ems nov/december 2008 by Michael Dominguez

NOV/DEC 2008 BUYERS GUIDE RECRUITMENT CONDITION MONITORING ISSUE 8

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

The power of

PREDICTION

INDUSTRY NEWS

TURN TO PAGE 2 FOR THE FULL STORY

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HEALTH & SAFETY

ATEX

www.engineeringmaintenance.info

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" SFDFTTJPO DBO CF UIF VMUJNBUF TUSFTT UFTU 4P CVZ XJTFMZ A recession is painful for most people. For maintenance professionals, it carries an extra burden. With capital budgets getting tighter, maintenance professionals are under even greater pressure to squeeze more value out of existing assets. Now, more than ever, you have to be ultra-careful in selecting the best solutions and partners for predictive, preventive and corrective maintenance. Thatâ&#x20AC;&#x2122;s why easyFairsÂŽ MAINTEC is a must attend event in 2009. Itâ&#x20AC;&#x2122;s YOUR opportunity to uncover the latest innovations and maintenance technologies designed to improve efficiency and asset performance. r FYIJCJUPST Meet cutting-edge suppliers of preventive / predictive maintenance solutions, condition monitoring, thermography, plant & environment safety and enterprise & asset management. r MFBSO4IPQT Attend free seminars and case study presentations on topics including energy & resource efficiency and value driven maintenance. 1-64 /&8 '03 r #SPBEFS FYIJCJUPS QSPĂ MF easyFairsÂŽ MAINTEC will be a showcase for energy management solutions, building services management, lubrication technology and mechanical equipment.

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LEAN MAINTENANCE The reliability formula

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INDUSTRY NEWS

Latest trends, news and technology

A higher level of cleanliness

There has been a decline in manufacturing in all major economies. There has been a reduction in the global demand for manufactured goods.

However there is a light at the end of the tunnel: In the long-term, manufacturing is open to technical progress and productivity growth. New technologies will lead to new products, new processes and higher value added manufacturing.

The BOE's forecast of inflation undershooting the central bank's target level of 2% over the next couple of years, gives the BOE more room to cut rates further. Furthermore, the central banker said that there was "an outside risk" of deflation, but that the situation in the UK was different than that in Japan during the 1990s, thanks in part to the faster response to the current economic slowdown. In these uncertain times lean manufacturing and predictive maintenance have never been so important. As a maintenance engineer your role will develop and will in fact help protect the future of your company.

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CMMS

TUNNEL The weak pound can in fact help manufacturing companies and companies that trade on overseas markets to see a more competitive pound. We might see a better performance from manufacturing in this recession than we have in previous recessions.

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EFFICIENT CLEANING

Light at the end of the

Removing the headache

When manufacturing growth starts to return and world economies develop new economic solutions, your company will be a leaner, more productive and efficient organisation. PUBLISHER’S COMMENT

EMS, MSL Group, Cobalt House, Centre Court Sir Thomas Longley Road, Rochester, Kent ME2 4BQ +44 (0)1634 731646 www.engineeringmaintenance.info

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VIBRATION MONITORING A feeling for what is likely to fail

18 PAGE

MOTORS Driving down energy costs

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer Idhammar Alan France, Mark Haarman editorial@engineeringmaintenance.info

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Published six times per year by EMS Annual subscription: UK FOC Rest of World £90

Articles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every effort is made to ensure the accuracy of information published. No legal responsibility will be accepted by the publishers for loss arising from articles/information contained and published. All rights reserved. No part of this publication may be reproduced or stored in a retrieval system or transmitted in any form without the written consent of the publishers.

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

For more information quote EMS Enquiry No. 102 on IBC

Thermoteknix Sytems have launched a new high resolution industrial thermal imaging camera

THERMAL INNOVATION

at work... VisIR 640 is designed with all the tools needed for today's industrial Predictive Maintenance programmes with crystal clear images from a highly sensitive 640 x 480 uncooled infrared sensor, precise temperature measurement and the most powerful range of easy to use camera tools and unique Condition RED database and software for your planned and routine Predictive Maintenance inspections. With a unique rugged industrial housing, an articulated central optics pod for ergonomic and safe operation and high contrast DayBright™ touch screen, VisIR 640 provides high definition thermal and visual image clarity in any lighting conditions. VisIR 640's high resolution detector and digital colour camera make surveys more efficient and cost-effective. With integral LED illuminator/flash, laser pointer and voice recording, VisIR 640 is set to be the choice of thermal imaging cameras for professionals working in the industrial Predictive Maintenance arena.

Predictive Maintenance, or Condition Monitoring, keeps a check on the health of assets through regular inspection. Effective Predictive Maintenance enables repair to be performed when it is most cost-effective, before assets lose optimum performance and when downtime is minimised. The 640 difference VisIR 640's superior thermal resolution gives sharp, high definition images, making fault diagnosis fast and reliable. With 4 times the resolution of 320 x 240 infrared cameras and 16 times the resolution of 160 x 120 cameras, VisIR 640 allows you to cover the same tasks in a fraction of the time. VisIR 640 and Condition RED® fully integrate your thermal camera and asset database to create an automated data store, image analysis,route planning and report generation system. Condition RED supports file formats from

all major thermal imager camera manufacturers including all FLIR Systems, Inframetrics, Agema, Avio and of course, Thermoteknix.

Articulated Central Optics Pod for safe, ergonomic use

wwwthermoteknix.com Reader Reply Number: 330 VisIR 640 - greater detail

2 EMS November/December 2008 www.engineeringmaintenance.info

High Definition 5” DayBright™ Touch Screen

To continue where we ended part I of this series of articles about lean maintenance, I like to give an example on the impact of reliability in a situation where you can not sell everything you manufacture as a result of increased reliability. The example also shows the importance of including the quality component of the reliability formula

LEAN

Maintenance II In a pharmaceutical industry there was a lot of over capacity and it was thought that manufacturing reliability wasn’t that important, after all they could catch up losses with the extra capacity they had and they could use overtime to compensate for any production losses. Management viewed that it was much was more important to have lower maintenance costs. When manufacturing efficiency was measured the only thing considered was availability. One day a tumbler broke in the end stage of the manufacturing of tablets. In the tumbler the tablets were covered with a coating before packaging and delivery. The break down was caused by a burnt and worn out v-belt. The shut down, which only lasted for 45 minutes, resulted in that lots of expensive medicine had to be scrapped at the cost of £49 000. Since that had happened one time before, two years prior, quality began to be included in how you measured manufacturing reliability. Instead of talking in terms of availability this plant now include quality performance when they identify losses and measure manufacturing reliability. Increased manufacturing reliability will increase product throughput and reduce the time between incoming raw materials to the finished product. Better reliability is the foundation to a faster and safer manufacturing flow. This will result in lowered losses in delayed deliveries, over production, work in progress and energy expenditure. Here lie the biggest gains if you can’t sell everything you produce. This cannot materialize if you don’t have equipment with very high reliability. If you

do have it then you can, with prosperity, apply the “Dell model” or “Just- In- Time” manufacturing principles very successfully. In addition work related injuries and energy costs are always positively affected by high reliability.

I often get the question, ”What is good manufacturing reliability?” It obviously has to do with your process and equipment quality. Also pay attention that we aren’t only talking about equipment efficiency. It is common to use the concept OEE – Overall

In this study we evaluated the Manufacturing Reliability of 38 very similar process lines. The blue line shows the lowest to the highest manufacturing reliability. The only thing we could correlate to higher manufacturing reliability was the level of professional planning and scheduling. Depending on what different plants included in their maintenance costs, this cost was lower the higher the level of manufacturing reliability and level of planning and scheduling was.

3 EMS November/December 2008 www.engineeringmaintenance.info

Equipment Efficiency when measuring manufacturing reliability, but that is only a part of the reliability concept, the other part is Overall Process Efficiency which is the manufacturing process, or the chemistry of making your product such as raw materials, pressures, temperatures, chemical mixtures, packaging material, operating practices etc. In this concept we are discussing OMR Overall Manufacturing Reliability. From the maintenance point of view there are three elements that we have seen that affect how good OMR can be. 1. Equipment quality. 2. The number of components that can cause a problem. 3. The maintenance organization’s efficiency. Equipment quality including maintainability and reliability design I have covered in the previous articles. The number of components that can cause a problem. I often use paper machines as a guideline when I judge possible reliability in different processes that I don’t have data on. The most reliable paper machines are machines that produce, for example, towel and tissue paper. Such machines often have one or two driers, so called yankee cylinders or driers, each with one drive unit. A paper machine with several layers and surface coatings has many more components that can cause problems. Such a machine can have over 100 drier cylinders. Thus OMR differs between 96 % for a tissue/towel machine and 82 % for the more complicated machine. A package line with good OME can reach 85 - 90 %. All of these calculations are based on 8760 hours per year (in 2008 we have 8784 hours per year). The maintenance organization’s efficiency One of the best indicators of effective maintenance is still the degree of planned and scheduled maintenance. This is because it affects both manufacturing reliability and maintenance efficiency to a very high degree. Furthermore, a high level of planning and scheduling cannot be reached without the support of all of the other elements of good maintenance including maintenance prevention, preventive maintenance, store room support, root cause problem elimination etc. In studies that we have performed we have established a strong correlation between high manufacturing reliability and a high degree of planning and scheduling of all maintenance and operations work.

