Download - Engineering Maintenance Solutions Feb 2012
February 2012
MAINTEC 2012 the premier event for plant & asset management Pages 29 - 37
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A culture of reliability
How CMMS software can improve your chance of successful Implementation
Maintec Show Preview.
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Industry Latest News
Maintenance Best Practice
Product Spotlight – Including Dry Ice
Cleaning
Maintec Show Preview
Humidity Calibrators
Editors Choice
Buyers Guide 2012
Contacts
PublisherMichael Dominguez
Editorialeditors/contributing: Jon Barret,
Christer Idhammar, Alan France
AdvertisingPaul Clappison - Magazine
Paul Miles - Online Advertising
Websitewww.engineeringmaintenance.info
Phonetel: +44(0)1634 731646
Fax: +44(0)1634 631644
AddressMSL Group, Cobalt House, Centre
Court, Sir Thomas Longley Road,
Rochester, Kent, ME2 4BQ
5engineeringmaintenance.infoJan/Feb 2012
Latest News
These new Norbar products are safe, easy-to-use and extraordinarily accurate, to better than the International Standard. They offer high performance capabilities for dealing with a wide range of precision tasks requiring sensitive and safe screw connection. These include:• Electronic assembly• Automotive applications such as assembling
crash sensors, inertia reel fixtures, airbags and interior trim
• Fitting cutting tool inserts
All adjustable tools are supplied with traceable calibration certificates.
Further features and benefits:Easy torque adjustment without need of additional tools• All tools feature a lock to prevent the accidental
adjustment of the set torque• Tools ‘slip action’ occurs when required torque
level is reached, avoiding over-tightening • All screwdrivers supplied with ¼ inch hexagon
bit holder using a 4mm hexagon stem• For maximum versatility and particularly for
applications with limited access, the bit holder can be removed and replaced with widely available screwdriver blades.
Sterling-SIHI Demonstrates Energy Saving Potential at Tate & Lyle Sugars
Sterling-SIHI performed an energy audit at Tate & Lyle Sugars, London, which demonstrated the potential to save 90% of energy costs associated with the assessed pumping system.
Initially the auditing team visited the Silvertown refinery to assess the current system, gain an understanding of
the layout, gather historical data, and most importantly – identify the system and process requirements. During the subsequent audit and thorough process research, Sterling-SIHI were in a position to take measurements and carry out run tests, enabling the auditors to determine a number of “what if” scenarios and establish an accurate process demand. Tate & Lyle Sugars received a detailed report and presentation, illustrating the energy-saving potential that could be achieved.Impressively, Sterling-SIHI’s recommendations on one pump alone, would lead to an installation previously using 590MWh of electricity per year, to operate using only 40MWh. This would cut Tate & Lyle Sugars energy costs by £27,400 (the equivalent of 300 tons* of CO2 per year). Imagine the possibilities, should such advice be extended to the several hundred pumps currently operating at the plant.* based on 0.544kg of CO2 emitted / kWh as standard values, not necessarily actual sites values.
• Comfortable, durable handle, constructed from a strong base material covered with a soft overlay for comfort and slip resistance
Philip Brodey, Director of Norbar, comments: “The new screwdrivers are an invaluable addition to our TruTorque™ range. Accurate, robust and reliable, they expand the potential of applying torque measurement principles to the most precise and delicate applications.”
Norbar TruCheck™ Screwdriver TestersNorbar has introduced three new products specifically designed to calibrate torque screwdrivers, applicable to both its own products and those of other manufacturers. Accurate to +/- 1% of reading, Norbar TruCheck™ Screwdriver Testers allow operators to perform quick and simple calibration checks from easy-to-read LED displays without the need to call on third party calibration services, saving both time and expense.
NORBAR LAUNCHES TRUTORQUE™ SCREWDRIVERS
An important development in torque tools has taken place with the launch of an innovative range of Norbar TruTorque™ torque screwdrivers. The selection includes adjustable tools providing exceptional flexibility of use and also fixed torque versions, ‘P’ Types, that have been designed for the production environment and pre-set for specific workplace demands.
For further information about Norbar products and services, contact:Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxfordshire, UK OX16 1XJT+44 (0)1295 270333 [email protected]
ifm electronic at Drives & Controls 2012From 17th to 19th April this year ifm electronic will be joining almost 300 other world class companies at the NEC in supporting Drives & Controls, the UK’s leading event for Drives, Automation, Power Transmission & Motion Control.
For further information, contact Mel Lewis, ifm electronic Ltd., Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD. Telephone: 020 8213-0000. Fax: 020 8213-2228. E-mail – [email protected] or visit our website www.ifm.com/uk
ifm electronic is well known as a market leader in sensing technologies, from inductive, magnetic and optical position sensors to flow, pressure and temperature process sensors, and ifm electronic has a growing reputation for up-to-the-minute condition-based maintenance systems, along with plant safety and efficiency. On the control side, ifm electronic also offers much from dedicated controllers, including a major AS-interface offering, to identification systems covering RFID and barcode solutions.At the Drives & Controls exhibition ifm electronic will be displaying the very latest from one of the most innovative companies in these fields of expertise, with experienced staff on hand to introduce, demonstrate and explain the latest products.
A show like this with free entry and leading manufacturers such as ifm electronic is an opportunity not to be missed.
ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.
Sterling Fluid Systems (UK) LimitedAtlantic Street, Altrincham, Cheshire, England, WA14 5DH Telephone: +44 (0) 161 928 6371 Fax: +44 (0) 161 925 2129 e-mail: [email protected]
7engineeringmaintenance.infoJan/Feb 2012
Latest News
Atlas Composites are industry leaders in the design and manufacture of carbon, glass, kevlar and aramid composite components and tooling for the Aerospace, Defence and Satellite Communications industry. Customer approvals include Airbus, Agusta Westland, BAE Systems, Bombardier Aerospace, Cooper Antennas, GKN Aerospace, Lockheed Martin, MBDA, Meggitt, Nordham and Thales.
Work towards the revised standard began in 2010 using a gap analysis database designed by strategic partner TPT Consultancy, to verify the effectiveness of the management system and practices.
The gap analysis identified the need for Atlas Composites to make the transition from its procedural-based quality management system, which satisfied the requirements of AS9100 Rev B, to the required new process-led approach.
