ems sept/october 2007

SEPT/OCT 2007 LAUNCH ISSUE INDUSTRY NEWS GUIDE TO BUYING ISSUE 1

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

Spotlight on ATEX:

Understanding reliability?

Plant Management

Facilities Management

Exploding the myths Energy Matters

www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 101 on IBC

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INDUSTRY NEWS

4

Tracking trends in the ever changing maintenance world

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MAINTAIN 2008

7

Show time: products, services, knowledge and more

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ATEX

15

When it comes to explosive atmospheres, be safe not sorry

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FACILITIES AND PLANT MANAGEMENT

19

Automated calibration planning lowers maintenance costs

IT’S ALL IN THE NUMBERS

At the start of my engineering career I was lucky enough to land a design engineering post at a company specialising in factory automation systems. From that day forward, I learned the true meaning of words like maintenance, reliability and quality.

Think about this, a family car averages 40mph throughout its life and suffers a major failure at 100,000 miles. That’s 2,500 hours or 104 days run-time, including 10 scheduled services. Big deal, factory systems might be expected to run un-serviced 24/7 for a year or more. I remember one company contemplating a 50-year un-serviced design life for a bearing system buried deep in a tunnel.

With these examples in mind, it’s easy to see how creeping legislation, shrinking budgets and productivity demands are making engineering maintenance a tricky game. Fear not, the answers are there, it’s just a matter of finding the optimum technology and right supplier.

To this end we welcome you to EMS magazine, packed with products, technologies, suppliers and advice, all aimed at making engineering maintenance a relaxed, profitable and rewarding career. Enjoy.

Jon Barrett, EDITOR www.engineeringmaintenance.info THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

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ENERGY

26

Asset management’s role in curbing greenhouse gas emissions

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DUST AND FUME EXTRACTION

30

Time to clean up: extracting damaging dust and fumes at source

Editor: Jon Barrett editorial@engineeringmaintenance.info Advertisement Sales: Paul Reynolds p.reynolds@engineeringmaintenance.info 0207 9933355 Directmail/Online Sales: Paul Miles paul@engineeringmaintenance.info 0207 9933355 Web Manager: Oliver Gibbs info@engineeringmaintenance.info Database Manager: Steve Hill info@engineeringmaintenance.info

Technical Manager: Igor Seke Production Equiries: production@engineeringmaintenance.info

Published six times per year by EMS Annual subscription: UK FOC Rest of World £90 © 2007 EMS

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.

For more information quote EMS Enquiry No. 102 on IBC

DEVELOPING A TPM PROGRAMME Total Productive Maintenance

Is this all there is to TPM? Not really!

Although Autonomous (Operator) Maintenance is a distinctive feature of TPM, it is not the whole story. TPM is an equipment based improvement programme which aims to involve everyone in improving the performance of manufacturing equipment.

This involves Measuring equipment performance and Analysing losses, Improving equipment through restoration, focused problem solving activities or equipment modification, and then Controlling equipment condition through appropriate maintenance activities.

For more details of training and support in developing a comprehensive TPM Programme phone 01234 215867 or visit our website www.productivityeurope.org

For more information quote EMS Enquiry No. 103 on IBC

Learn more about implementing better reliability and maintenance performance at Reliability Week UK, Leatherhead, Surrey, 29 October to 1 November 2007. Visit www.reliability-week.com

I am excited to be a regular contributor to Engineering Maintenance Solutions. In the first series I will discuss implementing world-class reliability and maintenance performance in industrial plants. A good start point is defining common terms

What is reliability?

Christer Idhammar, president Idcon Inc Reliability seems to be a buzzword commonly used to describe maintenance improvement initiatives. Several books have been written with titles such as Reliability Centered Maintenance, Reliability Based Maintenance etc. In these books I have not yet found a definition of reliability.

Many suppliers of predictive maintenance tools also use the term reliability to describe their products and services.

Dictionaries describe reliability as: dependability, trustworthiness, consistency.

To me reliability is best described as ‘being able to be trusted to do what is expected or has been promised’. Here we talk about reliable production in industrial plants so it is obvious the term reliability can not only focus on maintenance improvement initiatives or only predictive maintenance.

We use the term ‘production reliability’ to lay the foundation for the vital partnership between operations and maintenance. In this concept operations and maintenance both deliver reliability as a product of their work. Operations focus on delivering reliable process and maintenance focus on delivering reliable equipment.

To become true partners the operations and maintenance departments must have one common performance measurement as described in Figure 1.

Another way to measure overall production reliability is the reliability index. There are three things you need to know to use this index: production calendar time; number of production losses; and total production losses including losses in quality, time and speed.

In summary, the reliability index says you want to operate as long as possible without losses and when you have losses you want to fix them as quickly as possible.

Fig1: The common way to measure overall production reliability is to measure quality, time and speed performance. Time performance must include all available hours, for example 8,760 hours in a year less market related down time and time for capital rebuilds in plant operating 24-7

What is good reliability performance?

Based on the quality, time and speed formula a good performance for a news print paper machine is >94 per cent, while a packaging line might only reach 85 per cent. As a general rule the reliability performance is higher the fewer components, including raw material and packaging, that are involved in the process.

Some time ago I worked with an organisation that focused very much on front line involvement in what we call ‘design out problems’. With the front line I mean supervisors, operators, trades people and planners. The complex process line had reached a reliability performance of over 95 per cent. It was built in 1968 and 37 years later it had 30 per cent fewer components in the process line then it had 1968. This organisation’s focus is to constantly analyse problems and implement solutions. It freed up time to do this by better execution of preventive maintenance and planning and scheduling

supported by an excellent spare part store organisation. The key here is that they involved the front line. If a separate group of design engineers had been in charge, they would probably have added components, resulting in lower reliability performance and higher maintenance cost.

What is asset management?

Asset management is another word hijacked by providers of maintenance services and products, especially computer system suppliers. To me, asset management includes more than maintenance management software. As an example I wonder how many maintenance managers would respond to an ad for a position as Asset Manager in the Financial Times. A company’s assets include more than maintenance management, for example: brand name, patents, money, etc.

New terms for the same things can only lead to confusion and lack of followers for improvement efforts. Whatever you chose to call your concept, explain it well and stick to it long-term. An idea would be to use the term maintenance to describe maintenance activities and production reliability to describe and measure the results of your operations and maintenance organisation’s work.

Reader Reply Number: 300 Christer Idhammar is a world renowned expert in reliability and maintenance management best practices. He started the Idhammar group of companies in Sweden in 1972 and Idcon Inc in USA in 1985. In 2002 he received the Euromaintenance Incentive award (EFNMS) for outstanding international contributions to improve reliability and maintenance in industries world wide. He is the author and co-author of several books and hundreds of articles. He can be reached at info@idcon.com

3 www.engineeringmaintenance.info Sept/Oct 2007 EMS

INDUSTRY NEWS

MORE DETAIL, MORE DATA CHAIN Infrared measurement specialist, InfraTec, has introduced the VarioCam, a portable uncooled, microbolometer, thermographic camera with 1.23 mega-pixel resolution. The camera is designed to provide high quality image detail and sharpness, making it ideal for use in a range of industrial and research and development applications, such as predictive maintenance, building inspection, process monitoring, control and automation, quality assurance and non-destructive testing.