Over manufacturing and over maintenance Over manufacturing is to make more than what has been sold and before it needs to be delivered. This is one of the biggest sins in lean manufacturing. The same view should be taken when it comes to maintenance. To perform more maintenance than is needed or to perform maintenance before it is needed should be considered a waste or an opportunity to improve. The biggest improvement the opportunities lie in: Optimizing old preventive maintenance systems. Decide if work that is performed during scheduled downtime actually needs to be done. Prioritize, plan and schedule work in a disciplined way. Optimize Preventive Maintenance (PM) Please see earlier articles where I have described optimization of preventive maintenance more in detail. Here I like to add more information as it relates to lean maintenance. To optimize your PM is one of the efforts that can give the fastest return on investment. If you have a PM system that has all PM activities documented under each equipment identification number, optimization can be done relatively quickly. If you have a system where all PM inspections and other PM activities are documented in a work order, then the work becomes much more extensive, if not impossible. If you want to optimize your PM then you must have a system that can collect all PM efforts in a lucid way under respective identities on the maintenance object. This is important because more than 95% of all PM activities are performed as route based activities while the manufacturing process is operating. Through more and more integration between what lubricators, mechanics, electricians and operators do, the system must always change and it has to be able to change in a very simple way. It can be easier to start from the beginning with a route based system if your existing system is based on work orders. A route based system can be set up at a very low cost. During the 1970’s I myself led the implementation of many PM systems in industry. Thirty years later I have visited many of those plants and I am surprised to see that many of these systems still looked like they did thirty years ago. The distribution between what is done by different work groups is still the same as

4 EMS November/December 2008 www.engineeringmaintenance.info

back then. In many of these companies the operators are now involved in the preventive maintenance but their efforts are added to all the other PM measures. Here lies a big opportunity to optimize PM inspections, lubrication, etc. As an example. In a chemical plant most pump units had the following PM measures done on most of their pumps. Lubricators lubricate everything, except for electric motors. Electric motors are lubricated by electricians. (Believe me, even if it is old-school and a waste of the electricians skills, it still happens today when you come across old work systems that should have been changed forty years ago) A mechanical PM inspector performs mechanical inspections. Gear couplings are overhauled during a scheduled shut down each year. (This can easily be moved to inspections while equipment is running and repair are done when needed) Electricians and instrument technicians inspect electrical components and sensors. Vibration analysis is done by a technician. Operators do general inspections of unit. In this case PM activities were reduced by 50% and the new PM activities were better than before. It can be a good idea to take photos of several pieces of the equipment and then show which PM is performed and by whom. Then show how you can integrate and optimize all PM. After that you can determine costs and savings. To be continued. www.idcon.com Reader Reply Number: 300

Christer Idhammar, president IDCON INC President of IDCON INC in the USA and founder of the Idhammar group of companies, Christer Idhammar, will address further steps to lean manufacturing in the next issue.

INDUSTRY NEWS

Elfab launches first atex-approved wireless burst detection system Elfab, Europe’s leading manufacturer of rupture discs, has launched a unique ATEX-approved burst detection system, Radio-Tel. The new system combines the latest wireless technology with Elfab’s proven non-invasive detection system, Flo-Tel™+. Suitable for the largest sites, Radio-Tel features real-time process monitoring of disc status and temperature. Situated in close proximity to the rupture disc, Radio-Tel’s transmitters plug easily into the Flo-Tel +. This eliminates the time-consuming and expensive wiring work necessary with all other detection systems. The transmitters send a health message to the receiver every minute. When the transmitter detects that a disc has operated, the message changes to an alert signal. Elfab has designed Radio-Tel to deliver maximum flexibility to its customers. Each transmitter emits a unique identification code with each health message, providing end-users with control over individual units. The system’s PC-compatible software indicates disc status, enabling customers to easily monitor their processes from the control room. The software allows for detailed monitoring of each device, including exact location, process temperature, battery life and signal strength. Additionally, Radio-Tel can be hardwired to deliver maximum control over individual processes, or to trigger a beacon or siren in the case of a burst detection occurring.

Reznor 104% efficient UESA condensing gas fired unit heater Joining Reznor’s well proven V3 gas fired heaters is the new, third generation UESA range of high performance condensing room-sealed unit heaters, designed to further increase fuel efficiency. The new UESA range incorporates advanced burner technology together with a patented aluminium MacroChannel heat exchanger to increase thermal efficiency. Achieves 104% efficiency Unlike condensing boilers and other condensing heaters the high efficiency is achieved even at full heat output Available in 4 sizes with outputs ranging from 35kW to 102kW

Vibration and noise isolated fan motor Sealed control department isolating all electrical components 25% lighter than previous condensing models Simple installation ECA approved 2 to 4 year payback (depending on usage) Payback periods may be further reduced when Enhanced Capital Allowances are taken into account in new installations. This allows qualifying end-users to offset 100% of the capital cost of the units plus associated installation costs against Corporation Tax in the first 12 months of operation. Specifiers and end-users looking to reduce carbon emissions and combat escalating fuel costs will find that Reznor’s new UESA condensing unit heater is the perfect solution. www.reznor.co.uk Reader Reply Number: 302

Radio-Tel’s failsafe receiver module features optimal outputs and is pre-set for both hardwiring and software monitoring. The module can receive signals from a distance of up to 0.5km; for larger sites, harsh operating environments or where buildings and structures weaken signals, repeater aerials are recommended. Suitable for use in even the harshest of operating conditions, all Radio-Tel parts have at least an IP65 rating, with the transmitters being fully ATEX Zone 0 approved. For further information on Radio-Tel, or to request a site survey, please contact Elfab. www.elfab.com Reader Reply Number: 301

only provides increased comfort underfoot, but its cross grip 30mm x 10mm open holed design gives effective slip resistance too. This latest Cobamat® installation at Acushnet has predominantly been used in the assembly area for golf clubs, with additional matting also used in the warehouse. Any swarf is captured in the open holes of the mat to prevent slipping on ® dry dust and debris. Most of the workstations have Acushnet Europe Ltd has opted for Cobamat® with bright recently installed a substantial yellow bevelled edging quantity of Cobamat® Inter (factory-fitted) along three safety matting from COBA in its sides for increased safety UK manufacturing and awareness and to minimize trip warehousing facility in St Ives, hazards. The non-edged side Cambridgeshire. allows for the matting to be One of the largest manufacturers placed flush against the of golf equipment in the world, manufacturing equipment. Acushnet is synonymous with Cobamat® is available in Light, brands including Titleist, FootJoy Standard, Inter and Heavy and Cobra employing some 400 configurations in black, blue, people in the UK alone. green and red with optional Cobamat Inter is one of many bevelled edging. Six standard industrial safety matting sizes with custom sizes also products manufactured by available on special request. COBA Europe Ltd. Manufactured www.cobaeurope.com from flexible interwoven PVC ® Reader Reply Number: 303 extrusions, Cobamat Inter not

ACUSHNET PLAYS SAFE WITH COBAMAT

5 EMS November/December 2008 www.engineeringmaintenance.info

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INDUSTRY NEWS

Teseo air system makes news in Scotland Teseo’s modular aluminium hollow bar system has been installed to manage compressed air deliveries for the Daily Record & Sunday Mail, Scotland’s leading newspapers. Publisher Trinity Mirror Printing Saltire Ltd (TMPS) recently embarked on an upgrade to the papers’ plant room, the engine house of the printing plant, which was previously using 15-20 year old galvanised steel pipes to carry compressed air around the facility. Scot Industrial Air, from Glasgow, was contracted to design the new system. Experts in the field and wellversed in the TESEO products having been using them for many years, Scot Industrial Air’s Alan Mathie specified the TESEO 110mm pipe for the whole installation, which ran during a 3 month period and was designed to make as little

impact on the day to day running of the plant as possible. “In my opinion the TESEO system is the best on the market,” says Alan. ”Its modern look makes it ideal for a contemporary industrial space and the design gives an extremely neat finish.” The benefits are numerous. From the installation viewpoint Teseo’s aluminium modules are much easier to handle compared to the traditional galvanised tubes, more energy efficient due to the high flow rates (generally 30% higher than steel) which equates to a lower pressure drop and overall energy savings from day 1. The HBS (hollow bar system) and the AP (aluminium profile) products feature aluminium extruded piping which has an external rectangular section with tee slots and a fine, smooth internal bore. A wide selection of angle and straight

MainTech CMMS

MainTech CMMS contains a database with web and/or software front end providing: Maintenance, Regulatory inspections, Asset tracking, and Parts inventory control

SOLDER PASTES

joints, quick clamping pieces and connectors make the Teseo system totally flexible in layout design and quick to install. The speed and ease of accurate installation reduces labour time and skills to make the Teseo system an attractive technical

Easy to use screens customized for clients Multi language Screen captions and Work Orders. Translations and selection done by user Legal records, saved USD 9 million for one client in court case Approved by DNV for replacing teardown inspections in class survey of ships Used by Nabors Drilling, CalDive International, and many others for units located in USA, Mexico, Venezuela, Brazil, Congo, Oman MainTech provides services in setting up the system and website hosting Reps in UK and China. www.maintech-usa.com Reader Reply Number: 305 The EFD advanced solder pastes help improve your soldering applications. The paste is packaged in syringes, cartridges, jars and flex packs. Its unique features include:

Precise, clean and reliable soldering; Manual and automated dispensing systems; No work, no reject and Compatible with all reflow process.

and economic choice for modern compressed air and fluid delivery. The customer has also been impressed with the result. David Beagan, Chief Engineer at Trinity Mirror Printing Saltire Ltd said: “We were setting about a significant reconfiguration of our plant room, relocating 3 existing compressors, installing two new air dryers and a new variable speed compressor to power the printing plant. Compared to the traditional piping system that we previously had, it was immediately obvious that the TESEO product was a superior system and more energy efficient. It has the benefit of simplicity and versatility and since we had it installed we have been extremely happy with it.” www.teseoair.com Reader Reply Number: 304

Software helps building industry The purchase of DATATRACK production software, specifically suited to batch assembly and manufacturing has led to significant cost and productivity benefits at Andromeda Telematics, of Byfleet, Surrey. Intelligent building integrator and KNX member, Andromeda Telematics (ATL), does not manufacture in the traditional sense but complex projects involving batching parts and assemblies in its stores, workshop and on site, made its activities ideal for the DataTrack treatment. The company has grown very quickly in size and reputation, being involved in such high-profile projects as T5 (Heathrow), British Library and the renovated St Pancras Railway Station.

www.efd-inc.com

www.psldatatrack.com

01582 666334 Reader Reply Number: 306

08456 345932 Reader Reply Number: 307

7 EMS November/December 2008 www.engineeringmaintenance.info

INDUSTRY NEWS

CONDUIT AND CABLE MANAGEMENT SOLUTIONS FOR HAZARDOUS AREAS Electrical Cable Management Solutions for Hazardous Areas are the subject of a guide from Kopex International. It provides concise information on current ATEX directives and information on the use of electrical equipment and cabling for areas having the potential for explosion.