The first stage was to determine Key Performance Indicators for all the required processes. This was followed by integrating a review process where performance was measured against planned targets and improvements made where targets were not being met.
SGS conducted the successful audit in July 2011 and issued the AS9100:2009 accreditation with no non-conformities identified.
As a result, Atlas Composites business objectives are now clearly defined, deployed and integrated into the company, supported by clearly defined KPIs. The business process interactions are defined using the process approach and process owners identified. The process performance is measured through the effective deployment of KPIs to support continual improvement.
Delivery performance over the past 12
Fentex Ltd have consolidated their spill trays and absorption materials providing a range of products to achieve compliance with the national Pollution Prevention Guidelines (PPG26). Spill trays can be supplied for use with single or multiple primary containers of 1, 5, 20 and 25 litres capacity together with drums up to 205 litres. These provide the necessary secondary containment facilities during the storage or decanting of liquids, ensuring that drips, leaks and accidental spills can be successfully contained. They help maintain a clean, safe work area environment while preventing pollution or contamination of land, surface waters and groundwater from the run-off of inks, oils, solvents and a wide range of potentially harmful or noxious fluids. Applications for spill control equipment are truly universal, but typical industry sectors that would benefit from the use of Fentex products include motor trade and transport, printing, plastic production and the food industry, together with any areas where hydraulically powered machinery or plant are in use.
In general workshop conditions, spill trays can be used to provide a contained cleaning/dispensing area and can also deal with machinery leaks or the storage of oil contaminated components during breakdowns/servicing of machinery. They help to reduce floor contamination leading to better, safer working conditions, while leaked fluids that would have been lost can be recovered for
recycling or reuse.Individuals, private businesses and both large or small companies and commercial organisations are required to meet the pollution recommendations covered by the PPG26 guidelines as relevant to Scotland, Northern Ireland, England and Wales. Current legislation and recommended good practice requires that provision should be made for a spill tray capacity being provided to accommodate 25% of the total fluid volume of any stored primary container(s).
The spill trays are manufactured from durable, lightweight rigid plastic, in a wide range of rectangular and square sizes and various depth configurations. They incorporate an all-around moulded lip, some featuring a pouring spout, which ensures extra rigidity and good lifting control for trays during moving when they are full with their spill contents. Trays can also be supplied with moulded ridges on the base to allow for airflow under stored containers. For more generous sizes, on trays providing the larger spill retention capacities, drop-in removable grids can be supplied providing a non-slip storage surface while allowing for easy access and cleaning of the spill tray itself.
Mini spill trays from 35 to 76cm in
Further information is available
on request to:
Fentex Ltd, Units E1 – E3, Brook
Farm Business Park, Ellington,
Huntingdon, PE28 0AE
Telephone: 01480 890104
Fax: 01480 890105
e-mail: [email protected]
www.fentex.co.uk
length can be supplied, suitable for small bottles and containers, or as convenient machine drip
trays. Larger trays from 40 to
60cm in width and 56 to 120cm in
length provide fluid spill retention
capacities from 2 – 28 litres. These
are complemented by larger
capacity drip pans and extra deep
trays with spill retention capacities
up to 120 litres. Handy trays for
general maintenance operations
or use as drip trays underneath
mobile plant or other vehicles
include a 41 x 31cm size tray
together with an 85cm octagonal
tray which covers a large floor
area. Both general purpose and
specialised oil and fuel absorbent
material rolls can also be supplied
for use with spill trays for easier
handling of leaked fluids. Spill
trays providing storage for multiple
standard 20 litre containers can
also be supplied. These cover
combinations of 2, 6, 9 or 16
containers per tray, all supplied
with removable internal grids to
elevate the stored containers away
from any spilt liquid and for easy
cleaning.
ENSURE COMPLIANCE WITH PPG26
POLLUTION PREVENTION GUIDELINES
months stands at 100%, and Quality Performance 99.4%.
“Making the transition from Rev B to Rev C was a key objective,” says Shaun Moloney, Managing Director, Atlas
Composites Ltd. “Without this there was potential that business could be lost. Delivery and Quality was excellent, and the challenge was to measure how effective we were in achieving this.”
Atlas Composites Ltd Achieves AS9100:2009 Rev C Accreditation
The latest revision is now the established benchmark for any company in the composite engineering industry wishing to tender for new business in Aerospace and Defence. Compliance with it proves that a company’s Quality Management System relies on clearly defined business processes to measure its effectiveness in meeting customer requirements.
8 engineeringmaintenance.infoJan/Feb 2012
International Industry News
The new initiative (http://machinery-surveillance.eu) was launched at a conference in Brussels on 24th November 2011, hosted by the European Commission, at which Thorworld managing director John Meale chaired a discussion on Market Surveillance to Protect Innovation. The highly successful event was an unprecedented partnership between seven major European trade organisations, representing the construction, machine tools, weighing, agricultural machinery, plastics & rubber machinery industries, as well as Orgalime, the European Engineering Industries Association, and FEM the European Materials Handling Federation – www.fem-eur.com.
As John Meale explains, this is a vital issue designed to ensure a fair and level playing field for European manufacturers and peace of mind for customers.
“As consumers, we are all familiar with the concept of illegal goods that do not comply with regulations, and we are aware of the hard work done by the authorities to prevent such products from being sold.
“The aim of this conference was to address the question: why, if there is such robust market surveillance for consumer goods, is there not a corresponding level of protection for commercial equipment and machinery?
“Too often, market surveillance for materials handling equipment is reactive rather than preventative – which means that it is then too late for reputable suppliers who have been undercut by unscrupulous manufacturers, or for the workers who face injury or even death.
Thorworld Backs Calls For Increased Market Surveillance Of Materials Handling Machinery
Leading loading/unloading equipment specialist Thorworld Industries Ltd is supporting a European-wide initiative to raise awareness of the importance of market surveillance, to prevent non-compliant and potentially unsafe machinery entering the European market.
For more information about Thorworld’s market-leading equipment and to obtain a copy of their latest Product Range Catalogue contact Tel: 01246 260982, Fax 01246 260493, Email: [email protected] or visit Web: www.thorworld.co.uk
The combination of Brammer UK and Buck & Hickman brings together extensive capabilities and resources to create a complete one-stop shop for industrial MRO supply, operating from some 120 locations across the UK. The appointment will see Ian build on the significant growth and development that he has overseen at Brammer since his appointment as UK managing director in December 2003.