A focal plane array detector with a choice of 384 by 288 or 640 by 480 pixels lies at the heart of the camera. This is combined with an opto-mechanical resolution enhancement function, to achieve continuous resolution of 768 by 576 or 1,280 by 960 pixels. Temperature measurement ranges from -40 to 2,000°C and the camera can be combined with InfraTec’s IRBIS image analysis software to provide a thermographic inspection and analysis aid. www.infratec.co.uk Reader Reply Number: 301

InfraTec's VarioCam thermographic camera features 1.23 mega-pixel resolution

Utilising x-ray fluorescence, the handheld Xlt is said to provide laboratory quality readouts of alloy composition

Alloy analysis on the up Niton UK, the specialist in portable alloy analysis and alloy sorting instruments, is celebrating the sale of its 500th unit: an XLt alloy analyser from the company's flagship range.

Sales and marketing director, Michael Sibbald, heralded the sale as a milestone, reflecting the hard work of all at Niton UK, as well as the company's innovative product range.

Utilising x-ray fluorescence, the hand-held Xlt is said to provide laboratory quality readouts of alloy composition. Its small size and rugged design make it suitable for a range of demanding field applications. In fact, applications for the Xlt and its sister product the XLi range from simple metal sorting through to elemental soil analysis and decontamination control. The instruments are also ideal for checking RoHS and WEEE compliance, scrap metal recycling, lead paint analysis and precious metals analysis as well as mining and prospecting.

In addition to x-ray fluorescence instruments, Niton UK also supplies the MiniSort II metal sorter. Using optical emission spectroscopy, this hand-held unit can be calibrated for sorting different base metals including ferrous, aluminium, copper, titanium and nickel. Its point-and-shoot, rugged design makes it ideal for scrap metal rapid sorting. www.nitonuk.co.uk Reader Reply Number: 303

4 EMS Sept/Oct 2007 www.engineeringmaintenance.info

ASSEMBLY MADE SIMPLE Bolt ‘N’ Go is a new flexible 4Braime's Bolt 'N' Go flexible drop-forged chain system is said to offer easy drop-forged chain system installation and minimal maintenance from 4Braime. The chain consists of high strength hollow pins, heavy-duty washers and nylock nuts, which enable bolts to pass through to connect the links together and attach flights. There is no need to remove the chain from the conveyor for installation and with no circlips to come loose, no intricate assembly and no welding required on the flights, Bolt 'N' Go is said to offer simple and reliable operation with minimal down time and maintenance costs.

The system can be used with steel or plastic flights. www.go4b.com Reader Reply Number: 302

Safe pumping solutions Two Netzsch progressing cavity pumps have been specified by Orica Mining Services, a supplier of explosives, initiating and blasting systems to the mining, quarrying and construction industries. The new equipment is being used to pump ammonium nitrate emulsion and oil that is batch produced at Orica's plants in Glensanda and Wigan. The four-stage pumps, which are capable of continuously pumping 10m3/hr of emulsion at pressures up to 18 bar, were supplied to Orica specifications.

To reduce the risk of wear and breakdown and achieve ATEX II certification, both pumps were supplied with a double-sealed,

closed gear joint with patented Nemo SM seal and protective cap, as well as dry-run protection on the stator. www.netzsch.com Reader Reply Number: 304 Cavity pumps designed for ATEX II certification

SPRING INTO ACTION Instron, a provider of testing equipment designed to evaluate the mechanical properties of materials and components, has introduced the SF1390 motordriven spring testing system.

Designed to test tension and compression springs and other spring-type products, the SF series is ideal for spring manufacturers and end-users.

The equipment features a floor standing design with two lead screws and two precision guide columns for stiffness. A servo

drive controls the frame's loading crosshead for automatic load testing with speeds up to 1,000mm/min. The SF1390 series is available in two frame capacities: 50 and 100kN. Instron's heavy-duty spring testing load cells also incorporate mechanical overload stops and at least 300 per cent overload capacity, minimising the chance of damage during overload conditions. pr.instron.com Reader Reply Number: 305

INDUSTRY NEWS

Kit improved for complex testing Instron has enhanced its 5800 series materials testing equipment with improved performance and reliability capabilities. When configured with 32-bit LabVIEW software drivers, the system allows the user to develop complex testing sequences with important enhancements such as a faster setup time and response to test control events. The digital design of the 5800 controller allows synchronous data capture on all channels up to 5kHz, providing the best combination of accuracy, resolution and bandwidth for data acquisition.

Test control features, such as definable waveforms, auto-tuning and amplitude control also help users accurately evaluate the properties of new materials, components and devices. pr.instron.com Reader Reply Number: 306

WHAT A WASTE A new system for the collection and recycling of waste lamps has been described as ‘a wasted opportunity and an environmental nonsense’ by recycling specialist Balcan Engineering. The scheme, which is organised by lamp manufacturers, involves the collection of whole lamps stored in large steel and plastic containers. To be truly environmentally friendly however, managing director of Balcan Engineering, John Rinfret, says the scheme should have utilised a precrushing service, such as that offered by Balcan.

The company, which has been handling waste lamps for nearly 30 years and last year won a Queen’s Award for its recycling plant, promotes onsite crushing, which can reduce the volume of lamps by five times, significantly reducing traffic volumes.

Unfortunately, the new manufacturers’ scheme

involves the collection of whole lamps only, from designated collection points, with the lorries having to carry a forklift because of the size of the containers. To organise the new service, manufacturers formed the company Recolight and have added a 15p surcharge to each new lamp to cover the cost.

John Rinfret explained: “Defra, SEPA and the Northern Ireland Heritage Department have exempted the use of lamp crushers from the WEEE regulations, in recognition of the merit of handling and transporting pre-crushed material. It therefore seems environmental nonsense to add fleets of heavy vehicles to our roads unnecessarily.”

With containers being collected and replaced from designated sites fortnightly and each lorry carrying a fork-lift weighing three tons, Balcan has calculated that over a year each lorry is

carrying around 750 tons of dead weight. This is in addition to the weight of the containers and the fuel consumption required to carry the extra volumes of uncrushed lamps. The environmental implications, says Balcan, are considerable.

John continued: “We also have health and safety concerns for small businesses trying to save on the cost of proper transport. In the real world, users often put waste lamps in the back of a lorry or van to transport them to the designated collection point. The dangers associated with consequent breakages and the release of mercury are considerable.”

Overcoming all these issues, Balcan accepts both whole and pre-crushed lamps at its Lincolnshire recycling plant.

The company also offers an on-site pre-crushing and waste collection and recycling service, using a fleet of specially adapted vans. www.balcan.co.uk Reader Reply Number: 307

Balcan's on-site crushing service eliminates environmental issues associated with transporting whole waste lamps

EMS Enquiry No. 104

www.engineeringmaintenance.info Sept/Oct 2007 EMS

5

For more information quote EMS Enquiry No. 105 on IBC

Now in its third year, Maintain 2007 offers visitors the opportunity to explore products and services offered by 200 companies stretching from the UK to Finland. Some 5,400m2 of exhibition (an increase of 200m2 on 2006) will be occupied by organizations ranging from major international corporations to small specialised supplier companies

Products, services, knowledge and more Maintain 2007, 16 to 18 October 2007, MOC Event Centre, Munich Following consultation with industry representatives, associations and media, the event’s main sectors (maintenance services and management) have been expanded to include disposal/ environmental protection, occupational safety, personnel leasing, technical infrastructure management, contracting and energy management.