Kopex International provides of a range of cable management products that carry certification under the IECEx Certified Equipment Program. The company’s full hazardous product range is featured in the guide. Copies are available from the Marketing

Department, Kopex International Limited, Station Road, Coleshill, Birmingham, B46 1HT, Fax: +44 (0)1675 464276, Email: marketing@kopex.co.uk

services and details of the various national and international approvals testing standards which Clare products enable manufacturers to test to.

The catalogue is available at sales@clareinstruments.com or telephone 0191 5863511

www.kopex.co.uk Reader Reply Number: 308

New Catalogue from Clare Instruments Clare Instruments’ comprehensive range of electrical safetyv test equipment for manufacturers is features with a new full colour A4 product catalogue. The free ‘Electrical Safety Test Instrumentation’ catalogue explains how Clare’s products can be custom designed and built to meet specific requirements, while the benefits of the range’s added value features feature in a section about test traceability. Extensive details are provided about all the Clare products

available including the HAL series and Sentinel flash/HiPot, ground bond and insulation testers. There are also sections about the multi functional electrical safety testers and customised systems such as SwitchSmart, PowerSmart and the Quad Test series. Further sections provide focus on the benefits of Clare enclosures, Test N Tag printer, PAT Guard 2 software and accessories (calibration check unit, fault simulators, flash probes and high visibility beacons). A final section features fast track calibration

www.clareinstruments.com Reader Reply Number: 309

RILEY INDUSTRIES RELAUNCH

After 40 years in the surface finishing industry, the company has been relaunched under a new brand name. From 1 July, it has been trading as Riley Surface World, reflecting its expanding product portfolio and global reach. To mark the relaunch, a

new website provides full access to huge stocks of used surface finishing plant and equipment, with photos and full technical details on over 1,000 machines. It includes details of complete production plants for electroplating, anodising, powder coating

8 EMS November/December 2008 www.engineeringmaintenance.info

and wet paint finishing. The site is updated daily. www.rileysurfaceworld.co.uk 01922 458000 Reader Reply Number: 310

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CONDITION MONITORING Protect your critical rotating plant

SENSONICS predictive maintenance systems are used and appreciated around the World, providing cost-effective, monitoring for all types of critical rotating plant. O Vibration

Monitoring Supervisory O Displacement Measurement O Overspeed Protection O Bearing Condition O Seismic Monitoring O Turbine

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Northridge Road, Berkhamsted, Herts HP41EF For more information quote EMS Enquiry No. 106 on IBC

For more information quote EMS Enquiry No. 107 on IBC

For more information quote EMS Enquiry No. 108 on IBC

For more information quote EMS Enquiry No. 109 on IBC

RELIABILITY

A significant number of electronic fuel injectors for diesel trucks in use worldwide are produced in the Stonehouse, Gloucestershire factory of US-owned Delphi Diesel

EFFICIENT CLEANING

of diesel injectors ensures their reliability Delphi Diesel customers include Volvo, DAF, Daimler, John Deere and Asian commercial vehicle manufacturers. Delphiâ&#x20AC;&#x2122;s global market dominance in the sector is underpinned by the reliability and robustness of its products. High precision machining and rigorous quality control during manufacture of injector components is one reason for this success. Another is the efficient cleaning and degreasing of the components in automated, multi-stage, industrial washing machines prior to assembly of the injectors in clean room conditions. The match paired body and plunger, for example, are washed in ultrasonically assisted, aqueous cleaning machines purpose-built by FinnSonic, Finland, and supplied through UK agent, Turbex, based in Alton, Hampshire. Tony Bray, a manufacturing systems engineer at Delphi Diesel's Stonehouse plant, explained that in 2004/05, two such washing machines were installed, a stage wash in the Body Hard (BH) area and a final wash in the Assembly and Test (A&T) area. Both cleaning systems are of similar design. The BH wash removes heavy soils from the injector bodies and plungers, including heat treatment scale, machining debris and cutting fluids, so that they are of the required cleanliness standard for a critical hydraulic test.

The A&T wash achieves a higher level of cleanliness, as it is processing parts already cleaned to an agreed standard. The final wash, which involves some changes in the process sequence and chemicals, ensures that the bodies and plungers are suitable for assembly, consistent with the extremely fine clearances between the mating injector parts. The A&T wash includes automatic demagnetisation of components to ensure that any minute particles will not be attached by residual magnetism. Delphi was particularly pleased with this installation, as FinnSonic managed to incorporate the demag coils around the input conveyor without any increase in the overall footprint of the washing machine. Tens of thousands of two main product lines are manufactured each week at Stonehouse â&#x20AC;&#x201C; Electronic Unit Injectors (EUIs) and Electronic Unit Pumps (EUPs). Matched body and plunger pairs for EUIs are mounted together, 32 at a time, on bespoke wash frames for their journey through the automated FinnSonic BH and A&T lines. In the case of the physically larger EUP components, the wash frames accommodate 16 component pairs. Frames enter each cleaning machine one at a time on a motorised input chain conveyor and are picked up by a robotic

arm that handles them through six stages: heated spray pre-wash in a 500 litre tank (with lid to prevent overspray), heated ultrasonic washing with pulsing jets on stages 2, 3 and 4, heated ultrasonic rinse with pulsing jets, double station recirculating hot air drying, and cooling using high flow, water-chilled air. The entire system is enclosed, with interlocked access doors and alarms, and is controlled by a Mitsubishi PLC with operator panel. Cleaned and cooled parts emerge on their frames via the output conveyor. From the BH machine they are taken for back leak testing, whereas from the A&T machine they go directly to final assembly. Before they do, an operator lubricates the plunger, assembles the matched pair and attaches an identifying tag used for data collection. Investment in the FinnSonic equipment was required due to forecast production increases and the need to replace older, spray-type cleaning machines. Cleanliness standards within the automotive industry are stringent and the introduction of more efficient cleaning systems was considered necessary. Several suppliers were approached and FinnSonic equipment was finally selected following development of an effective cleaning process. Transducers impart ultrasonic agitation as close as

11 EMS November/December 2008 www.engineeringmaintenance.info

RELIABILITY

possible to the critical areas of the components, which combined with sequenced underwater jetting, achieves the required cleanliness standard. The overall robustness of the FinnSonic system, stainless steel construction and realistic price were other key considerations during the selection process. Specifically, Mr Bray cited the configuration of the ultrasonics on the Finishbuilt machines, developed with Turbex, as being a significant improvement over other systems being considered. The transducers are mounted either side of the tanks, rather than underneath, imparting lateral ultrasonic agitation that he regards as more effective for cleaning these particular parts. Development of the specific cleaning processes was provided as part of the turnkey service by Turbex at its cleaning technology centre in Alton. The optimised cycles currently being used at Stonehouse are based on that original work. While the first automated FinnSonic machines were under construction, Delphi required an additional machine for cleaning low volumes of a different design of

injector body. Turbex supplied a hire machine at short notice, a FinnSonic multistage, manually operated aqueous cleaning machine. This was subsequently purchased and is still in production use today. In the last 10 years, Delphi has continuously grown in size and now employs 1,000 people at its Stonehouse factory. It continues to increase its market share within the fuel injection sector and has now reached the point where additional washing capacity is required. Consequently, two further FinnSonic automated cleaning systems were supplied by Turbex in October 2008, one for BH and the other for A&T, each being of similar specification to the existing machines. Mr Bray said that the output and reliability of the first FinnSonic machines, combined with the resulting component quality, made it likely that Delphi Diesel would return to the same supplier, but this was not a formality and the company researched the market again before reordering. www.turbex.co.uk Reader Reply Number: 311

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12 EMS November/December 2008 www.engineeringmaintenance.info

CMMS Does your maintenance tend to be very reactive? Do you know what you would like to do but unexpected breakdowns and problems get in the way?

TAKE THE HEADACHE

out of CMMS

Faced with this situation many people reach for a computer maintenance management system (CMMS) in the hope that this will bring some structure to each weekâ&#x20AC;&#x2122;s work and deliver order from chaos. There are many competent CMMS systems on the market but implementing them properly so that they add value is tremendously difficult. Therefore with the usual pressure to keep costs low, corners may be cut and a system is force-fitted into place. The result is often that a CMMS is like a monster sat in the corner of the room which has to be fed constantly with data. A valuable technician may have to be taken out of what is probably a very small group to help administer the day-to-day activities, input data and provide some planning capability. It is such a relief to get to the

end of each day and each week, that no one has the energy left to look back at history and analyze patterns and trends to ensure that resources are being put into the most needy areas. This is a real headache which many have to endue stoically! What if there was another way? What if someone implemented the CMMS for you and managed all of the administration on your behalf? Not only that but they also provided planning support and monthly reports highlighting problem areas and improvement opportunities. Sounds too good to be true? Well ESS Ltd. has been providing such an award-wining service for several years now across a diverse range of industries including manufacturing, food & drink, pharmaceuticals, timber processing and facilities. The service is

called Continuous Maintenance Improvement, CMI. CMI allowed one of our clients, a timber processor, to resolve reliability issues and increase throughput by 46% over a 12 month period and improve annual profits by more than ÂŁ200,000. All of this was achieved with no capital investment or change in the maintenance budget. With our CMI service, the CMMS software works for you in the background and you are able to concentrate on what you do best â&#x20AC;&#x201C; the maintenance activities on your plant and equipment. You always have access to your data but we also provide regular reports, analysis and advice - all tailored to your individual requirements. Job input can be directly to the computer system, but we find that many of our clients prefer to work with job cards and a planning board because this provides a visual stimulus to action and a focal point for discussions that is absent when just using a computer screen. The goal of CMI is to drive your maintenance department to World Class levels by delivering an efficient and effective maintenance service to the plant. The return on investment is provided by the capture of a good data set, maximization of your CMMS software tool and superior maintenance management expertise. The CMI service turns information into knowledge which in turn allows you to turn that knowledge into value. Our CMI service engineers and administration staff will capture all relevant asset performance information regarding your manufacturing process, including: Plant Performance Maintenance Management Materials Management Asset Condition Assessment Condition Monitoring The required overall plant performance

13 EMS November/December 2008 www.engineeringmaintenance.info

CMMS

and maintenance key performance indicators of your manufacturing process will be made available to your on-site team. Plant specific asset performance data and information can be access on-line and displayed on-site, including pre-configured reports and trends. Manufacturing teams will also have access to various industry specific benchmarks, maintenance best practices, and asset type performance comparisons. The ESS CMI model allows for two levels of engagement spread over eight areas that are impacted from the service: maintenance, work planning and control, information management, safety and compliance, spares and materials management, performance management, financial management, continuous improvement. Level 1 is designed with small to medium sized manufacturing plants where there is no planning office and no on-site CMI champion. All reports are available online or mailed to the client as required. There is limited interaction between our CMI Engineer and the client. The service growth path allows for eventually moving to Level 2.