Ian commented: “The acquisition of Buck & Hickman is an excellent strategic fit with Brammer’s ambitious development plans in Europe and the UK, with the tools, maintenance and health & safety market offering significant growth opportunities. There are strong synergies across the two businesses and bringing their operations together will allow us to further enhance our customer offer.”
“Combining the knowledge and expertise within both businesses will create a unique resource able to offer unrivalled product knowledge, advice and technical support, backed by a depth of product range and supply capability which is second to none. It also underpins our own belief in being
local and close to our customers, with an expanded branch network enabling customers to benefit from our commitment to customer service right across the UK industrial landscape.”
Brammer plc acquired the business and assets of Buck & Hickman, a market leader in tools, maintenance and health & safety products, many of which are supplied under the well respected ‘Roebuck’ brand, from Travis Perkins plc in September 2011 for £27.6 million.
Senior appointment aligns strengths of Brammer and Buck & Hickman
Ian Ritchie, managing director of Brammer, the UK’s leading distributor of maintenance, repair and overhaul (MRO) products and services, has an expanded remit to lead the recently acquired industrial tools, maintenance and health & safety product distributor Buck & Hickman, following its acquisition by Brammer plc.
For further information on Brammer
visit www.brammer.co.uk and for more
details on Buck & Hickman visit www.
buckandhickman.com.
Professor Miklas Scholz has developed a quick assessment toolkit which has been used in Baden (Germany) as well as in Scotland and England. Using the toolkit he has assessed over 220 dams in the German region and found that although most are well maintained, there is very little publicly available information on their risk of failure and the impact this can have. With his system, people living in areas near dams would have access to a simple traffic light scale of risk based on a scientific and rigorous series of tests, which can be applied in under three hours. He’s now calling for Germany’s engineering associations to relax their strict rules on how assessments are carried out and how the results are communicated. “I have sent my research paper to several engineering journals in Germany and met a very unnecessarily and unhelpful traditional attitude.” he said. “My novel and timely toolkit has been proven in the United Kingdom to be easy to use. It can be carried out without costly detailed site visits to identify the most at-risk dams. “It seems that German engineers who are responsible for these dams are unwilling to change their methods or open them up to proper public scrutiny.”
More public access to German dam data, academic demands
A University of Salford
academic is calling for
more public access to the
state of dams in Germany
after his quick assessment
toolkit uncovered several
at a comparatively high
risk of failure.
9engineeringmaintenance.infoJan/Feb 2012
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Latest Product News
They feature a patented arrangement of structurally packed, permeable hollow fibres spirally wound on a support core. This creates an optimised design combining efficient air flow with high contact areas to maximise the drying performance within a compact unit size. These products are ideal for in-line installation to ensure the delivery of dry compressed air at the point of use. This ensures maximum effectiveness with virtually any dewpoint or degree of drying being achievable.As the humid compressed air passes through the Hi-DRI unit, water vapour diffuses through the walls of the hollow membrane fibres without loss of compressed air. At the dryer outlet, a small volume of the now dry air is expanded and released into the annular space between the membrane fibres and the outer aluminium shell. This air purge then sweeps away entrained water vapour to atmosphere as a humid air stream.The Hi-DRI air dryer makes it easier and less expensive to supply pneumatic equipment and instrumentation with clean, dry compressed air. This simple, proven technology helps eliminate condensation, oxidation and microbial growth, resulting in reliable and predictable performance of downstream air operated equipment. It also reduces component failures, improves equipment performance and operator satisfaction while showing savings on both warranty and production costs.These dryers are designed to provide the superior solution for existing compressed air systems, maintaining maximum process reliability while remaining virtually invisible to the process installation. They do not contain moving parts and there are no desiccants or refrigerant to replace. They are also compact and lightweight, do not incorporate valves, drains or electrical connectors and do not require adjustments.Filtration combined with compressed air drying contributes most to the performance and reliability of airline powered operations. Humidity in airline systems is a major factor of corrosion and tooling wear, which can lead to production breakdowns. However, humidity also creates conditions conducive to the growth of micro-organisms within an airline, which can result in contaminated condensate. This is obviously highly detrimental in food or pharmaceutical production processes as well as in dental, medical or laboratory applications. Almost any dewpoint can be achieved, even when accommodating high humidity ambient conditions as experienced outdoors, in open workshops or on seagoing vessels.These Hi-DRI membrane air dryers are suitable for a wide range of industrial plant installations including specialised commercial operations. The range of models available cover air flow rates from 17 to 1050 litres/min. Multiple dryer units can be used in parallel to achieve higher flows where required. Outlet dewpoints from +15° to -40°C can be achieved at 7 barg
pressure (12.5 barg max) and with 35°C inlet air temperatures. With in-line connection ports at each end, the dryers can be easily integrated into an existing airline. They are compact, lightweight and cost effective, while the polymeric hollow fibre membrane is maintenance-free and does not need replacing where adequate pre-filtration has been provided. A 0.01 micron coalescing filter element is recommended to prevent damaging particulates, oil aerosols and liquid water entering the Hi-DRI filter. The use of a Hi-line HF series filter with regular replacement of the cleaning element will ensure long-term continuous, trouble-free dryer operation.Where cost effective centralised refrigeration drying is required, a Hi-line CDA dryer connected directly to a compressor can
be combined with individual Hi-DRI units of varying outputs fitted at points of use.
Further information is available from: Hi-line Industries Ltd,5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PGTelephone: 01283 533377Fax: 01283 533367 [email protected]
MEMBRANE DRYERS SET HIGHEST STANDARDSFOR COMPRESSED AIR SYSTEMSThe new range of Hi-DRI compressed air membrane dryers from Hi-line Industries have been re-engineered to be technologically superior products, achieving new standards for reliability, performance and energy efficiency.
The latest HI-DRI compressed air dryers from Hi-line Industries Ltd, offering dewpoints from +15°C to 40°C.