Forums and conferences offer additional opportunities to gather, exchange information and discuss the latest maintenance trends, developments and innovations.

The exhibitor forum (organised

by Verlag moderne industrie) is an integral part of Maintain on all three days.

The 2007 Maintenance Summit is planned for 16 and 17 October. This conference, being organised by Management Circle for the

first time, is designed to give participants information on trends and opportunities associated with modern maintenance management.

A workshop (part of the Maintenance Summit) is scheduled for the last day.

Qualified, motivated and informed employees are an important factor for successful maintenance. The changing mentality in companies is reflected by the growing demand for maintenance experts in all branches of industry. In addition, the requirements that trained specialists have to meet have increased considerably.

Unfortunately, officially recognised maintenance courses are not always obvious so Maintain is responding to industry demand by establishing a job exchange.

Industry representatives can

post their job openings and contact qualified specialists at www.maintain-europe-jobs.de.

Visitors can purchase their free admission ticket or redeem their guest ticket via online registration. Besides free admission, registered visitors enjoy other benefits including: fast entry; free admission to the exhibitor

forum; and a free catalogue.

Finally, Maintain claims to be the only German exhibition offering visitors refreshments.

A free Bavarian snack will help visitors keep their strength and encourage experts and decision-makers to sit together and exchange information. www.maintain-europe.com Reader Reply Number: 308

Just ask the specialists ...

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For more information quote EMS Enquiry No. 106 on IBC

www.engineeringmaintenance.info Sept/Oct 2007 EMS

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For more information quote EMS Enquiry No. 107 on IBC

For more information quote EMS Enquiry No. 108 on IBC

A new, versatile and comprehensive handheld machine condition analyser is launched by SPM Instrument

Leonova™ Infinity is lightweight, ergonomic and easy to operate. Under menu guidance, you select Leonova functions via the key pad or the touch screen. The fast processor and very large memory make data logging more efficient than ever. Load Leonova from the PC, then simply measure and save. All input data is pre-programmed.

You get an instant condition evaluation on a green – yellow – red scale

it is fast, light and offers many analysis options.

SPM Instrument UK Ltd Suite 12, Hardman Business Centre New Hall Hey Road, Rawtenstall Lancashire, BB4 6HH Tel: 01706 835331 Fax: 01706 260640 e-mail: info@spminstrument.co.uk www.spminstrument.co.uk

For more information quote EMS Enquiry No. 109 on IBC Untitled-3 1

09/02/2007 12:38:22

PLANT MANAGEMENT

Designed to meet growing demand for versatile all-in-one infrared cameras, FLIR Systems’ new ThermaCAM T/B-series is engineered to combine robust construction with innovative features

The camera comes in T and B-versions for industrial and building/construction applications respectively

IR innovation heats up FLIR Systems’ new ThermaCAM T/B-series portable IR camera features a 320 by 240 pixel resolution, touch screen (plus stylus), integrated digital camera and full measurement options.

The camera comes in T and B-versions for industrial and building/construction applications respectively. Based on the latest visual digital camera design, it is enhanced by specific ergonomic elements such as a 120deg tilting infrared lens unit and easy-to-reach command buttons for greater user comfort.

Imagery is displayed on a 3.5in touch screen (an innovation for the market), opening up new functionalities such as sketching directly on screen and easy menu handling. Another new feature is Thermal Fusion, designed to allow a seamless transition of imagery from thermal into visual (and vice versa) inside the screen,

while retaining all measurement functions in both view modes. Thermal Fusion benefits inspection and product development tasks requiring a detailed follow up of temperature developments.

The T/B-series is compatible with ThermaCAM Reporter 8.2 software, a wizard-based reporting suite with image processing and temperature calculation functions.

Designed as a go-anywhere camera for tough on-site and field conditions, the T/Bseries features an uninterrupted four-hour battery life and is dust/water splash proof, shock-resistant, and weighs just 880g.

The T/B-series comes in four versions: basic T360, B360 and T400 and B400 with a complete range of measurement modes suited for professional use. Cameras are delivered with: a carrying case, power supply, cabling, battery charger, LCD screen sun shield, battery, ThermaCAM

QuickReport software (quick PDF report creation), SD card and user manual.

FLIR Systems Thermography Division’s vice president sales and marketing EMEA, Karsten Eggert, said: “The new ThermaCAM T/B-series is our response to a market increasingly looking for versatile all-in-one infrared cameras. With its engineering power and experience, FLIR Systems is in an excellent position to tackle the challenges posed by an increasingly application-driven market.”

FLIR Systems 01732 220011 www.flir.com Reader Reply Number: 309 Imagery is displayed on a 3.5in touch screen opening up new functionalities such as sketching directly on screen and easy menu handling

9 www.engineeringmaintenance.info Sept/Oct 2007 EMS

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FACILITIES AND PLANT MANAGEMENT Infrared thermocouple: small, low cost and reliable

In this extract from their white paper entitled Hunting the Mighty Milliwatt: The Next Technology Step, president Exergen Corp, Dr Francesco Pompei and director QHi Group, Ross Kennedy, introduce the benefits of infrared thermocouple technology

Hunting the mighty milliwatt Milliwatts can turn into ‘mighty milliwatts’ (MMWs) when resistance increases: typically in loose or bad connections. If undetected and allowed to develop, MMWs can become megawatts of energy causing catastrophic failure.

Exponential growth from milliwatt to megawatt takes seconds but the initial milliwatt energy signature is often too small for detection by conventional metering measurement. The only way to detect elusive MMWs is via temperature

rise using sensitive and reliable noncontact infrared sensors.

For high downtime cost organisations such as data centres, new infrared technology allows continuous, cost effective monitoring inside panels. Such systems can also integrate with BMS/SCADA systems, providing on-line real-time data.

So what is the mighty milliwatt? Small amounts of resistive energy losses, converted to heat from electrical circuit elements in high power electrical systems,

usually at connections, are manifested as a temperature rise above ambient. For example, 0.001W resistive energy lost by circuits using kilowatts to megawatts of power represent less than 0.0001 of energy transmitted.

Fig 1 shows the level of milliwatts created from a 1in2 connection 1°F warmer than ambient: is just 2mW. Milliwatts are created as the resistance from a lose connection increases. Fig 2 shows the example for a 100A cable.