Level 2 is designed for medium to large manufacturing plants where there is no planning office but a CMI champion onsite. There are high levels of interaction between the CMI Engineer and the on-site CMI champion – this promoting a continuous improvement culture. Key benefits to your company of CMI are: A focus on best practices and continuous improvement which is not diverted by daily issues No additional infrastructure is required, therefore there is no additional capital investment Your people are still doing all of the maintenance so there are no industrial relations problems Improved asset performance from access to industry benchmarks and best practices Internal benchmarking is facilitated by the routine reports and KPI dashboard Compliance is assured (ISO, QS, VDA6, HACCP, etc). www.essltd.ie Reader Reply Number: 312

Paul Wheelhouse is a Principal Consultant with ESS Ltd. specializing in maintenance engineering and asset management. Paul worked in the specialty chemicals business for 20 years where he managed pan-European engineering and production organizations. A large part of his time was devoted to enhancing the performance of plant, work processes and the functioning of groups. For the past 14 years Paul has been engaged in maintenance and asset management consulting. This has involved identifying solutions for clients to enhance their return on assets through improved equipment reliability, reduced working capital and effective use of resources. His assignments have been across a multitude of industries located in Europe, North America, Middle East and the Far East. He regularly makes contributions to maintenance conferences and maintenance-related publications – dividing his remaining time between consulting and training. Paul holds a BSc (Hons) from University of Manchester in the UK. He is a Chartered Engineer, a member of the Institution of Engineering technology and a Council member of the Institute of Asset Management He is also a visiting lecturer at the University of Manchester where he lectures on their MSc and MBA programmes.

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14 EMS November/December 2008 www.engineeringmaintenance.info

VALUE DRIVEN MAINTENANCE

SYSTEMIC CRISIS in the maintenance sector? It is 8.30 a.m. on Friday the 17th of October. The FTSE 100 on the London Stock Exchange has slumped over the past few weeks and now stands at 3861.9 points, a historic low. The world has been in the throes of a financial crisis for some time. The trouble started in the USA, where high-risk mortgages (assets) have failed. Famous names in the banking industry like Lehman Brothers in the USA and Royal Bank of Scotland in the UK have gone bust or have been nationalised. Other banks are facing problems too as the flow of money between banks has frozen up. Governments have stepped in to guarantee loans between banks and protect peoples' savings. The time is now 9.05 a.m. and the market has opened with a slight rise. For the past few days, I have been

wondering whether a similar systemic crisis could occur in the maintenance sector too. After all, this industry deals in asset management and risk management as well. Maintenance programmes for factories, aircrafts and infrastructure are based on the risk that installations could fail. But how are these risks assessed? When is a risk acceptable and when is preventive maintenance vital in order to stop it? And how do maintenance engineers manage risk when there is a need to boost company results in the short term? Hopefully not in the same way as the financial engineers in the banking sector. Unfortunately, many of these companies are at a lost to come up with the answer to these questions. Risk management in maintenance is still in its infancy, and the process is rarely

transparent and open to review, as it should in fact be. The Institute of Asset Management (IAM) could probably encourage moves in this direction and develop a kind of seal of approval or â&#x20AC;&#x153;risk ratingâ&#x20AC;?. Just like the system applied in the financial world, but rather more robust. It is now 6.00 p.m. The markets have just closed, up more than 5% on the day. It looks as if the tide has turned. Let's hope that the dams have been kept in good order. One of the founders and managing partners of Mainnovation, Mark Haarman is an expert in maintenance and asset management and is the author of Value Driven Maintenance, new faith in maintenance.

www.mainnovation.com Reader Reply Number: 313

15 EMS November/December 2008 www.engineeringmaintenance.info

OEE

Fear of FAILURE? In August I talked about the dark clouds of recession, really hoping they were a little further away. Now for many manufacturers financial crisis is

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Some estate agents haven’t sold a house since May. In the US we’re told 30% of the properties on the market have been repossessed. It’s even worse for some industries; I mean who has the nerve to buy a new car, even at 50% off? The lack of confidence hit the car makers first, although many were probably over-producing in the good times. The problem is that the car makers and their multi-tiers of suppliers represent a lot of consumers – so the casualty figures are high. Take Honda’s decision to pull out of F1; the direct impact to 600 employees at the Brackley site is significantly amplified when you consider the knock on effect to the several thousand staff working for Honda’s core suppliers. But it’s not all bad; the sun’s still shining, most of us are still eating too much, the kids are still going to school, and unleaded and the bank rate are both down. And anyway, many of us have been through it before. I can remember working at the largest food factory in Europe several recessions ago; we had £30k of CAPEX to last the entire year, in a plant that had cost £30m to build a few

For more information quote EMS Enquiry No. 113 on IBC

EMS November/December 2008 www.engineeringmaintenance.info

years before. Where on earth do you start? Unfortunately there is no magic formula or quick fix - but factories can and will ride this storm. Don Sull (London Business School) highlights the benefits of an ‘active waiting’ strategy in order to counter the ‘sudden death’ threat. In operational terms this means focussing on things that you can control - like streamlining internal improvements, and seizing every opportunity, however small: Take advantage of lower prices and negotiate: Try and get 20% off everything (except with your software supplier!). Don’t dilute the business by cutting everything: Broad 20% head reductions across the business are not always the best solution. If someone has a broken arm you don’t cut off both arms and legs to fix the problem. If you can, increase your training and make your people valuable assets to your company and the best in your industry. Use spare time effectively: Do all the things you’ve been putting off – starting with plant maintenance.

OEE Operational excellence is a business imperative in the current climate, and is the best way to ensure the future of your company. ‘For tomorrow belongs to the people who prepare for it today.’ (African proverb)

Make improvements so that the plant becomes the most effective operation. Improve ‘real’ productivity: Don’t just look at the biggest problems in the plant, measure and investigate everything; lots of small improvement can add up to big money, but make sure you chop the costs associated with wasted product, effort and energy. Invest: Investing in a proven performance measurement system like OEE to quantify weaknesses and seek out every bit of financial opportunity in your operations is vital – and ‘investment’ does not necessarily mean huge initial set up costs. No doubt the last point will raise wry smiles. ‘Investment’ is a difficult recession strategy to endorse. But aside from funds, what is the underlying reason for not adopting proven ways to improve production efficiency and making significant – and immediate - bottom line reductions? Is it fear of failure? I think so. The fact of the matter is that adopting an OEE system to measure performance can, and probably will reveal problems that your in-house measure has concealed and this is likely to result in a drop in performance figures. Yet this is the true value of OEE. Why try and hide poor performance? The identification

and acknowledgement of existing failings is the first important step towards making improvements and significant operational savings. When you get over this hurdle there is often further concern about the level of the risk involved in investing in OEE Software: Do our people have the skills to use it properly and will it really make improvements? What is the Return on Investment? How do I convince my boss who has been told to spend nothing? OEE software itself will not manufacture improvements, but the measure is a real catalyst for change and there are ways to ensure the potential risk is low, and calculated, so that you can be confident of achieving financial return on the solution in which you invest: 1 Choose a supplier with skilled implementers and extensive production management experience that will commit to managing the loss reduction process for you. Then ensure you fully engage your operators in the improvement process. Let’s face it the most successful sites gain most of their improvements from on-the-floor operators and team leaders. 2 Not sure of the financial potential? Get the

prospective supplier to work with your teams to identify the opportunity for improvement and calculate an accurate ROI. You don’t need as much information as you think, just labour, energy, materials, fixed costs, products, targets and revenue for a typical week. 3 What can you do about a lack of capital? Find a supplier who can offer a rental arrangement. That way, even with small early improvements, the on-going benefits will more than fund the monthly payments. There is no doubt that it’s going to be tough, but there will always be opportunities and managers need to find the courage to concentrate resources to effectively tackle problems head on. The fittest companies, with the lowest cost base, highly trained people,

efficiently maintained plant, and the best OEE measurement system to support cost effective operations, will survive. And not only will they survive, but they’ll be better placed in the market when the health of the economy is restored. www.idhammarsystems.com Reader Reply Number: 314 ABOUT THE AUTHOR Alan France is Operations Director of Idhammar Systems Limited. Contact him by e-mail: alan.france@idhammarsystems.com, or visit www.idhammarsystems.com for more on OEE software.