Ball valves, utilising a drilled-through ball rotating in a retaining socket, are widely used for process line control operations within industry. Typical areas of application for these valves include oil and gas, chemical processing, power generation together with pulp and paper industries among many others.Ball valves offer both flow throttling and full shut-off conditions, while applications can involve an extensive range of pressures, temperatures and even the use of chemically aggressive fluids. The importance of specifying the right sealing products for use within these valves becomes paramount, particularly where breakdowns or plant shutdowns caused through valve failure can be catastrophic.The specialist sealing company, Dichtomatik Ltd, are able to provide the Kalrez® range of perfluoroelastomer ‘O’ rings from the Dupont™ Performance Polymers range, which have been formulated to provide superior sealing qualities for even the most difficult applications.A recent problem application featured a trunnian mounted ball valve used in the gas cleaning/sweetening processes. This involved the removal of carbon dioxide and acidic gasses such as hydrogen sulphide from gas streams, including synthesis gas produced by the gasification of coal, coke and heavy hydrocarbon oils. Gas sweetening is commonly undertaken in refineries, petrochem plants and NG processing etc, where the process often utilises a glycol-based solvent for the acid gas removal.
The solvent chemistry, together with RGD (Rapid Gas Decompression), can attack the valve seals and ‘O’ rings typically located in the valve seat. This can lead to seal life reduction, premature valve leaks and higher costs for both plant operation and maintenance.A successful solution was achieved by the fitting of DuPont™ Kalrez® Spectrum 7090 seals. These perfluoroelastomer products offer an excellent combination of chemical compatibility, with both RGD and high temperature resistance for ‘O’ ring applications, particularly where handling glycol-based solvents. Valve leakages can be dramatically reduced, with a reduction in maintenance procedures resulting from the extension of MTBR (Mean Time Between Repairs).
SOLVING SEALING PROBLEMS FOR FLOW CONTROL PRODUCTS
Further information is available from:Dichtomatik Ltd, Donington HouseRiverside Road, Pride Park, DerbyDE24 8HXTel: 01332 524401Fax: 01332 [email protected]
1111Jan/Feb 2012
engineeringmaintenance.info
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Maintenance Best Practise
Reliability is a term that has become more commonly used in
the industry. Many organizations are using reliability to describe
their predictive maintenance department. To me reliability has
always encompassed the measurement of manufacturing
efficiency and includes Operations, Maintenance, Engineering
and Spare Part Stores as the major players. Together these
departments shall deliver Manufacturing Reliability and we know
that better reliability results in:
• Improved safety.
• Faster manufacturing throughput.
• Lower manufacturing cost.
• Lower energy consumption.
There are many ways to measure manufacturing reliability. The
least complicated is to divide Quality Tons Manufactured by
Capacity Quality Tons. However it is beneficial to break up this
equation in three elements: % Quality Tons x % Time Efficiency
x % Speed performance. If each of these is 95% the total
manufacturing reliability is 85.7%. By measuring these three
elements it will be easier to pinpoint where the biggest losses
are. It is not uncommon for mills to only measure the time
element of this formula often expressed as % availability or “%
time we have sheet on reel” for a paper machine. To me this is
wrong because you might have a high availability but you might
have to scrap all products made or you are not running at full
speed.
I see the equipment reliability component of manufacturing
reliability as the revenue side of what the maintenance
organization does and the process reliability component as
the results of what the operations organization does. The
maintenance organization is supported by efficient and cost
effective stores and engineering is responsible for cost effective
design including maintainability and reliability considerations.
The roles of these departments must be clearly defined and
their joint goal should be manufacturing reliability. They are in a
relationship of equal partners and never in an internal customer
relationship between each other. (See article in October 2011
PPI issue).
Organizational silos.One of the biggest obstacles to overcome is that organizations
are set up in silos with different goals.
For the engineering organization it is not necessarily so that
lowest Life Cycle Cost (LCC) over more than fifteen years
of ownership is most important. Costs as a result of poor
maintainability and reliability design might consequently be
much higher than necessary over the years equipment is owned
and operated. In most organizations the project manager is
A Culture Of ReliabilityChrister Idhammar is a world
renowned and award winning
Reliability and Maintenance
Consultant and Guru. He is the
Founder and CEO of IDCON,
INC in Raleigh NC, USA; A
reliability and maintenance
training and consulting company
to the Pulp and Paper Industry
worldwide since 1972.
www.idcon.com
13Jan/Feb 2012
engineeringmaintenance.info
driven and awarded if projects come in on time and under
budget not by lower LCC. Key operations and maintenance
people are often not included in the early specification phase of
a project and many good ideas are lost. It is not uncommon that
basic documentation such as detailed bills of materials is left
out. This will lead to difficulty to optimize stores and much extra
work to document these bills of materials later.
The operations organization is rewarded by tons manufactured.
The maintenance organization is measured primarily by cost as
set in the maintenance budget and stores are often challenged
to reduce inventory value. It is not necessarily so that these
measurements are wrong but if applied in organizational silos
they lead to sub optimization and total results will suffer.
To improve this situation mills need to rethink their departments
roles and goals and bring them together in a partnership
work system with one goal expressed as manufacturing
competitiveness e.g. Quality Tons/Cost (instead of Cost/Ton) to
articulate the focus on manufacturing reliability. All other goals
and performance indicators shall drive actions to support this
goal.
Increased reliability will drive down costs.
Cost to achieve improved reliability is important. Most of the
cost consists of implementation of better maintenance and
operations practices and training of your employees to do better
with what they already have. After a short period of increased
costs reliability will improve and manufacturing costs including
maintenance costs will continuously go down over many years.
An established fact is that improved reliability is a major driver to
improve safety and costs.
To simplify there are three ways to reduce maintenance costs:
• Cut the cost.
• Prevent Maintenance.
• Execute remaining maintenance more efficiently.
Cut the cost
To just cut the cost instead of improving what drives cost is the
wrong thing to do.
If maintenance costs are cut by layoffs of people and no
improvements in systems, processes and practices are done it
will within one to two years lead to more overtime, more use of
contractors more total maintenance hours, lower reliability and
higher costs. Some valid maintenance work can be deferred
with the risk associated with that but sooner or later the work
must be done.
To just cut the cost is a short term action with expensive long
term results. My observations are that this is not as common as
it used to be but it is still far from uncommon.
