a removable USB flash card memory for validation. For full product information contact us. Tel: +41 44 838 11 44 Email: or visit

PORTABLE CALIBRATORS November/December 2011



When Plugs Don’t Plug And Play Plugs that have not been used for a while can quickly turn plug and play into plug and pull. As the operator uses force to break the cold weld which forms between the pins and the contacts, the time clock begins to tick and the risk of damage increases. Simply changing to a different contact design can solve this. The unique spring-loaded butt-type contacts in MARECHAL Electric decontactor sockets meet head-on and feature self-cleaning silver-nickel tips which provide a low contact resistance in addition to a 10kA short circuit rating. A release latch quickly disconnects the plug into a parked position, allowing equipment to be disconnected under load and visibly isolated in complete safety. NDT

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To learn more about decontactors please contact MARECHAL Electric. Tel: 0844 804 2066 Fax: 0844 804 4231 Email: Web:


The AX Multi-Line system The Interlube AX Range of compact electrically operated Multi-Line lubrication systems is capable of delivering SAE80/90 oil up to NLGI 2 heavy grease over 15 metres away from the pump. Suitable for a wide range of industrial applications AX is available in three reservoir sizes servicing up to 60 lubrication points. The robust, compact design makes it easy to install/operate and virtually maintenance free. Each pump element feeds an individual grease point with a precise amount of lubricant at pre-determined intervals with 6 pump elements able to deliver from 0.010 to 0.100cc’s per stroke. Individual bearing lubrication via the AX Multi-Line system ensures that accidental pipe breakage will affect only one point and not the complete system.

Interlube Systems Ltd, St Modwen Road, Parkway Industrial Estate, Plymouth, Devon. PL6 8LH Tel: 00 44 (0)1752 676000 | Fax: 00 44 (0)1752 676001 |




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BUYERS GUIDE 2011 November/December 2011



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Engineering Maintenance Solutions December 2011  
Engineering Maintenance Solutions December 2011  

EMS magazine, the leading journal for engineers responsible for maintenance and asset management