These OEE dashboards reveal that there are a number of failings in the plant and processes. Recovering this ‘lost opportunity’ would result in thousands of pounds of savings per week. For more information quote EMS Enquiry No. 114 on IBC

EMS November/December 2008 www.engineeringmaintenance.info

CONDITION MONITORING

Donald Lyon, Managing Director of Monitran, explains how predictive maintenance (PM) strategies are most effective when they employ vibration-based condition monitoring (CM) techniques

A FEELING FOR what’s Whilst the adage that ‘prevention is better than cure’ is well known and respected within the industry, particularly where plant equipment is concerned, standing by these words requires walking the fine line between suffering the occasional failure of a machine and over-maintaining equipment. Predictive maintenance (PM) is the tool that helps us walk this fine line. Knowing what is wearing (or failing in some other way), and how fast this is taking place, enables repairs to be undertaken as and when necessary, thus maximising the life of good components. It also facilitates the timely removal of parts which have worn unexpectedly fast. Unexpected component failure is therefore minimised and, by extension, so is machinery, line and plant failure. PM also enables best use to be

likely to fail

made of human resources (labour), by ensuring advance order and delivery of necessary components ahead of the start of the maintenance programme. However, accurately predicting if, how and when any particular component or machine is likely to fail requires a clear understanding of all the circumstances. Most failures in plant are associated with moving parts, such as motors, gearboxes, pumps, roller bearings, valves and so on. These are the parts at the beginning of the ‘domino chain’. If these fail then conveyors stop, rollers come to rest, fluids cease to be pumped, essential cooling fails and the knock-on effects start with potential local or plant-wide ramifications. All of the above parts can be placed under a condition monitoring (CM) regime and, as most of the components in question are either directly or indirectly driven by electric motors, the easiest parameter to monitor is electrical power. This can be misleading, however, because an increase in absorbed power can be difficult to detect and analyse, particularly

at the onset of a potential failure. For this reason many a PM strategist turns to monitoring temperature levels. But once again, whilst it is undoubtedly a valuable indicator, temperature cannot be trusted in all applications. In fact it can even be dangerous when used on machinery with high ambient temperatures as, by the time the temperature has risen sufficiently to raise an alarm, the equipment may already have reached a high enough temperature to start a fire. However, as most of us know from years of driving, the earliest indication of a mechanical problem is often in the form of vibration (in the form of noise or just a feeling in terms of how a piece of machinery such as a car is responding). Accordingly, vibration-based CM is playing an increasingly important role in PM strategies. Getting the shakes Essentially vibration (whether audible or not) is a form of energy loss, so if a pump, motor, gearbox, drive train or servo-valve is vibrating more than usual then the component is either being overloaded or its sub-components, such as bearings and gear teeth, are probably failing. Monitoring vibration (this ‘leakage of energy’) is neither as difficult nor as costly as most assume, as vibration sensors and associated signal

Fig 1: The piezoelectric vibration sensor

conditioning hardware are an extremely cost-effective alternative to having equipment fail. Vibration sensors are electronic devices, employing either piezoelectric or piezoresistive technology. Of these two technologies the former is more prevalent in plant monitoring applications. The structure of a typical sensor is shown in figure 1. Circuitry within the sensor converts the charge into a voltage for output to monitoring systems. Although vibration monitoring can be carried out as and when required with portable measuring equipment, predictive maintenance is best implemented through the use of permanently located sensors. As for the top-level, ‘efficiency benefits’ associated with including vibration monitoring as part of a PM strategy, it is perhaps best to cite an example. Within the last few years Corus Strip Products, which prepares coal for injection into blast furnaces, has incorporated hardwired vibration monitoring into its plant. The results have been dramatic. After only a single year of the regime being in place, Corus has managed to shrink its third party maintenance costs to just one eighth of the previous level. www.monitran.com Reader Reply Number: 315

18 EMS November/December 2008 www.engineeringmaintenance.info

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MOTORS/DRIVES High-efficiency motors from ABB are saving a leading supplier of bakery products over £10,000 a year in energy costs and a further £5,000 in spare parts

ABB motors save Cereform

£15K PER YEAR Cereform is the only manufacturer of soya flour in the UK and produces around 12,000 tonnes a year at its site in Royston. It has some 120 motors on site and is gradually phasing out its older models in favour of high-efficiency alternatives. Most recently, ABB Motor Service Partner, Heasell Electromechanical Services, supplied 18 high-efficiency AC motors from ABB to run nine flour mills. Each mill uses two 22-kilowatt motors to turn the 80-kilogram plates that grind the soya beans. The site runs 24 hours a day during the week and the old motors were causing a real maintenance headache. “Failure of the old motors was a major concern and repairing them was a major cost,” says site engineer Rory Perks. He estimates that Cereform was spending around £5,000 a year on replacement parts associated with the old motors. “Reliability is now excellent

and the new motors are virtually maintenance free,” he adds. Perks also estimates that the 18 EFF1 motors are saving over £10,000 a year in energy, thanks to their high-efficiency performance. EFF1 is the highest efficiency category for motors sold in Europe. EU officials estimate that replacing all the inefficient EFF3 motors now in use across the Union with standard-efficiency EFF2 versions would yield energy savings of 6TWh, or £200m a year. Even higher savings would result from the increased use of the highest-efficiency, EFF1, motors. High-efficiency motors are typically more reliable than low efficiency versions. This is partly because they waste less energy as heat, which degrades the motor windings. Windings are second only to bearings in terms of the number of breakdowns they cause.

Theoretically, a reduction of 10 -15º C in the running temperature will double the life of the winding. The normal running temperature in high quality motors running at full load can be as low as 60-80º C, while lower quality motors frequently run in excess of 90º C. According to Perks, the windings on Cereform’s old motors didn’t often fail completely, but when they did they had to be sent away to be rewound, which cost the plant £1,400 and several days of downtime. Service and support were other important factors in Cereform’s decision. “I have received excellent service and support from Heasell over many years,” says Perks. “However, they still had to be very competitive on price.” www.abb.co.uk Reader Reply Number: 316

21 EMS November/December 2008 www.engineeringmaintenance.info

PUMPS

Fully restored and protected pump with a Belzona Supermetalglide system

The rising cost of energy has lead to more companies searching for technologies to improve operational efficiency

IMPROVING PUMPING EFFICIENCY Belzona Polymerics Limited, a manufacturer of polymer repair composites and industrial protective coatings has the solution for improving the operational efficiency of pumps by the application of a hydrophobic coating system. Considering that the transfer of fluids accounts for the largest single use of energy worldwide with millions of litres pumped from one location to another every second of everyday worldwide, it is therefore understandable that all industries would benefit from any solutions aimed at increasing pumping performance. Belzona has, of late, seen a dramatic increase in the use of Belzona products for pump restoration. According to Jérémie Maillard, Business Development Engineer, and pumping industry specialist for Belzona, the number of repairs to damaged pumps and/or components has nearly doubled in the last two years. He commented, “Many companies are working to minimise running costs by exploring alternative means of tackling energy consumption. Meanwhile, more and more pump manufacturers are considering coating new equipment with Belzona 1341 Supermetalglide due to its proven economical benefit.” A major problem is increased turbulence caused by the detrimental effects of erosion corrosion. This leads to rough and pitted surfaces which in turn, increase drag, therefore reducing the efficiency of the system. David Blackwell, Engineering Director for Belzona explained “It is not unusual for a pump which has been in service for a number of years to be operating at 15-20% below its design efficiency, due to the effects of erosion corrosion. By rebuilding and protecting these damaged areas with a Belzona corrosion and erosion resistant material it is possible to not only restore flow rates, but also increase the

efficiency level of the pump to beyond that when it was newly installed.” Belzona’s rigorous research and development programme spanning decades has further advanced polymer technology in the area of efficiency enhancement. The Belzona solution has been specifically designed as a hydrophobic, smooth surface coating with low surface energy and erosion resistant fillers. The material allows an ultra smooth surface that reduces turbulent flow, thereby increasing efficiency. The testing of Belzona 1341 Supermetalglide was carried out under strict independent laboratory conditions utilising the most up to date fluid flow test facilities of the National Engineering Laboratories (N.E.L.) who, as part of the UK’s Department of Trade and Industry, represent the most comprehensive pump test facilities of their type available anywhere in the world. In this case, the test vehicle chosen was a single stage, end suction centrifugal pump with 10 inch suction and discharges branches. The pump, in uncoated

Worn and damaged pump awaiting repair

22 EMS November/December 2008 www.engineeringmaintenance.info

condition, running at 1300 rpm, was found to deliver 875m3/hr at 26.5 meter head with an overall peak efficiency of 83.5%. Testing of the same pump coated with Belzona Supermetalglide gave a 6% increase at peak efficiency, giving a power reduction of 5.1kW at duty point. Assuming a 5,000 hour operating cycle/annum, the power saving over this period would amount 25,400kW.hr. Belzona 1341 Supermetalglide, through independent testing, has been proven to increase pump efficiency across its operational range while maintaining its original head/flow characteristics. By repairing worn and damaged equipment, or protecting new pumps, the Belzona 1341 Supermetalglide system will have an immediate effect on performance and operating costs giving many years of power savings in conjunction with high performance erosion corrosion protection. sales@belzona.co.uk www.belzona.com Reader Reply Number: 317

STEAM TRAPS Savings made from installing GEM’s Sapphire range of steam traps will help companies offset recent rises in gas and oil costs with energy savings of up to 55%

Sapphire steam trap

OFFSET POWER RISES A further addition to GEM’s growing range of award winning venturi steam traps, the GEM Sapphire has been specifically developed for screwed pipework applications. Removing the need for steam trap surveys, regular maintenance and replacement traps, the highly efficient GEM Sapphire has no moving parts to fail open thereby wasting steam and energy, or jam shut risking water hammer and system failure. Instead the highly efficient GEM Sapphire uses the patented venturi orifice design to effectively drain condensate from the steam. Available in five sizes ranging from 15mm to 50mm, the hardwearing GEM Sapphire is manufactured from corrosion resistant stainless steel and performance guaranteed for 10 years. The GEM Sapphire provides the

THE

ultimate in reliability necessitating only minimal maintenance and requiring no spares, testing or monitoring equipment. The three smaller sized GEM Sapphire steam traps are supplied with a strainer and unions as standard for easy installation. The simple design enables the GEM Sapphire to be quickly installed into existing and new applications with operating pressures of up to 17.2bar. According to Government figures released last year, industrial gas prices in the first quarter of 2006 were a staggering 65.2% and industrial electricity prices 48% higher than during the same period of 2005. As a heat transfer medium, steam has an advantage over fluids such as hot water and oil as it is able to store very large quantities of heat, which can be

given up at constant temperature as the steam condenses. Unfortunately, more energy is lost in industry through steam wastage than through any other medium. The GEM Sapphire provides a fast payback – on some processes within a matter of days – from reduced energy costs and increased equipment reliability due to a reduction in damaging condensate build up in steam systems. In addition it improves product processing by enhancing the quality of steam and also reducing equipment repairs, downtime and replacement costs. Unfortunately, when it comes to steam traps, people often ignore them. This complacency is costing steam users much more than they realise. The hard reality of a plant maintaining its boiler and forgetting about the rest of the steam system can be a horribly wasteful proposition. Fortunately, installing the low maintenance GEM Sapphire there is no steam loss through a trap, fuel is conserved, reliability improved, downtime reduced and safety increased. www.gemtrap.com Reader Reply Number: 318

GREASOMATIC'96 ® AUTOMATIC LUBRICATOR

British, European and international patents. Can be set by means of the control knob to discharge lubricant continuously for any of 7 periods ranging from 1 to 12 months. Completely selfcontained. No tools or separate starters needed.