Over the years this will repeatedly happen in mills where a well
defined, documented, communicated and executed reliability
and maintenance strategy is absent. 60% of mills have had
more than three mill managers, production managers and
maintenance managers in the last ten years per response to a
survey on www.idcon.com .
If you do not have a reliability and maintenance strategy to
execute there is a risk that each new manager will implement a
new program. This will very often confuse the organization and
ongoing improvements will discontinue.
Prevent Maintenance.To prevent maintenance work from occurring is the right thing
to do.
“To me reliability has always encompassed
the measurement of manufacturing
efficiency and includes Operations,
Maintenance, Engineering and Spare Part
Stores as the major players.”
Maintenance Best Practise
Jan/Feb 2012engineeringmaintenance.info14
15
Whatever name you give your maintenance program it will
always be important to execute the fundamental elements
of maintenance better and better. To prevent maintenance
or maintenance prevention includes the following must do
essential elements.
• Right equipment. Procurement of new equipment should
be based on lowest Life Cycle Cost and include reliability
and maintainability design.
• Lubrication. It is still one of the most important things to
do well by trained people.
• Alignment must be done to a precision level with
considerations to operating temperature, pipe strain,
number of shims etc.
• Filtration of hydraulic fluids, lubrication oils, seal water for
mechanical seals must be done to specified levels.
• Balancing must be done to precision level.
• Operating Practices are essential to prevent maintenance.
Operators must understand how to operate equipment and
the impact wrong operating practices have. E.g. how to
start a pump, what happens to an electric motor if it is dirty
or is frequently started. Redundant equipment should be
shifted to operate same amount of hours etc.
• Fixed Time Maintenance is very seldom justified and often
leads to over maintaining. Only if it is justified based on
failure developing times and distribution of failures in time it
can be cost effective to do.
Execute remaining maintenance more efficiently.Maintenance Prevention will increase reliability and reduce
maintenance work. All work cannot be prevented so remaining
work should be done more efficiently by skilled people in the
following process:
1. Identify work early through good inspections of
equipment and disciplined priorities.
2. Plan work.
3. Schedule work.
4. Execute work according to schedule.
5. Record work done.
6. Use recorded information to trigger a Root Cause
Problem elimination action.
What is the secret?The secret is that there is no secret. The above concepts are
very well known and documented in hundred of books the last
fifty years. So why is it so difficult to do something so simple
well? One of the reasons for this is that companies often make
it much more complicated than it is. New names on well known
concepts confuse people. They think it is another new program
that will only last until we get the next manager so why make
too much effort to buy in? We need to realize that to improve
maintenance is 90% about people and 10% about technology
and as engineers we often like to deal with technology more
than with motivating people. Most maintenance people like
gadgets while they might not like to change to working in a
disciplined system. A reactive system rewards action and extra
income through overtime.
The big challenge is to change the way maintenance work is
viewed by top management. Maintenance is often controlled
way too much based on cost instead of the results delivered
through efficient maintenance work. As mentioned above,
the results of maintenance work include equipment reliability
followed by better safety and lower costs. Maintenance
managers are often not aggressive enough. As a maintenance
manager you need to know how good your organization is
compared to how good it can become. Then you need - a well
documented plan showing how you are going to close that gap,
what benefits you will deliver and how much it will cost. Then
you need to sell that plan to top management and then to the
people in your organization that will help you deliver the plan
over the next three to five years.
Remember that almost all improvement initiatives have to
be executed by your front line organization; if they are not
supported to execute nothing will be delivered. As the picture
above describes the front line organization in a bigger mill
includes planners, supervisors, coordinators, operators and
maintenance crafts people.
Maintenance Best Practise
15Jan/Feb 2012
engineeringmaintenance.info
16 engineeringmaintenance.infoJan/Feb 2012
Non Destructive Testing
Condition Monitoring
The TD Pocket-Scan coupled with Technology Design’s Corrosion Mapping Kit is the ideal solution for recording material loss data without the need for bulky and costly mechanical scanners. Data is collected manually with a standard normal ultrasonic probe and positional information is recorded by the
Condition MonitoringThe TD Pocket-Scan coupled with Technology Design’s
Corrosion Mapping Kit is the ideal solution for recording
material loss data without the need for bulky and costly
mechanical scanners.
For more information on all our
products, please contact Jackie Berry:
W: www.agr.com/fo
video tracking system.The TD-scan Ultrasonic Software provides integrated tools for both setup and analysis of data. The data is viewed as a true depth C-scan with associated side views that can be interrogated using a range of powerful software tools including an easy to use report generator. The TD Corrosion Mapping Kit is easy to use and is the answer to your ongoing condition monitoring challenges.
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The compact, battery-powered logger features burn-out response, and has a built-in temperature channel allowing the particular process and the ambient air temperature to be monitored simultaneously. It incorporates a connection that supports both standard and miniature thermocouple plugs. Data is downloaded to a PC via a USB connection and viewed with easy to use Tinytag Explorer software. From £99 + VAT.
New Tinytag Thermocouple Data LoggerGemini Data Loggers’ Tinytag Ultra 2 Thermocouple
data logger provides fast response, versatile and
cost-effective temperature monitoring. It supports
the most popular thermocouples types – K, J, T and
N – providing monitoring from -270°C to 1370°C,
depending on the type being used.
Gemini Data Loggers (UK) LtdScientific HouseTerminus RoadChichesterPO19 8UJ
+44 (0)1243 [email protected]
17Jan/Feb 2012
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18 engineeringmaintenance.infoJan/Feb 2012
Non Slip Flooring
Cranes
Efficient Lifting and Handling from 125 Kilos to 200 Tonnes
Street Crane Company overhead travelling cranes for industry are available in configurations for safe lifting and handling up to 200 tonnes. In the mainstream one to 50 tonne category they offer the advanced ZX modular hoist.
For lighter lifts, LX chain hoists meet handling meet needs from 125 Kilos up to five tonnes safe working load. These may be used for static lifting or attached to crane beams for easy product transfers.Light crane systems are designed for local handling and productivity, freeing the main factory overhead crane for heavier lifts and down shop transfers.
More information Andrew Pimblett, Tel. 01298 812456 Fax. 01298 814 945Street Crane Company, Chapel-en-le-Frith, High Peak, SK23 0PH, UKE-Mail: [email protected] Web: www.streetcrane.co.uk
With our first of a kind heated version called the Arctic Pad, this innovative all season solution gives year round protection for colder climate operations.