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Tel: 0191 2963816 email: sales@cayman.co.uk Web: www.cayman.co.uk For more information quote EMS Enquiry No. 111 on IBC

For more information quote EMS Enquiry No. 112 on IBC

www.engineeringmaintenance.info Sept/Oct 2007 EMS

11

FACILITIES AND PLANT MANAGEMENT

Fig 1

q=hr x A x (T - TA) = 1 x 1 x 1 = .007 Btu/hr Ft2 144 Convert to Watts .007 ÷ 3.4 = .002W

Rs

= 2mW

Vs

Fig 2

P = I2 x R = heat dissipated as MMW

R2

RT

R3

V+ R1

Calculate R for 2MMW (1°F Rise)

C1

For 100A cable

V-

P = .002 = I2R = (100)2R R = .002 = .002 = .0000002ohm

Self powered IRt/c circuit diagram

(100)2 10,000 Undetectable via meter However the mighty milliwatt is well named. When current is increased and resistance increases (the connection were to loosen with time/oxidation and resistance increased to 1ohm) then For 100A Circuit Power = I R = (100)2 (1) = 10,000W 2

=10kW The mighty milliwatt has turned into 10kW: sufficient to melt one ounce of copper in 0.6s and for the organisation involved, catastrophic failure. When resistive loss exceeds a threshold value, temperature increase causes rapid, irreversible increase in resistance triggering positive feedback that escalates to exponential level.

Resistive energy is lost approximately 50 per cent radiation and 50 per cent convection. Radiation is detectable via infrared radiation methods of sufficient sensitivity and reliability as a temperature rise above ambient. Temperature rise is sensitive to load, when load changes by factor of three, delta T changes by factor of 10.

Thus, for high downtime cost organisations, continuous thermal monitoring represents a significant increase in risk mitigation. Further, with trend data, intervention maintenance cycles can be extended with confidence.

Technology steps The most recent technology step was the introduction of the infrared thermocouple (IRt/c). Being self

Look at the whole picture

12 EMS Sept/Oct 2007 www.engineeringmaintenance.info

powered (like a standard thermocouple) the IRt/c requires no amplifier and thus lifetime repeatable calibration. IRt/c sensors are small, plastic, low cost, ultra reliable, non contact devices, which measure rise above ambient. They have recently gained UL certification.

Small plastic cable sensors have also been introduced for applications involving cable joints rather than bus bars.

Temperature rise resulting from a bad connection’s increased resistance is conducted down the cable to the sensor located a few inches away.

Data acquisition cards (DACs) have been developed to linearise and condition the sensor signals: ideal for noisy environments. These DACs can accept eight mixed inputs, are din rail mounted and panels are linked via 485 data cable.

This continuous thermal monitoring technology can be designed into new installations or retro-fitted during shutdown.

Where total shutdown is not possible the system can be fitted progressively.

Additional benefits of continuous monitoring include: Can potentially provide circa 20 per cent extra life on major capital assets on basis of trend data Extend conventional intervention maintenance by circa two to three years, thus achieving downtime savings which make thermal monitoring quickly self financing Eliminate the need to remove panels for live imaging: major risk mitigation Cost of installed monitoring as a percentage of job typically one to two per cent amortised over equipment life QHi Group 01582 461 123 www.Qhigroup.com Reader Reply Number: 310

For more information quote EMS Enquiry No. 113 on IBC

For more information quote EMS Enquiry No. 114 on IBC

VIBRATION ISOLATION

-

Neoprene Turret Mounts Neoprene Hangers Spring Mounts Spring Hangers Flexible Connectors Floating Floors

- Inertia Bases - Noise & Vibration Surveys - Ex-stock Delivery - Selection Service - Special Design Service

EUROVIB ACOUSTIC PRODUCTS LTD Goodwood House, 86 Holmethorpe Avenue, Redhill, Surrey RH1 2NL Telephone: (01737) 779577 Fax: (01737) 779537 sales@eurovib.co.uk www.eurovib.co.uk For more information quote EMS Enquiry No. 115 on IBC

For more information quote EMS Enquiry No. 116 on IBC

For more information quote EMS Enquiry No. 117 on IBC

SPOTLIGHT ON ATEX

With the launch of Hawk IR’s Ex|CAM systems, infrared programmes can now expand into explosive atmospheres, increasing coverage, efficiency and worker safety. EMS spoke to Hawk IR International Director, Tony Holliday, to learn more

Safe, not sorry If a facility has an explosive atmosphere it must comply with Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) regulations and the ATEX Directive. Schedule 3 of DSEAR states that equipment used in an explosive atmosphere be selected on the basis of the requirements set out in the Equipment and Protective Systems Intended for Use in Potentially Explosive Atmospheres 1996.

Previously there was no alternative.

Infrared inspection is a required practice, where the benefit was offset against increased risk of explosion associated with using non-certified cameras in an explosive atmosphere.

Ex|CAM resets the benchmark. Certified

by DNV to ATEX 2 IIG T4 for use within Zone 1 areas, Ex|CAM does not require hot work permits and supplementary safety systems for operation.

Tony Holliday explained: “Imagine an application where a motor driven pump is operating in an potentially explosive atmosphere. Naturally, the big problem with mechanical systems like this is surface temperature. For example, if a bearing started to fail the surface temperature of the housing could increase to the auto-ignition point of the gas surrounding it,

causing an explosion. A thermocouple might be used to check the surface temperature but this only provides a point measurement. Using Ex|CAM, operators can take live readings, thus building a traceable history of the equipment’s performance.

“It is important that users of ATEX certified products are made aware that the cost of such systems relates not just to design and certification but also to manufacturing standards. A company can design and test an ATEX product but it can’t manufacture it without an upgrade to BS EN 13980:2002.

“All protection processes, such as intrinsic safety, flame proofing and purge and pressurise, must be quality managed to 13980. For example, Ex|CAM displays had to pass a drop test (1kg ball at 2m) because, if smashed in an impact, an LCD can release significant energy. Likewise the short circuit current of a standard 7V lithium ion battery would compromise safety so Hawk designed its own intrinsically safe cell system which limits voltage and current should the battery short.”

In use, Ex|CAM is designed to withstand the rigours of continuous life in corrosive, explosive environments, featuring a polymer coated aluminium body, armoured display,oversized manual focus ring, simple one button FASTStore rapid save function and IP67 ingress protection rating higher than any other portable radiometer on the market today. Thanks to its strong casing design, Ex|CAM can also be used as a ‘crawl-aid’ during an emergency in heavy smoke or low light situations during restricted access search and rescue operations. www.hawkthermography.com Reader Reply Number: 311

15 www.engineeringmaintenance.info Sept/Oct 2007 EMS

ATEX THERMAL IMAGING STATIONS - SURVEILLANCE & SECURITY - PROCESS MONITORING - OIL SPILLAGE DETECTION - SEARCH & RESCUE - ZONE 1 EXPLOSION APPROVED

www.hawk-ir.com

SEE US AT

16th - 18th October MOC, Munich

Email. info@hawk-ir.com Tel. +44 (0) 1642 497000 For more information quote EMS Enquiry No. 118 on IBC

SPOTLIGHT ON ATEX Dual temperature sensors are supplied: one intrinsically safe sensor for the enclosure; another embedded in the heater body

With the launch of Intertec's programmable heater for hazardous area applications, process instrumentation engineers have a compact, versatile solution for precise air temperature regulation inside enclosures

Explosion-proof heater enhances temperature control Element styles include finned, block and fluid

Approved for worldwide Zone 1 use by IEC, ATEX, GOST and CSA, Intertec's heater comprises a heating element and networkable digital PID controller with encapsulated electronic circuitry. Dual temperature sensors are supplied: one intrinsically safe sensor for the enclosure; another embedded in the heater body. These sensors let the system control air temperature while ensuring safety in hazardous areas by limiting the heating element's maximum surface temperature to the required T-rating: T3 to T6 (200 to 85째C).