ROBUST RELIABLE INEXPENSIVE USER FRIENDLY Suitable for the lubrication of lift-car guide rails, diverter sheave bearings and all ancillary motors and drives. The use of the GREASOMATIC will extend component life and reduce downtime. Manufactured by:

WYMARK

Web: www.wymark.co.uk

Runnings Road Industrial Estate, Cheltenham, GL51 9NQ,England. Fax: 01242 519925. Telephone: 01242 520966.

For more information quote EMS Enquiry No. 118 on IBC

EMS November/December 2008 www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 119 on IBC

CONDITION-BASED MAINTENANCE

Industry is a place of motion and since most of this is rotary its no surprise to find that a lot of the effort in Condition Based Maintenance and hence machinery condition monitoring is aimed at rotating machinery. In fact recent advances have greatly simplified this area of CM in terms of both portable instruments and continuous monitoring systems

Thereâ&#x20AC;&#x2122;s more to condition monitoring (CM) than

KEEPING THE WHEELS TURNING Amidst the excitement of these developments its important not to lose sight of the need to be aware of the condition of all machinery that is critical to the production process. At some stage in many production processes this involves machinery which is not simply rotating such as : presses, guillotines, stacking mechanisms, packing machines, valve operations, incrementing conveyors, rams & actuators, robot arms, pick & place machines, injection moulding machines, crane operations, transformer tap changers, locking mechanisms etc.. On such machines there can sometimes be a temptation to believe they fail with little or no warning since developing faults are not always easily detected by the human senses. However to reap the benefits of Condition Based Maintenance you need to not just detect such faults but to detect them early enough to be able to minimise both secondary machine damage and disruption to production. The key to detecting mechanical degradation of non-rotating machines is to recognise that a feature they usually have in common is a repeated time sequence and developing faults cause subtle changes to this. An approach to recognising these is based on the Acoustic Emission (AE) technique which provides a sensitive and convenient way to detect the energy losses

associated with such time sequences in terms of a time profile signal. It is well documented that surface mounted AE sensors detect the high frequency structure borne sounds which are directly produced by processes such as friction, impacts, crushing and turbulence. Hence changes in the shape, magnitude and precise timing of the various features making up the AE time profile from a nonrotating machine can be used to provide early warning of wear and degradation. Furthermore the point of occurrence of such changes within the time sequence provides a route to diagnosing the fault when interpreted alongside specific knowledge of the machine cycle. Of course this is entirely academic if the necessary AE instrumentation for detecting and collecting such time profiles is impractical for industrial use. This is where a new development from Holroyd Instruments, the AE-Ultraspanâ&#x201E;˘ sensor (see photo), represents a significant breakthrough. This sensor incorporates the high frequency AE sensing element and its associated amplification and filtering together with wide dynamic range signal processing and much more. The AE Ultraspan sensor can continuously stream out the dynamic envelope of the AE signal into a remote PC via its built-in aerial and industrial strength Bluetoothâ&#x201E;˘ Class I wireless

24 EMS Novenber/December 2008 www.engineeringmaintenance.info

communications. Installation times and costs are dramatically reduced compared with conventionally wired AE systems. A further benefit of wireless communications is that the sensor can be easily installed on moving parts of machinery. Standard PC software supplied with the USB to Bluetooth PC interface enables ongoing real time capture onto the PC memory. Alternatively a trigger level based single shot mode can be used which has pre-trigger to allow capture of the entirety of discrete transients. Stored data files can be replayed on the PC screen or exported as a text file to third party analysis software as required. For longer duration machine (or industrial process) cycles the AE-Ultraspan sensor also has a statistical mode in which the AE signal is continuously pre-processed in terms of Maximum, Minimum and Mean (over user defined averaging periods). This reduces the information being transmitted and stored by the PC whilst retaining pertinent signal information. For permanent installation provision is made to power the sensor from a local DC supply however a small rechargeable battery within the sensor allows for completely wireless sensing in short-term investigations. www.holroyd-instruments.com Reader Reply Number: 319

BEARINGS

More than 40 per cent of all premature failures of rolling bearings are caused by inadequate or incorrect selection of lubricant. Choosing the most appropriate grease and re-lubrication equipment for a bearing application is therefore vital, says Ian Pledger of Schaeffler (UK) Ltd

Selecting the right grease for

ROLLING BEARINGS More than 80 per cent of all rolling bearings are lubricated with grease. It is therefore critical that engineers select the most appropriate grease for the bearing and the application it is operating in. Not only will correct selection prolong the life of the bearing, enabling it to operate at its full capacity, but it also ensures smoother running behaviour and improved operational safety. But selecting a suitable lubricant for a rolling bearing can be a complex process. Grease is basically a type of oil with a thickening agent added to it, giving it a more viscous form. There are many different types of bearing grease available, so engineers should take the time to make more informed selections that ensure a long and trouble-free life for the bearing. Greases can be used effectively to lubricate bearings over a

very wide range of operating conditions. However, initial selection is based on two critical parameters. First, the ‘P/C’ ratio, which is a measure of the load ‘P’ on the bearing in relation to the dynamic capacity ‘C’, which is calculated according to international standards and quoted by all leading bearing manufacturers in their technical literature. In general, if the ‘P/C’ ratio is greater than 0.15, the bearing is regarded as heavily loaded, and special lubricants with extreme pressure additives will be required to increase the load carrying capacity of the bearing and to prevent metal-to-metal contact, which leads to high wear and premature bearing failure. Generally, a P/C of less than 0.15 for radially loaded bearings using standard lithium soap greases (normal operating conditions) is 400,000 min-1.mm. It is also important to keep the ‘P/C’ ratio above 0.02, as in general, below this value, the bearing will ‘skid’ rather than roll, again resulting in possible premature bearing failure due to high wear and an increase in friction. To avoid slippage with caged ball bearings, engineers should work on a P/C of 0.01 and for caged roller bearings, a P/C of 0.02 is advised. Second, the ‘ndm’ value – which is calculated from the speed of the bearing ‘n’ in rpm and the bearing mean

diameter ‘dm’ in mm – will give an indication of the relative speed of rotation to the physical size of the bearing. In general if the ‘ndm’ value is below 400,000 then standard general purpose bearing greases can be effectively used to lubricate the bearing. For ‘ndm’ values in excess of this, special greases are required, which have relatively low base oil viscosities, in order to reduce the amount of heat generated by the bearing when rotating at higher speeds. It is quite possible, with recent developments in both bearings and grease lubricants, to achieve ‘ndm’ values of up to 2,000,000. Whilst grease lubrication is inherently simple, there are many bearing applications where oil is the only choice available, since it has the key attribute of being able to remove the heat generated in the bearing due to load and speed. It is quite possible that ‘ndm’ values up to 4,000,000 are achievable for oil jet lubrication. Schaeffler’s Arcanol range of rolling bearing greases provides optimum conditions for achieving reliable, durable and cost effective bearing solutions. The company works closely with lubricant manufacturers to develop special greases that are suitable for rolling bearings. Schaeffler conducts a series of stringent in-house tests on the lubricant to determine their service life, friction and wear characteristics. Only the bestperforming greases are then selected to undergo subsequent tests under simulated field conditions in far more complex rolling bearing test rigs. If the grease fulfils Schaeffler’s stringent tests, it is decorated with the Arcanol seal of quality. In addition, each incoming batch of grease is

25 EMS November/December 2008 www.engineeringmaintenance.info

BEARINGS

100% inspected by Schaeffler to ensure the uniform quality of the product. The Arcanol range includes 15 rolling bearing greases, each graduated to cover all application areas. For example, MULTITOP is a universal grease for ball and rolling bearings that is suitable for use in construction machinery, automotive engineering, rolling mills and grinding machine spindles. VIB3 is a mineral-based grease with a polycarbamide thickener, which is suitable for use in blade adjusters in rotors for wind turbines, packaging machinery and rail vehicles. The grease offers excellent resistance to high temperatures, high loads and oscillating motion. MULTI3 is a specially formulated grease for large electric motors, agricultural machinery and fans. FOOD2 is a

white oil-based grease for use with ball and roller bearings in applications where contact with food occurs. Relubrication Equipment In harsh operating conditions or aggressive environments, rolling bearings should be relubricated frequently via lubrication nipples. Schaeffler therefore offers its FAG grease guns and matching reinforced hoses for this, which enable rapid manual relubrication of bearings. Controlled relubrication of bearings is often required in order to extend service and maintenance intervals and minimise plant downtime. Schaeffler offers three main products for this. Motion Guard COMPACT is a single point electro-chemical lubrication system that comprises a housing filled with 120cm3 of grease, controlled

via an activation screw. Motion Guard CHAMPION is a single point, batteryoperated lubricator that comprises either a 120cm3 or 250cm3 volume of grease, with drive unit and adaptor. Motion Guard CONCEPT6 is an electromechanical single point lubrication system that can be expanded to include up to six lubrication points. FAG metering devices are also provided, enabling customers to supply grease to rolling bearings in metered quantities, from 10cm3 up to 133cm3. By using a pneumatically driven, double direction piston pump, the lubricant is transferred from the grease drum (25kg or 180kg) via the metering valve to the point of application. Reader Reply Number: 320

SELF-CONTAINED AUTOMATIC LUBRICATORS The Worldâ&#x20AC;&#x2122;s Champion Lubricator FOR SINGLE OR MULTI-POINT APPLICATIONS The most powerful self-contained, lubers available!