Safety, Warmth & Comfort it all starts with the feet!
Take the next step towards improving safety.
PROVIDING SOLUTIONS FOR THE LEADING CAUSE OF ALL ACCIDENTS AND INJURIES – SLIPS, TRIPS & FALLS.
At AMS we believe that one slip or fall injury is one too
many, so whatever the application or environment, our every
expanding line of solutions called the Advanced Mat System
ensures that you have the right mat for the right application.
www.advancedmatsystems.com
19
Dry Ice Cleaning
Used by many leading names in the dry ice
sector- Air Liquide, Messer, Linde, BOC,
Praxair, Coljet, Yara, etc -the combination
of high quality insulation and robust plastic
construction with steel fittings ensures
that the containers have a very long life.
The ease of movement on casters or feet
makes the containers very easy to handle
so that the dry ice pellets for blast cleaning
can be taken direct to the point of use and
still at exactly the right temperature.
Olivo contain dry iceOlivo portable insulated containers
have been manufactured for over
fifty years.
Contact: www.olivo.fr
19Jan/Feb 2012
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20 engineeringmaintenance.infoJan/Feb 2012
Dry Ice Cleaning
As well offering ranges of
traditional industrial cleaning
machines such as parts washers,
vacuum cleaners and stationary
high-pressure cleaners, Kärcher
has developed highly innovative
blast cleaning products to improve
safety, reduce costs, and offer
new levels of blast cleaning
standards.
Kärcher ‘s range of Ice Blasters
offer a portable, non-aggressive,
but thorough method of cleaning
surfaces, tools, moulds and
machines without causing
damage to the substrate or the
environment. The machines
can be used in indoor and
outdoor areas and do not require
Safe, mess-free cleaning with Kärcher Ice Blasters
As one of the world’s largest manufacturers of cleaning equipment, Kärcher has the products and knowledge to provide the best cleaning solutions for a wide variety of industrial environments.
chemicals.
The process is
particularly suited
to environments
where machine
cleaning and
maintenance is
essential, and
can significantly
reduce downtimes
and costs.
The system uses
dry ice pellets kept at -79ºC,
injected into a jet of compressed
air, accelerated to speeds in
excess of 150 m/s and then fired
at the surface to be cleaned. The
abrupt cooling of the surface
causes a thermal shock and
produces fine cracks in the top
layer. The dry ice pellets
penetrate these cracks
and sublimate instantly
(turn into a gas without
becoming a liquid) lifting
the contaminant from
the surface, and return
to the atmosphere as
CO2 gas leaving only the
contaminant behind. As
cleaning with dry ice
is performed without
chemicals or detergents,
and leaves no
wastewater, it is
environmentally
friendly and can
be used in areas
To find out more about how ice
blasting can make a difference to
your business, and to find your
nearest specialist, call 01295 752
142, email [email protected]
or visit www.karcher.co.uk
where cleaning with water is
prohibited or inconvenient. Unlike
sand blasting, ice blasting keeps
surface abrasion to a minimum,
and there is only the contaminant
to collect after cleaning has been
completed.
This superb technology is available
from Kärcher’s officially appointed
Ice Blaster specialists, all of whom
can offer expert advice on your ice
blasting requirements.
21engineeringmaintenance.infoJan/Feb 2012
Dry Ice Cleaning
Dry Ice Cleaning
Jan/Feb 201222 engineeringmaintenance.info
Flow Meters
Flow Meters
To learn more about the M series Mass Flow Meter, and all of Alicat’s flow control products, visit:www.alicatscientific.com, or call +1 520 290-6060.
Alicat Mass Flow MetersTucson, Arizona – For industrial analytical lab use, Alicat
Scientific, Inc. offers the ATEX-rated M series Mass Flow
Meter. The M series mass flow meter is a good choice for
analytical applications including process measurement,
calibration of HPLC and analyzers, and in pilot reactors.
The M series mass flow meters quickly and accurately measure pressure, temperature and volumetric flow in addition to mass flow. Alicat’s patented laminar flow differential pressure technology delivers highly accurate results with a much faster response time than that of competing technologies. Devices come pre-calibrated (NIST traceable) for Acetylene, Hydrogen, Ethylene, and Propane, as well as 16 other gasses and 10 gas mixes. For use in a wide range of applications, an ATEX approved -X option is available.Operating simply as a stand-alone device, the integrated digital display of the M series Mass Flow Meter enables users to change the configuration of the meter without the need for computers, complicated software or scripts. For more complex operation, the M series also interfaces with most process control software without requiring any additional equipment or controllers, a simple to install and cost effective solution.
23engineeringmaintenance.infoJan/Feb 2012
Leak Protection
Corrosion Monitoring
The engineers at the plant were looking for a long term repair solution for a caustic tank suffering leaks on the welded seams where the caustic acid was leaking from the painted mild steel tank. The tank was situated within a stainless steel secondary containment area and was made up of four half round sections which were welded together. The tank contained around 8000 liters of 28% caustic soda.
The tank was fully drained prior to the application and the front of the secondary containment area was removed to aid access. A scaffold was erected to gain access to the higher parts of the tank.
Application service provider Belzona Technosol won the contract to refurbish the tank. The entire area was pressure washed to ensure full adhesion of the Belzona products. An 80mm wide repair area was then masked off along the length of the welded seam and prepared
using a Monti® MBX Bristle Blaster, a hand-held surface preparation tool suitable for use on a variety of substrates including metals, rubbers and plastics.
The product selected for the repair of the leaking areas was Belzona 1111 (Supermetal) a multi-purpose, machinable, repair and rebuild system. The two-component paste grade product is based on a ceramic steel reinforced polymer system which when cured is durable and chemical resistant. The product is ideally suited to applications on tanks, pipes, casings, keyways, bearing housings, shafts, hydraulic rams, engine blocks and flange faces.
The first layer of Belzona 1111 (Supermetal) was applied incorporating Belzona 9341 (Reinforcing Tape) to the repair area. Once cured, a second coat of the reinforced product was applied. After removing the masking tape the product
was left to cure. This application will provide a long term, corrosion protection solution for this caustic tank.