A range of different element styles and sizes (including finned, block and fluid) are

available, plus types that mount directly onto ANSI/ISA standard SP76 analyzer substrates. Power density heaters can be high, as systems can feature elements from 500W to 2 kW. By comparison, trace heating cables offer typical outputs of around 10 to 30W/m.

This heating capability means the heaters suit higher temperature control applications up to 150째C. This upper limit, combined with the system's control over surface temperature, means the heater suits instrument and analyzer applications with difficult media in hazardous chemical, petrochemical, oil and gas processing areas.

Whatever the output and element type, systems are supplied as an approved and certificated system for use in Zone 1 environments (and/or Class I, Division 1 areas for USA applications). Compared with building explosion proof heating systems from trace heating cables, controllers and terminations, no costly inspections and certification processes are required.

As standard, the heater comes with an RS485 serial networking interface for

programming and to network heaters to a PC for monitoring and diagnostic purposes.

A USB or RS232 interface converter is an option. Systems are supplied with a PC software package.

The PID controller measures 5.7 by 12.5 by 8cm, making it easy to install in instrument enclosures when compared with lengths of trace heating cable.

Intertec can also supply complete instrument enclosure systems featuring instrument, manifold and tubing, ready for hook-up on site. The company offers a broad portfolio of enclosure, cabinet and shelter solutions for protecting field instrumentation. The range includes: GRP enclosures and protective shades in a range of shapes and sizes; GRP cabinets and shelters for use in most climate or weather conditions; accessories including heating systems; and custom design and turnkey system assembly services.

Intertec 01202 822277 www.intertec.info Reader Reply Number: 312

Available to purchase, or hire, a wide range of instruments from leading manufacturers INCLUDING: Chauvin Arnoux, Digitron, DP Measurements, Druck, Energy Conservatory, FLIR Systems, Fluke, Grant, LEM, Macam, Retrotec, Rotronic, Robin, Testo, TSI, Vaisala, Elcomponent etc

Test and measurement instruments available, range of electrical energy monitoring and power quality analysers.

Flir Systems ThermaCAMTM T-Series

For more information quote EMS Enquiry No. 119 on IBC

17 www.engineeringmaintenance.info Sept/Oct 2007 EMS

Beamex® MC5 Multifunction Calibrator Beamex® CMX Calibration Software

Save costs and improve quality of calibrations.

The Beamex® calibration system improves the quality and efficiency of the entire calibration system through faster, smarter and more accurate management of all calibration assets and procedures. Beamex calibrators, workstations, calibration software and professional services form an integrated, automated system. ister to dow n

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info@beamex.com www.beamex.com

Portable calibrators Workstations Calibration software Professional services Industry solutions

For more information quote EMS Enquiry No. 120 on IBC

Applications: - Trench Covers - Industrial Flooring

DURA SLAB

Fibreglass Structural Flooring

- Work Platforms - Tank Covers - Gully Covers - Bridge Decking - Service Duct Covers

Benefits: - Light weight - High strength - Easy installation - Anti-Slip Surface - Corrosion/Fire resistant - Impact resistant - Zero maintenance

BS EN 124 APPROVED

Tel: +44 (0) 1255 423601 Fax: +44 (0) 1255 435426 info@fibreglassgrating.co.uk www.fibreglassgrating.co.uk

For New or Replacement Flooring Projects FIBREGLASS GRATING LTD High Performance Composite Construction

For more information quote EMS Enquiry No. 121 on IBC

FACILITIES AND PLANT MANAGEMENT In this article, Croda Chemicals Europe shows how automated calibration processes are saving time and money

Automated calibration planning lowers costs Calibration is an essential element of instrumentation maintenance programmes. Unfortunately, calibration operations can be long and tedious, even with the aid of automated electronic calibrators. The data volume can be overwhelming when there are hundreds of sensors with multiple data points.

The experience of Croda Chemicals Europe is typical. It uses pressurised vessels to purify lanolin for health care and beauty products. Each vessel needs to be certified at least once every two years to demonstrate it is safe and structurally sound. This includes a functionality check on all pressure instrumentation, plus the sensors monitoring incoming chemical additives and outgoing effluent.

Senior instrument technician, David Wright, remembers what it was like to perform all those calibration operations with paper and pencil during regularly scheduled maintenance shut-downs: “It took us a week to perform the calibrations and a month to put together the paperwork.”

Today, Croda uses the Beamex CMX calibration software system to coordinate data collection operations and archive results.

Wright continued: “It’s faster, easier, and more accurate than our old paper-based procedures. It’s saving us around 80 manhours per maintenance period and should pay for itself in less than three-years.”

Beamex CMX runs under the Windows operating system and connects directly to several kinds of calibrators. It can track

pre-defined, customised process instruments and calibration standards such as pressure, temperature, electrical, indicator, recorders and mass.

Multidimensional plant hierarchy with uninstalled, installed and spare equipment can have multiple functions, multiple procedures and work orders, including equipment classification.

Once a calibration task has been performed, CMX can record the calibration history together with timestamps, electronic signatures, record status and a complete audit trail. These functions are especially necessary in regulated industries, such as pharmaceutical, where routine calibration operations are required to show quality-critical instruments continue to perform within the defined tolerances.

Records must be stored and retrievable on demand to demonstrate to an auditor that the plant is maintained to an acceptable level. CMX complies with new legislation concerning electronic records and signatures, defined in regulations set forth by the FDA in 21 CFR Part 11.

Calibration planning Calibration software like CMX can also help with planning calibration operations.

Calibration schedules account for the accuracy required for a particular sensor, plus the duration it has maintained that degree of accuracy. Highly stable sensors need not be re-calibrated as often as sensors that drift.

Croda’s calibration schedule is determined

Croda Chemicals Europe’s senior instrument technician, David Wright, states Beamex CMX calibration software is faster, easier and more accurate than old paperbased procedures

by three criteria. It must first comply with governmental and insurance regulations that mandate protection for the plant, personnel and environment. These are Croda’s top priorities and, in some ways, most expensive: not just direct costs of complying with the mandated calibration operations, but potential costs of failing to comply. In the UK, EU and US, government agencies can shut down a plant for violating health and safety regulations, including calibration.

Croda also enforces its own in-house safety and quality standards requiring certain sensors are checked: every week; every time an area shuts for maintenance; or every year. Most frequent calibrations are reserved for critical sensors such as pH meters that measure acidity of effluent discharged to the river.

Wright describes Croda’s third criteria for calibration planning as ‘experience of practice’. Management analyses the history of previous calibration operations and determines the optimal interval between calibrations for sensors that do not require regular checks. This analysis can be performed automatically with calibration software like CMX, thus improving the efficiency of creating a calibration schedule and relieving maintenance personnel of the need to remember when a particular sensor is due for calibration.

Bottom line Net returns from using Beamex CMX calibration software for calibration management will be greatest under the following conditions.