ULTIMATE LUBER More Adaptability Can be used in single or multi-point configurations. More Power Up to 900 PSI lets you lubricate up to 8 bearings using a distribution block.

500cc

250cc

125cc

Available in 3 sizes

More Versatility Runs off internal battery pack or optional external power sources. Now custom programmable Ask us for more details.

SINGLE POINT LUBER Safe, inert nitrogen gas Variable from 14 days to 1 year Remote control option Temperature range -40F to +131F (-40C to +55C) Easy-to-use-simply select the flow rate, install & activate Flashing light confirms operation Approvals: Intrinsically Safe Safe Approvals CSA, UL, Instrinsically ATEX ia E, IICF,T3 Class 1,Certified Groups A, EEX B, C, D, G, MSHA, Energy Mines

BLE REFILLA

Available in 4 sizes

Jumbo 475cc

Budget 250cc

Mini 125cc

Micro 60cc

ELECTRO-LUBE (UK) LIMITED INC. A.T.S.A.T.S. ELECTRO-LUBE INTERNATIONAL TOLL FREE 1-800-663-8141 FREETEAM FAX VALLEY 1-800-663-8140 www.atselectrolube.com 383L JEDBURGH COURT, ELEVENTHTOLL AVENUE, TRADING ESTATE, GATESHEAD NE11 0BQ TELEPHONE: 491 4212 FAX: 0191 491 4224 email: info@ats-electro-lube.co.uk OVER 25 YEARS OF 0191 MANUFACTURING RELIABLE LUBRICATION PRODUCTS FOR AN INDUSTRIAL WORLD OVER 25 YEARS OF MANUFACTURING RELIABLE LUBRICATION PRODUCTS FOR AN INDUSTRIAL WORLD

For more information quote EMS Enquiry No. 120 on IBC

EMS November/December 2008 www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 121 on IBC

ATEX

DSEARâ&#x20AC;Ś are you aware of your LEGAL responsibilities? You are probably aware that it is your duty as an employer to provide a safe place of work for your employees together with those visiting your worksite - and to protect them against the risk of fire and explosion arising from dangerous substances and explosive atmospheres used or present in the workplace. However, you may not be aware that the European Parliament recently passed additional workplace safety legislation for implementation within EU member countries. In the UK the legal framework implementing the safety aspects of that legislation (the European ATEX 137 Workplace Directive) is the Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR). Full compliance

with DSEAR has been mandatory in the UK since July 2006, with the Health & Safety Executive (HSE) having overall policing responsibilities for industrial sites. DSEAR requires a risk assessment to establish if a dangerous substance is present or likely to be present in the workplace and if it presents a risk to the safety of personnel on site. In workplaces where flammable or explosive atmospheres may occur, employers must classify and mark those places into clearly identified zones and must provide suitable protection from sources of ignition; both electrical and mechanical sources i.e. select and install appropriately rated ATEX compliant electrical and mechanical equipment.

Also included within DSEAR is the requirement to provide suitable and sufficient information, instruction and training to enable employees to safeguard themselves in the workplace and to have arrangements in place to deal with accidents, incidents and emergencies. DSEAR non-compliance can have the most serious repercussions; attracting at best an HSE improvement notice or at worst, a full prohibition notice together with immediate asset closure and the possible commencement of criminal proceedings not only against the asset owner, but also against responsible individuals. www.icm-uk.com Reader Reply Number: 321

27 EMS November/December 2008 www.engineeringmaintenance.info

ATEX

Many industrial processes consistently generate considerable quantities of fine dust, which starts as ‘just’ combustible but becomes highly explosive when enriched with oxygen. An ignition source in the plant can then set off an explosion with enormous damage to machinery and men

BETTER VENTING BOOSTS PROTECTION

against dust explosion Although ATEX directive 94/9/EG obliges operating companies to carry out primary explosion protection, compliance only statistically reduces the odds of a disaster while still leaving the dust explosion risk itself still in place. ATEX therefore strongly requests additional constructive explosion protection in plants operating with fine dusts, and the addition of explosion venting with relief panels approved by the directive provides the ideal solution. If a dust explosion occurs, its pressure is reduced to a harmless level within in the plant. These relief panels must resist operating pulsations and temperature changes, corrosive environments and the

early material fatigue of some makes which experience shows endangers safety and causes costly plant shutdowns. ‘Ex-Go-Vent’ explosion relief panels from REMBE of Germany and now available in the UK from Orthos distinguish themselves by bionic structures which eliminate all such operational problems. Approved to FSA 04 ATEX 1538X, their unique patented design guarantees durability and an exceptionally long working life under all production conditions. Combining the user benefits of full plant availability and simplified installation with considerable cost savings, these flat singlelayer panels give 100% venting efficiency.

28 EMS November/December 2008 www.engineeringmaintenance.info

They are available in 25 different standard dimensions for a wide range of applications. Quick and easy mounting is ensured by a patented concept of combined gasket and breaking point configuration that eliminates the need to control the clamping torque of the fixing bolts that is required by other manufacturers. Processes that generate fine dusts such as a flour mills, wood processing plants, animal feed compounders, sugar processing, fuel handling plants are typical applications for the Ex-Go-Vent explosion relief panels. www.orthos.uk.com Reader Reply Number: 322

Dust and fume extraction hoses from Masterflex

Temperature range -260째C to +1100째C Size range 38 mm to 900 mm Very flexible, small bend radius Long service life, low operating costs Suitable installation and connecting systems Masterflex Technical Hoses Ltd GB-Oldham OL1 4ER Tel: 0161 626 8066 www.masterflex-uk.com PU / FABRIC HOSES

CONNECTIONS

TUBE PROTECTION

For more information quote EMS Enquiry No. 123 on IBC

For more information quote EMS Enquiry No. 122 on IBC

For more information quote EMS Enquiry No. 124 on IBC

For more than three decades, easyFairs MAINTEC has been the event for asset management and condition monitoring

NEWCOMERS JOIN FAMILIAR FACES

at easyFairs MAINTEC Showcasing the latest developments in hazard detection and predictive maintenance technologies, MAINTEC has become an industry byword for cost and efficiency savings – considerations that, due to the economic slowdown, have been propelled up the priority list of Plant Managers and Engineering Directors. Like all successful trade shows, easyFairs MAINTEC has evolved…and the 2009 event, at Birmingham’s NEC from 17-19 March, is no different. Suppliers of mechanical equipment, lubricants, buildings and facilities management, and energy efficient products will feature more prominently; there’s a new easyFairs MAINTEC Summit where key industry issues will be debated; and plans are in place to introduce a ‘Student Zone’ where exhibitors and visitors can chat with engineering innovators of tomorrow. As a result, it continually attracts event newcomers to exhibit alongside easyFairs MAINTEC stalwarts who have used the show as a platform to meet influential industry professionals for many years. New product launches Almost 100 companies are already committed to next year’s show (organisers are confident of surpassing the 2008 tally of 150 exhibitors) with around 10 per cent appearing for the first time. Amongst the debutants are circuit breaker retrofit specialists Santon; cable supplier Lapp Group; Leicestershire-based Enercom – which offers instruments to monitor and meter electrical grid networks to protect against power disruptions – and multi-key management solution providers Keytracker. Others include Olympus Industrial – a leading manufacturer of advanced testing instruments such as remote visual inspection devices, ultrasound, eddy current, and highspeed video – and Eurotron, experts in calibrators, infrared thermometers and combustion gas analysers. And the added focus on industrial facilities management providers has led to Promanex – an industrial support operation in Hurley, Warwickshire, that offers traditional FM, asset management, and maintenance services – signing up to easyFairs MAINTEC 2009.

Promanex Group Marketing and Communications Manager, Gemma Tunley, said: “We’ve chosen MAINTEC as it gives us the opportunity to promote our services to key industry buyers and decision-makers, and the handy, central location makes it an easy event to man. “As a company, we’re committed to reducing the environmental impact of our activities, so I was delighted to learn of easyFairs’ eco credentials and that they’re a low-carbon footprint trade show.” Several multi-nationals will also be appearing at easyFairs MAINTEC 2009 for the first time. These include Shell Oil Products – which will demonstrate how effective fluid management can help reduce operational costs and boost efficiency – and Festo, a world-leading supplier of pneumatic and electrical automation technology. Their arrival, alongside smaller players, emphasises easyFairs’ ethos of time- and cost-effective shows that are accessible to companies ranging from niche suppliers to those turning over in excess of £1 billion. And as the economic slowdown sees a shift to low-cost alternatives, the easyFairs’ proposition is proving even more appealing to businesses. easyFairs UK Managing Director, Peter Heath, said: “In good times, people might be more inclined to visit larger industrial shows and buy a complete new system. But now plant managers are more interested in buying replacement parts and upgrades to existing systems…easyFairs® MAINTEC is a unique trade show market for these kinds of technologies and products. “Companies are naturally more focused than ever right now on getting a great return on their investment. easyFairs MAINTEC enables exhibitors to do business, develop new contacts and make sales at a fraction of the cost of a traditional trade show. “Large trade fairs are demanding both in terms of time, resource and budget and there is a lot of casual footfall. That may be great for making a brand statement but if we’re heading, as many people predict, towards further economic uncertainty is that really enough? Exhibitors want a tangible return on investment in addition to raising their profile.