Belzona Repairs Leaking Caustic TankIn September 2011, Belzona refurbished a leaking caustic tank for a global soft drink manufacturer at their bottling plant in London.
Belzona Polymerics LimitedClaro Road, Harrogate, HG1 4DS England
Telephone: +44 1423 567641Facsimile: +44 1423 505967
http://www.belzona.com
24 engineeringmaintenance.infoJan/Feb 2012
Online Condition Monitoring
Online Condition Monitoring
An integrated plant-wide machine
condition and performance monitoring
strategy is essential to achieving this.
Since its inception in 1991, Brüel & Kjær
Vibro’s Compass platform has been the
industry leading integrated monitoring
solution. Successfully utilized in refineries,
offshore and onshore oil & gas production
facilities, LNG, olefin, polyolefin and
chemical plants, the system has delivered
considerable uptime, efficiency and cost
benefits to customers the world over.
Combined with our global sales and
technical support network, Compass can
deliver uptime to your plant!
Brüel & Kjær Vibro has delivered plant-wide condition monitoring
systems to the O&G and petrochemical industry for over 20 years
The oil & gas and petrochemical industries face
the most demanding challenges in fulfilling today’s
machine management and reliability requirements.
Brüel & Kjær Vibro is part of Spectris
plc, the leading supplier of productivity
enhancing instrumentation and controls.
Contact: Brüel & Kjær Vibro, e-mail:
[email protected], www.bkvibro.com
Brüel & Kjær Vibro is part of Spectris
plc, the leading supplier of productivity
enhancing instrumentation and controls.
Contact: Brüel & Kjær Vibro, e-mail:
[email protected], www.bkvibro.com
Brüel & Kjær Vibro provides a comprehensive integrated monitoring solution to the hydro industry
As the Operation & Maintenance
requirements become more demanding,
the importance of effectively monitoring
these machines becomes imperative.
Hydroelectric power plays an increasingly important
role in the worldwide energy market.
Over the past 20 years, Brüel & Kjær
Vibro has built a global customer base by
monitoring all types of turbines ranging
from 1MW to 1GW. Our dedicated hydro
monitoring systems are tailored to the
varying demands of the hydro industry
and include unique specialized functions
including the multiple machine state
monitoring function - ideal for pumped
storage applications. In addition to
comprehensive vibration monitoring, Brüel
& Kjær Vibro also provides integrated air
gap, magnetic flux, process, performance
and cavitation monitoring. Combined with
our global sales and technical support
network, we can provide a solution to
your Hydro application!
25engineeringmaintenance.infoJan/Feb 2012
Online Condition Monitoring
Online Condition Monitoring
EtaPROTM Detects Machinery Problems Sooner Rather Than Later
Productivity increases because plant staff
can be proactive with maintenance that is
focused on avoiding future failures rather
than reacting to them.
GP Strategies’ EtaPRO technology suite is the power
generation industry’s leading real-time Performance
and Condition Monitoring System. Our first principles-
based thermodynamic modeling software, VirtualPlant™,
calculates “targeted” performance, validates data,
and simulates “What-If” scenarios for combined cycle,
Rankine cycle, and nuclear power plants.
To provide early warning and reduce unplanned
maintenance, GP Strategies integrated advanced pattern
recognition (APR) technology into Version 10 of EtaPRO.
EtaPRO APR models are used to detect anomalies in
plant or equipment conditions by continuously comparing
current values to detailed empirical models of “normal”
data.
To learn more about EtaPRO please contact:GP Strategies CorporationEnergy Services GroupTel: +1 (716) 799.1065Fax: +1 (716) 799.1081Email: [email protected]: www.etapro.com
Brüel & Kjær Vibro is part of Spectris
plc, the leading supplier of productivity
enhancing instrumentation and controls.
Contact: Brüel & Kjær Vibro, e-mail:
[email protected], www.bkvibro.com
Wind turbines are subject to widely variable operating conditions, which together with the compact construction, non-rigid foundations, complex gearbox
Brüel & Kjær Vibro provides a unique dedicated monitoring system and service concept for the wind turbine industry
Condition monitoring requirements in the wind industry
are like no other, thereby requiring an entirely different
monitoring approach to traditional rotating machines.
and slow rotating speed complicate the analysis and diagnostic process. To deal with these challenges, Brüel & Kjær Vibro has developed a unique monitoring
concept that combines its dedicated wind turbine condition monitoring system with a unique service program; the surveillance centre. The GL certified surveillance centre uses ISO18436 certified specialists and the unique alarm management concept integral to the monitoring system to evaluate all alarms and provide actionable information to the client’s service organisation. This versatile combination reduces unplanned maintenance, enables just-in-time service, maximises uptime and reduces maintenance costs. Your wind turbines/turbine park can benefit from this dedicated monitoring concept.
Compressed Air
That is why Atlas Copco and its
distributors conduct energy audits as
the definitive approach to identifying
trends, establishing how well
operators’ systems are performing,
and recommending energy-efficient
solutions where needed.
Applying simple non-intrusive air
audit data logging techniques over
a fixed period of time will establish a
true indication of a system’s air usage
and cost and, ultimately, will help to
identify any wastage factors such as
leakage and pressure drops.
Whether the purpose of an air
audit is part of an on-going service
contract, a means to monitor
the progress of an established
installation or to determine the level
of efficiency of an existing system
for its potential replacement, the
fundamental question that the
Atlas Copco distributor asks of the
customer is ‘Do you know how
much compressed air you use and
how much it costs to produce?” For
the answer, the starting point is to
measure the power requirement for
the compressor installation, a simple
initial procedure that may be followed
by a full system audit where deemed
necessary.
Atlas Copco authorised distributors
have successfully applied these
monitoring techniques to a
considerable number of diverse
applications throughout industry,
and as a result of implementing
these energy-efficient measures, it
is not uncommon for operating cost
savings of as much as 40% to be
realised. For example, the Wales-
based distributor Control Gear helped
a bridgeworks and water engineering
products manufacturer in South
Wales to make savings of £8,000
per annum following an energy audit.