Plant is regulated A large number of instruments require regular calibration Calibration procedures are labour intensive.

Large amounts of calibration data are documented and reviewed www.beamex.com Reader Reply Number: 313

19 www.engineeringmaintenance.info Sept/Oct 2007 EMS

50-pages of information and advice on welding trends

FACILITIES AND PLANT MANAGEMENT ESAB has published the latest copy of Svetsaren, its 50-page journal covering developments in welding equipment, consumables, applications and related topics. This issue emphasises stainless steel welding and environmental issues

Understanding stainless Stainless steels are the fastest growing group of construction materials, with an increase in consumption of around five per cent per year. However, with the price of stainless steel increasing dramatically, it is important to understand welding technology developments designed to help minimise production costs without compromising quality.

Equipment, consumables and applications for welding stainless steels feature heavily in Svetsaren, including indepth technical articles about: strip cladding; MMA welding of pipe and sheet; and the selection of shielding gases for Mig and Tig welding of duplex stainless steels.

20

Application stories describe projects including: vessels containing superconducting magnets in liquid helium at -269째C; semi-automated production of beer barrels; and desalination plants where duplex stainless steels are welded to aluminium bronze and other exotic alloys.

In some industries, high-strength, corrosion-resistant supermartensitic steels are an economical alternative to stainless steels. Here, an interesting development is laser-hybrid welding, with Svetsaren featuring a case study explaining how a lorry chassis manufacturer reduced fixturing costs thanks to lower heat input reducing distortion. Also, welding speeds

For more information quote EMS Enquiry No. 122 on IBC

EMS Sept/Oct 2007 www.engineeringmaintenance.info

are over six times faster than conventional Mig welding in some applications and fatigue life is doubled.

In other news, ESAB is proud to announce global ISO 14001 certification. In ESAB's case, the certification covers development, design, production, sales and services relating to welding and cutting products. This is good for the environment and ESAB's customers benefit from less hazardous compounds, less packaging waste, fewer welding defects, reduced energy consumption and less administration.

ESAB Group (UK) 0800 3893152 www.esab.co.uk Reader Reply Number: 314

For more information quote EMS Enquiry No. 123 on IBC

How to reduce your customers’ cooling carbon footprint

ICS are specialists at providing chillers and air conditioning.

Although we can’t claim to being able to cool a whole metropolis, we are rather good at supplying energy efficient chillers and equipment from our 170 strong UK manufacturing facility.

Whether you need to provide reduced costs or new HVAC equipment offering the latest elevated efficiency rates (EER) – ICS have a wealth of experience and a proven track record to recommend the most resilient and climate conscious equipment for your client.

We can help you to specify and supply the correct components including the latest Turbocor, free cooling and Class A equipment. So, if you have no idea about how to reduce your customers’ carbon footprint, don’t worry because we can help. Call ICS free on 0800 169 3861 or log on to www.industrialcooling.co.uk

Chillers are our business For more information quote EMS Enquiry No. 124 on IBC

ICS chillers and air conditioning – helping you create a reliable, efficient and comfortable environment for your clients.

BOILER PROJECTS WHERE WILL YOUR FOCUS BE?

CAPITAL COST

LIFETIME RUNNING COSTS

With capital cost on average less than 1% of lifetime running costs, fuel efficiency must be the main focus when specifying industrial steam boilers. The new Yorkshireman 2 is the most fuel efficient boiler of its type, mainly by the incorporation of unique X-ID boiler fire tubes, only available from Byworth Boilers.

Web: www.byworth.co.uk Tel: 01535 665225 a l e s@byworth.co.uk s Email:

FOCUS ON EFFICIENCY

Parkwood Boiler Works, Parkwood Street, Keighley, West Yorkshire BD21 4NW For more information quote EMS Enquiry No. 125 on IBC

FACILITIES AND PLANT MANAGEMENT

Cutting the risk of static fires Innospec offers a material that can dose low-conductivity fluids, allowing them to discharge static to ground more readily and avoid the potentially disastrous process of fluids building up charge and possibly igniting. The company states Octastat can normally be added without any performance loss from the parent material. The technology has helped customers overcome H&S risk and mechanical losses due to electrostatic surface pitting damage on enclosed plant components. Innospec also offers a technical support service to companies unsure about the level of fluid conductivity or its potential to create electrostatic problems.

Innospec 0151 348 6868 www.innospecinc.com Reader Reply Number: 314

Vibration levels a click away Monitran has launched VI-sage, a combined hardware and webbased solution to help companies monitor remotely vibration data. VI-sage can notify users, via SMS text messaging and email, if user-defined vibration levels are reached.

Hardware is available with either eight or 26 input channels (for sensors) and either four or 16 outputs respectively. Users can log into their accounts (from any PC with Internet access) and check near real-time data, view historical data and control VI-sage’s outputs.

Monitran’s sales and marketing director, Neill Ovenden, said: “By enabling users to access vibration levels

via the web we’re making visible, from anywhere in the world, the very information that will help companies realise truly cost-effective, remote monitoring and control. There’s no need for expensive cables, no need for bespoke software and, if all’s well, a reduced need for site visits.”

Monitran 01494 816569 www.monitran.com Reader Reply Number: 315

IT’S AS EASY AS 1, 2, FREE!

ONE Discuss your Condition Monitoring requirements with our Sales Engineers TWO Place your order for your equipment through Proviso FREE Receive your free product training PLUS for your FREE Beginners Guide to Vibration, please log onto: www.proviso-systems.co.uk/beginnersguidetovibration.htm

Proviso Systems Ltd • Tel: 01777 817536 • email: info@proviso-systems.co.uk • www.proviso-systems.co.uk For more information quote EMS Enquiry No. 126 on IBC

www.engineeringmaintenance.info Sept/Oct 2007 EMS

23

For more information quote EMS Enquiry No. 127 on IBC

ENERGY MATTERS

In this extract from its white paper entitled Global asset sustainability: The key to a greener organization, Infor, discusses the role of asset management in curbing greenhouse gas emissions

Asset management’s role in curbing greenhouse gas emissions Asset management? Unfortunately, asset management is often forgotten as a key contributor to energy use. Assets are purchased and expected to perform satisfactorily until their estimated end-of-life. However, assets represent a significant portion of a business’s operating expense, impacting environmental as well as financial performance.

Since careful asset management will affect a company’s overall environmental efficiency, it is important to integrate energy management into a company’s enterprise asset management (EAM) program: to support CSR goals and to continue improvements in the company’s overall financial performance. The best and most well-rounded EAM programmes include: Maintenance programme management: factoring asset operating performance (energy consumption) into maintenance strategy and activities Event management: alerting of an existing asset condition or trend outside of optimum operating parameters for evaluation or remediation Planning: assessing existing asset configuration (design basis) and performance (energy consumption) for optimisation This means carefully monitoring assets’ energy usage, implementing a comprehensive preventive maintenance program that considers energy use, and factoring energy consumption into plans that include asset acquisition, allocation or replacement. Note the emphasis on monitoring and preventive maintenance.

Energy efficiency cannot be estimated without accurate data as a basis for that estimation. Preventive maintenance, proven over decades of operation, is the single greatest contributor to asset useful

life and optimum equipment productivity.