30 EMS Novenber/December 2008 www.engineeringmaintenance.info

International appeal easyFairs MAINTEC 2008 attracted almost 2,000 industry decision-makers – and next year’s show is expected to be a ‘must do’ diary date for even more manufacturing and processing leaders. Visitors will discover the latest product innovations not just from UK-based companies but, thanks to easyFairs’ network of trade events across Europe, firms that have been convinced to attend after enjoying success at sister shows. Arms Reliability Engineers, based in Victoria, Australia, and SPX Hydraulics Technologies – which has its HQ in Eygelshoven, Holland – will both be making their debuts in the 2009 easyFairs MAINTEC exhibitor guide. SPX’s Sales & Marketing Manager, Sander Magnin, visited an easyFairs maintenance show in Brussels recently and, after being won over by the low-fuss, business-focused concept, will be showcasing its new range of hydraulic torque wrenches at easyFairs’ expos in MalmŒ, Antwerp, Zurich, Dortmund and Birmingham next year. Similarly, Arms Reliability Engineers – based in the Victoria coastal town of Ocean Grove – were persuaded to exhibit at easyFairs MAINTEC 2009 after their appearance at easyFairs’ Belgian maintenance show generated a large number of new business leads. Company Business Analyst Josh McIntosh, said: “We provide Asset Reliability Improvement Solutions across a wide range of industries. By predicting the performance of their assets, we are able to help clients align maintenance and engineering practices with strategic business goals, which in turn helps them design more efficient plants, modify existing plants, and maintain their assets over a chosen lifecycle. “The MAINTEC show promises to put us in front of exactly the right kind of industry decision-makers.” For stand bookings contact and

more information contact Sunita Puee on 0208 622 4416 or e-mail: sunita.puee@easyfairs.com

Reader Reply Number: 340

w w w. m s l re c r u i t m e n t . c o m JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY:

PRINCIPAL MECHANICAL DESIGN ENGINEERS 7708 STAFFORDSHIRE £Neg (per year) ENGINE DEVELOPMENT ENGINEER 7833 VANCOUVER, CANADA £Neg (per year) BUSINESS MANAGER 7909 SOUTH WEST £45 K (per year) + Benefits + Car QUALITY ENGINEER 7866 CROYDON £Neg (per year)

w w w. m s l re c r u i t m e n t . c o m

j o b s @ m s l re c r u i t m e n t . c o m JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY: JOB TITLE: REFERENCE: LOCATION: SALARY:

MEASURING ENGINEER 7669 MEASURING QUALITY ASSURANCE AUSTRIA ENGINE DEVELOPMENT ENGINEER 7833 VANCOUVER, CANADA £Neg (per year) ASSISTANT EMISSIONS ANALYST 7665 WEST SUSSEX £Neg (per year) VENTILATION BUILDING SERVICES ENGINEERS 5666 READING £NEG (PER YEAR)

j o b s @ m s l re c r u i t m e n t . c o m

TO ADVERTISE YOUR LISTING PLEASE PHONE 0207 9933355 Company WebsiteIN OUR BUYER’S GUIDE Email Contact Telephone Number ACCESS EQUIPMENT Planet Platforms

www.planetplatforms.co.uk

info@planetplatforms.co.uk

0800 0854161

ASSET MANAGEMENT Rockwell Automation

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

BOILERS Byworth Boilers Certuss Steam Generators Wellman Robey

www.byworth.co.uk www.certuss.co.uk www.wellman-thermal.com

sales@byworth.co.uk sales@certuss.co.uk info@wellman-thermal.com

01535 665225 0121 3275362 0121 543 0000

BOILER HIRE Kings Boiler Hire Wellman Robey

www.kingsboilerhire.com www.wellman-thermal.com

enquiries@kingsboilerhire.com info@wellman-thermal.com

01992 451629 0121 543 0000

BOLT SECURING SYSTEMS Nordlock Ltd

www.nord-lock.co.uk

enquiries@nord-lock.co.uk

44 (0)1980 847129

CMMS Cayman Venture Idhammar Systems Ltd PMI Software Productivity Europe Shire Systems Softsols Group Ltd

www.cayman.co.uk www.idhammarsystems.com www.pmisoftware.co.uk www.productivityeurope.org www.shiresystems.co.uk www.getagility.com

info@cayman.co.uk info@idhammarsystems.com Louis.Tuttle@pmisoftware.com m.jones@productivityeurope.org info@shiresystems.co.uk info@softsolsgroup.com

0191 2963816 0117 9309300 353 (0)1404 0000 01234 215867 44(0) 23 80224111 44(0)1924 200344

SolutionsPT Spidex Software Limited

www.assetpt.co.uk www.spidex.co.uk

martyn.williams@assetpt.co.uk info@spidex.co.uk

44 (0)161 495 4600 0121 779 0888

SRO Solutions

www.srosolutions.net

info@srosolutions.net

44 (0)845 408 4250

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info 31 EMS November/December 2008 www.engineeringmaintenance.info

ANNUAL BUYERS GUIDE continued TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE 0207 9933355 Company

Website

Email Contact

Telephone Number

Airchannel Ltd

www.airchannel.co.uk

info@airchannel.co.uk

0800 526581

Atlas Copco Compressors

www.atlascopco.co.uk

gba.info@uk.atltascopco.com

0800 181085

Gardner Denver

www.gardnerdenver.com

info.uk@gardnerdenver.com

01452 338116

www.speedyhire.co.uk/compressors

enquiries@speedycompressors.co.uk

0845 307 0777

Alpine Components

www.alpine-components.co.uk

mike@alpine-components .co.uk

01424 437000

Artesis

www.artesis.com

info@artesis.com

0845 634 3854

Elcomponent Ltd

www.elcomponent.co.uk

sales@elcomponent.co.uk

01279 503173

Holroyd Instruments

www.holroyd-instruments.com

sales@holroyd-instruments.com

01629 822060

Proviso Systems

www.proviso-systems.co.uk

sales@proviso-systems.co.uk

01777 817536

Monitran

www.monitran.co.uk

info@monitran.co.uk

01494 816569

Schaeffler

www.schaeffler.co.uk

info.uk@schaeffler.com

0121 351 3833

SPM Instrument UK ltd

www.spminstrument.co.uk

info@spminstrument.co.uk

01706 835331

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

www.metrum.co.uk

enquiries@metrum.co.uk

0118 973 3000

www.icm-uk.com

info@icm-uk.com

01779 474748

www.rockwellautomation.co.uk

ukmarketing@ra.rockwell.com

0870 2425004

www.dixoneurope.co.uk

enquiries@dixoneurope.co.uk

44 (0)1772 323529

www.totalprocesscooling.co.uk

sales@totalprocesscooling.co.uk

44(0)121 711 4014

www.bidgroup.co.uk

sales@bidgroup.co.uk

0870 607 5050

www.ambirad.com

marketing@ambirad.co.uk

44 (0)1384 489700

COMPRESSED AIR

COMPRESSED HIRE Speedy Compressors CONDITION MONITORING

CONDITION MONITORING EQUIPMENT/SERVICES Rockwell Automation DATA ACQUISITION Metrum HEALTH & SAFETY Integrity&Compliance Management HEALTH & SAFETY PRODUCTS Rockwell Automation HOSE AND COUPLINGS Dixon Europe INDUSTRIAL COOLING TPC(Total Process CoolingLtd) INDUSTRIAL DOOR SERVICES BID Group INDUSTRIAL HEATING Ambirad INDUSTRIAL FLOORING CG Flooring Systems Ltd

www.cg-flooring.com

info@cg-flooring.com

01484 600085

Dura Composites

www.duracomposites.com

info@duracomposites.com

44 (0)1255 423601

www.biz.fm

hire@biz.fm

44 (0)1344 459314

www.ats-electro-lube.co.uk

info@ats-electro-lube.co.uk

0191 491 4212

www.tcardsdirect.com

sales@tcardsdirect.com

01732 871417

Express Instrument Hire

www.expresshire.net

sales@expresshire.net

01772 815600

Flir

www.flir.com

sales@flir.com

01732 221245

Fluke

www.fluke.co.uk

industrial@uk.fluke.nl

020 7942 0700

Hawk-IR

www.hawk-ir.com

sales@hawk-ir.com

01642 497000

Testo Ltd

www.testo.co.uk/testo880

–

01420 544 433

www.infraredinstitute.co.uk

info@infraredinstitute.co.uk

44 (0)151 424 4060

www.nfpc.co.uk

enquiries@nfpc.co.uk

01909 504700

www.hansfordsensors.com

sales@hansfordsensors.com

0845 6801957

INSTRUMENT HIRE Bisra LUBRICATION ATS Electro-lube (UK) ltd PLANNED MAINTENANCE T Cards Direct THERMOGRAPHY

THERMOGRAPHY TRAINING The Institute of Infrared Thermography

TRAINING National Fluid Power Centre VIBRATION ANALYSIS Hansford Sensors

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info 32 EMS November/December 2008 www.engineeringmaintenance.info

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Artesis MCM – Advanced Technology for Simple, Effective Condition Monitoring

Every now and then, a new solution comes along and changes your thinking. Artesis MCM is a new approach to condition monitoring, providing all the benefits without the complication and costs of traditional systems. Artesis MCM monitors the condition of equipment driven by electric motors, using the motor itself as a sophisticated transducer. It requires only connection into the motor’s electrical supply, avoiding the need to attach specialised sensors to the plant. Because Artesis MCM is permanently installed, it provides continuous fault monitoring and doesn’t require the manual data collection that represents a major cost of using walkaround systems. So Artesis MCM is especially applicable to situations where the plant is not easily accessible, either because it is remote or because the local environment is hazardous.

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Artesis MCM uses advanced technology developed for NASA to bring you a selflearning capability in a compact, panel-mounted instrument. Over the initial period of operation, it teaches itself about the normal operation environment of your equipment so that it can accurately identify and diagnose faults when they start to occur. Artesis MCM doesn’t demand specialist setup or operating expertise, it just tells you what you need to know, when you need to know it. If you want all A S the benefits of condition monitoring but think it’s too difficult or expensive for you, Artesis MCM will make you think again.

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www.artesis.com For more information quote EMS Enquiry No. 125 on IBC