Thus, efficient assets minimise energy use and improve productivity. A business can be both environmentally responsible and economically competitive.

Green-centric Implementing and sustaining a quality CSRoriented asset management program requires the ability to gather, store and process large quantities of information related to energy consumption, asset condition, asset productivity and the like. Executing such a programme manually would be impossible because of data volume.

Forward-looking companies are investing in software applications designed to simplify and streamline the information aspects of environmentally responsible asset management. This chart from AMR Research (2007) illustrates that the relative portion of a company’s IT budget will shift toward CSR operations.

Proportion Driven by CSR Related Activities

Total IT Spending

Potentially 60-70% in 5 years

Time

With so much precious IT budget oriented toward CSR goals and so much riding on the success of environmentally responsible operations, a business must be careful selecting software applications.

The following features are recommended as a minimum.

Provide the ability to track commodity (electric, water, gas) consumption and rate details associated at meter level with value roll-up within the organisational asset hierarchy Provide the ability to track electric sub-meter interval data, via

26 EMS Sept/Oct 2007 www.engineeringmaintenance.info

integration with an enterprise energy management (EEM) application, at the operational asset or system level Provide existing and pre-existing asset performance monitoring and measurement via key performance indicators (KPIs) that can be displayed on a dashboard configuration page Provide asset condition monitoring through alert set-ups. Unacceptable asset condition should be easily observable Provide a comprehensive preventive maintenance program that can be triggered by set dates, by metered usage, or by selected time intervals Provide a thorough inspection capability that allows users to enter inspection results as subjective values (good, poor, fail) or as quantitative values Provide comprehensive data gathering capability for asset performance and maintenance history Provide library of preformatted reports covering best-practice business processes, including reporting on energy usage and comparison Support WAGES (water, air, gas, electricity, steam) usage logging and reporting It is critical for businesses to select a software application that gathers all disparate facility asset information (HVAC units, chillers, boilers, lighting) anything that consumes energy, into one place and provides operations staff with the critical knowledge of how and when to maintain, replace or alter those assets based on how much energy they consume, not a date on a calendar. The net effect is that total energy spend can be reduced while increasing asset performance and uptime. www.infor.com Reader Reply Number: 316

THERE’S NOTHING BETTER

Get your energy costs under control!

BEKOKAT®. GUARANTEED OIL FREE AIR FROM LUBRICATED COMPRESSORS. • Constantly oil-free compressed air.

Max. residual oil content 0.003 mg/m3 • Process-safe under all environmental and operational conditions • Long service life • Part-load operation without any restrictions

Reduce energy costs by as much as 30% with the new GD Belliss & Morcom range of oil-free compressors for PET applications.

• For the first time, the theoretical advantages of catalysis technology are integrated in a fully reliable process

Inflow of oily compressed air

Now with new optimised designs, the GD Belliss & Morcom VH, WH and VST ranges of speed controlled PET compressors can reduce energy costs by up to 30%, while offering improved levels of efficiency when generating high pressure air for PET bottle blowing.

With over 25 years experience in PET applications, GD Belliss & Morcom are the recognised industry leaders and customers worldwide enjoy greater productivity and lower operating costs from these key features:

Emission of oil-free compressed air and H2O

Take advantage of the unique combinations of clean technology free of hazardous waste with process reliability and performance.

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Advanced new VH, WH and VST ranges improve cost efficiency to both low and high volume users, delivering 125-3200, m3/hr FAD @ 40 barg.

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Intelligent Monitoring – smart technology gives greater operational control and even lower cost, through Air PET™ Control and CCS Energy Saver Systems.

Highly compact footprint for ease of installation and space saving.

• •

Improved valve and cylinder design increases parts life and minimizes service times.

•

Unrivalled global support 24 hours a day from the Gardner Denver worldwide sales and service teams.

Why not join them? The sooner you get in touch, the sooner your business could be making savings too!

We are looking forward to informing you in detail.

BEKO TECHNOLOGIES LTD. 2 West Court Buntsford Park Road Bromsgrove Worcestershire B60 3 DX

Phone +44 1527 575778 Fax +44 1527 575779 info@beko-uk.com www.bekotechnologies.com

SEE US IN HALL 08B, STAND A40

COMPLEX NEEDS – SMARTER SOLUTIONS™ Gardner Denver Ltd | Chequers Bridge Gloucester | GL1 4LL | England Tel +44 (0) 1452 338 338 Fax +44 (0) 1452 338 317

glo_sales@gardnerdenver.co.uk www.gardnerdenver.com

For more information quote EMS Enquiry No. 128 on IBC

For more information quote EMS Enquiry No. 129 on IBC

ENERGY MATTERS

Reduced fuel bills, lower maintenance costs and less emissions: these are the headline benefits of Byworth’s new Yorkshireman2 boiler range. The secret lies in a novel fire tube design. Read on to learn more

Driving down energy costs With boiler users increasingly suffering from rising fuel bills, Byworth Boilers embarked on a two-year research project with Leeds University to prove the optimum configuration of shell, furnace and tubes for maximum efficiency and minimum emissions.

Research finding drove the development of the Yorkshireman2 which features a revolutionary fire tube design.

Called the X-ID, the tube is said to achieve an >80 per cent increased heat transfer compared with conventional tubes, thanks to helical ribs on the internal walls. The company also states

X-ID tubes require less cleaning than traditional tubes, thus limiting efficiency losses through sooting and reducing maintenance time. X-ID tubes are only available from Byworth Boilers in Ireland and UK. With its special tubes and enhanced insulation, the Yorkshireman2 offers efficiency around 92.3 per cent (NCV): said to be over two per cent more efficient than other similar boilers.

Two per cent may not seem much but, for example, for a 10 tonne boiler, on even light load, fuel savings of around 20,000 euros per year could be expected.

It is estimated that 60 per cent of the world’s CO2 is produced by boilers. This statement may prick the conscience of industrial boiler users but given that profitability is the key businesses goal, conscience alone may not be enough to effect change. It may be lucky for the planet that emissions are intrinsically linked to fuel usage and expenditure.

With gas and oil prices predicted to rise again by the end of 2007, an evaluation of existing boiler plant is recommended.

Points to consider: Is the boiler the correct size? Oversized boilers use more fuel

For more information quote EMS Enquiry No. 130 on IBC

28 EMS Sept/Oct 2007 www.engineeringmaintenance.info

ENERGY MATTERS

Is the boiler relatively new and in good condition?

Boilers over 15-years old will have compromised efficiency through wear and tear. If water treatment was not up to standard, efficiency will be even lower Is the boiler the most efficient type and design?

For example, vertical steam

boilers or steam generators may not be as efficient as horizontal shell boilers Is the boiler correctly operated? Routines such as blowing down daily, if done incorrectly, could waste heat Is fuel usage and efficiency measurable? For sites with heavy fuel usage it is

The graph illustrates a feasibility study showing payback when replacing an old boiler with a more efficient Yorkshireman2. The example is based on a 10 tonne/hour boiler running on gas operating at MCR for seven-hours per day, five-days per week. Payback is within two-years and over 500,000 euros would be saved within 10-years

recommended to install metering equipment.

Only then could payback be calculated When evaluating a boiler project, it is easy to get transfixed by capital cost.

However as a boiler will consume its worth in fuel in a few months, the focus should be on running costs.

Even with today’s fuel prices it is common for running costs to be largely ignored, especially when consultants are instructed to procure the best ‘value for money’ equipment. The bigger picture is revealed when 10-years running costs are compared with capital cost. If presented with a choice of saving 10 per cent on capital costs or two per cent on efficiency: 10 per cent sounds the obvious choice.

However, view a 10-year projection and the opposite is the obvious choice.

A 10 tonne boiler running on gas operating at MCR for seven-hours a day, five-days a week

Byworth Boilers Tel: 01535 665225 www.byworth.co.uk Reader Reply Number: 317

For more information quote EMS Enquiry No. 131 on IBC

29 www.engineeringmaintenance.info Sept/Oct 2007 EMS

DUST CONTROL AND FUME EXTRACTION

On tool extraction from sanders during aircraft preparation

In this article, Dustcontrol highlights problems associated with dust pollution in modern production facilities and illustrates how integrated high vacuum systems can provide competitive advantage

Time to clean up Intense workloads and pressure to produce quality products are creating demand for cleaner production facilities. However, manufacturing intensity seems to make this need harder than ever.

Airborne dust and particulate waste from manufacturing processes

are increasingly unacceptable in facilities trying to achieve efficient working environments. If physical concerns over product quality and environmental health are not enough, external pressures from COSHH and recent ATEX regulations, add to the burden.

Dust and fume extraction hoses from Masterflex

VISIT

www.engineeringmaintenance.info

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

30

CONNECTIONS

for the latest Jobs News Interviews Online Seminars Events Training Products White Papers Case Studies Forum

TUBE PROTECTION

For more information quote EMS Enquiry No. 132 on IBC

EMS Sept/Oct 2007 www.engineeringmaintenance.info

For more information quote EMS Enquiry No. 133 on IBC

DUST CONTROL AND FUME EXTRACTION

Airbus and Lochkeed Martin); automotive manufacturers (Scania); body shop repair firms; wind turbine manufacturers; pharmaceutical companies; electronics manufacturers and food producers.

Rather than being a capital cost problem, integrated dust extraction systems can help businesses move forward through reduced health, working practice and quality issues. Clean environments and healthy staff reap benefits

from reduced sickness costs to projecting a better profile to customers.

Dustcontrol 01327 811800 www.dustcontrol.com Reader Reply Number: 318

STOP DUST AT SOURCE Centralised high-vac dust extraction systems for on-tool extraction and general cleaning.

While it may seem that air cleaning through large-scale ventilation is a primary option, many businesses could improve their facilities through on-tool extraction.

This involves high vacuum systems that transport waste to a centralised location for easy disposal or intermediate pre-separators for potential recycling.

Such systems can also be used as general in-house vacuums, negating the need for sweeping (which creates hazardous airborne dust) and mobile vacuums. While mobile units work in certain situations, they can fall foul of poor maintenance, may be fitted with unsuitable filtration and can cause trip hazards and manual handling issues.

With COSHH stating the primary method of dust removal should be at source, plus the fact that a proper inhouse cleaning schedule could reduce or eliminate requirements for ATEX zoning, it is no wonder that manufacturers are adopting Dustcontrol solutions.

Typical industry sectors include: specialised production facilities (SKF and Sandvik); aircraft manufacturers (EADS

Typical industry customers include: Printing, Manufacturing, Pharmaceutical, Electronics, Aviation and many others with applications such as: • Cutting • Grinding • General Cleaning • Sanding • Machining • Material Transport • Particle Extraction

SANDING

GRINDING

MATERIAL TRANSPORT

CLEANING

Dustcontrol can help in improving product quality, environment and the efficiency of your factory with its high quality modular extraction equipment specifically tailored to meet your needs.

For more information:

CALL 01327 858001 Dustcontrol UK Ltd. Old Barn, Home Farm Business Park, Church Way, Whittlebury, Northants NN12 8XS, England Tel: 01327 858001 Fax: 01327 858002 sales@dustcontrol.co.uk www.dustcontrol.co.uk

For more information quote EMS Enquiry No. 134 on IBC

www.engineeringmaintenance.info Sept/Oct 2007 EMS

31

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

Website

Email Contact

Telephone Number

www.byworth.co.uk

sales@byworth.co.uk

01535 665225

www.nord-lock.co.uk

enquiries@nord-lock.co.uk

+44 (0)1980 847129

Boilers Byworth Boilers Bolt Securing Systems Nordlock Ltd CMMS Cayman Venture

www.cayman.co.uk

info@cayman.co.uk

0191 2963816

Productivity Europe

www.productivityeurope.org

m.jones@productivityeurope.org

01234 215867

Idhammar Systems Ltd

www.idhammarsystems.com

info@idhammarsystems.com

0117 9309300

Compressed Air Atlas Copco

www.atlascopco.co.uk

gba.info@uk.atltascopco.com

0800 181085

Gardner Denver

www.gardnerdenver.com

info.uk@gardnerdenver.com

01452 338116

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

SPM Instruments

www.spminstruments.com

info@spminstruments.com

01706 835331

enquiries@metrum.co.uk

www.metrum.co.uk

0118 9734363

www.nfpc.co.uk

enquiries@nfpc.co.uk

01909 504700

Condition Monitoring

Data Acquisition Metrum Training National Fluid Power Centre

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info

WHAT’S NEW

Refresh rate rise Buying into motion Beka’s BA326C 4/20mA loop powered combined analogue and digital indicator has been updated to increase the analogue display refresh rate to four readings per second, further extending its applications.

A combination of 100 segment fast analogue bar-graph and 4.5 digit display provides operators with a quick, easy-toread indication of magnitude and trend, plus an accurate numerical

value in engineering units.

The BA326C has ATEX Group II Category 1G (EEx ia IIC T5) intrinsic safety certification, FM intrinsic safety and non-incendive approval. It only introduces a 1V drop in the loop allowing use in almost any 4/20mA intrinsically safe circuit.

BEKA associates 01462 438301 www.beka.co.uk Reader Reply Number: 319

control ITT Corporation has executed an agreement to acquire privately held International Motion Control (IMC) for $395 million. IMC is a global developer of motion control products with 2006 revenues of approximately $200 million. The transaction, which is subject to normal closing conditions, is expected to complete in the third quarter.

Midland-ACS 01902 384604 www.midland-acs.com Reader Reply Number: 320

Hose, couplings and more Dixon Group Europe has published its new Hose & Coupling Directory. The 400-plus page publication illustrates the company’s full range of hoses, hose assemblies and fittings.

In addition to the company’s

32 EMS Sept/Oct 2007 www.engineeringmaintenance.info

standard range of couplings, valves, fittings and adapters, the directory also features Dixon’s full complement of: hose; hygienic components and tubing; tanker fittings and equipment; permanent swage couplings for

high pressure applications; plus hydraulic and pneumatic quick release couplings.

Dixon 01772 323529 www.dixoneurope.co.uk Reader Reply Number: 321

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