With the aid of iiTraks and supporting
software a potential saving of
£12,000 was also realised by another
of the distributor’s customers who
manufacture vibration dampening
products in Wiltshire. In the North
West, Precision Pneumatics helped
a theme park to cut its annual
power consumption by 50% and
also achieved a 35% annual energy
savings for a newspaper publisher
in the area. In South Yorkshire, the
Compressed Air Division of the
Search Group of Companies was
also able to achieve £35,000 in
energy savings for a large engineering
plant and a further £15,000 per
annum for a health care products
manufacturer.
That is why it is standard practice
within the distributor network to
conduct these investigations as
part of its professional energy
management expertise. Every
distributor in the nationwide network
has the technical capacity and
dedication to help compressed air
users maximise energy savings
and to improve the reliability and
productivity of their compressed air
systems.
Using the latest iiTrak data loggers,
which basically supersede the
Distributors Lead The Way To Energy Efficient Compressed Air Systems
Most compressed air users would agree that to
get the best return from their capital investment,
the monitoring, measuring and management of
compressor installations is essential if optimum
control, improved productivity and energy efficiency
is to be achieved.
Jan/Feb 2012engineeringmaintenance.info26
27engineeringmaintenance.infoJan/Feb 2012
Compressed Air
conventional measurement box
monitoring procedure, Atlas Copco-
trained engineers can help operators
to establish a true indication of a
system’s air usage and cost without
any interruption of the air supply or
production process. The end result
is an accurate indication of a plant’s
compressed air demand and, most
importantly, of any potential wastage.
The compact, unobtrusive, battery-
powered iiTrak loggers incorporate
the latest data capture technology
to log compressor load status via
current sensing. They are designed
as stand alone units, with one
logger allocated to each machine
in a multiple installation, or one unit
dedicated to each compressor
characteristic to be measured. Easily
installed at the point of use, they
are connected by a single cable for
one leg of incoming power. All data
is captured by the unit’s flash card
memory for subsequent computer
download and scrutiny.
The true amount of energy drawn
by each compressor (both on load
and off load) is measured. The mains
voltage and power factor correction
is also recorded which gives the
true kilowattage consumed by
each compressor. The candidate
compressors are logged for a
minimum period of one week after
which the data is downloaded to
a computer. In some instances,
the user’s production process
programme and relevant air demand
variations may require an extended
measurement period to be necessary
but the battery power for the iiTrak
units is adequate for approximately
three weeks of operation before
replacement is necessary. The unique
Atlas Copco software programme
for the iiTrak enables simulated
compressor comparisons to be made
against the actual system.
It is usual for Atlas Copco’s iiTrak
energy monitoring to take place
prior to a full, in-depth investigation
to obtain a comprehensive
understanding of the air usage
by scrutinising every stage from
compressed air production to its
point of use.
The audit procedure employs
sophisticated equipment items such
as a mass flow measurement meter,
relative pressure sensor/transmitters,
ultrasonic leak detection apparatus
and power meter monitoring.
These instruments pinpoint
inefficiencies such as inadequacies
in the production and utilisation of
the compressed air supply, poor
pipework design and pressure drop
sites. It will also reveal where systems
are operating at too high a pressure
and where energy is being wasted
because of piping network leaks.
With this data available, the next
stage in the distributor’s investigation
is to look at the operator’s present
and future requirements in depth,
to submit a full report of the
application findings, and to make
recommendations on actions
and equipment solutions based
on precise audit data and close
knowledge of how the application
operates. As a result, customers can
be provided with the most energy-
efficient systems tailored to suit their
precise needs. The recommendations
may well include energy-efficient VSD
compressors that match compressor
output to process demand thereby
generating energy savings of up to
35%.
Jan/Feb 2012engineeringmaintenance.info28
29
Maintec Preview
More than 1,700 chief maintenance officers, engineering
and plant managers – many from UK blue chips like
Astra Zeneca, BAE Systems, NHS Trust, Royal Mail and
Walkers Crisps – attended the 2011 show to get their
hands on the latest kit and talk to the developers making
advances in condition monitoring, asset management
and hazard detection.
The 2012 show will once again play host to all the
major players within the sector such as Fluke (UK) Ltd,
Idhammer Systems Ltd, and Panasonic UK Ltd, as well
smaller growing companies such as 2011 debutants
Business Development Strategic Maintenance Ltd.
Colin Wilson, Consultant Director at the company,
commented: “At MAINTEC 2011 we had 59
conversations of note over the three days with several
potential companies interested in using or reselling this
product. This was our first MAINTEC exhibition, having
last year come as visitors to assess its suitability as an
exhibition for a small, growing company like ours. We’re
certainly glad we came as exhibitors.”
easyFairs UK, Managing Director Matt Benyon, added:
“Maintec is the perfect platform for both large and small
companies to showcase their latest maintenance and
engineering offerings to key decision makers within the
industry, as well as visitors wanting to witness first hand
the very best in maintenance technology.”
Exhibitors and visitors will get all the benefits of the
easyFairs approach to trade shows, including convenient
and cost-effective all-inclusive stand packages and free
learnShops™ that focus on practical knowledge sharing
and cover the latest trends, issues and technology
developments.
Exciting additions have also been added to easyFairs
MAINTEC 2012. In particular, a new hazardous goods
event called ‘HAZEX’ will be taking place, to reflect the
growing responsibilities of maintenance professionals,
and the growing concerns and tighter legislation over
plants’ health and safety.
The show also has the support of key sector
organisations, including the British Compressed Air
Society, the British Institute of Non-Destructive Testing,
the Institution of Diagnostic Engineers, Institute of Asset
Management, the Facilities Management Association,
United Kingdom Thermography Association and The
Institute of Engineering and Technology.
MAINTEC 2012 TO SHOWCASE THE VERY LATEST IN MAINTENANCE TECHNOLOGY
Now in its 37th year, easyFairs MAINTEC –
the only UK show dedicated to the industrial
maintenance and asset management sectors
– returns to Birmingham’s NEC next February
(28 February – 1 March 2012) to showcase
the very latest technologies in the sector.
To find out more information about the
show visit:
www.easyFairs.com/MAINTECUK
and for stand bookings and exhibiting
enquiries contact Jerry Dawson on:
+44 (0)20 8843 8823
or e-mail: [email protected].
29Jan/Feb 2012
engineeringmaintenance.info
30 engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
Maintec Preview
31engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
Nearly eight in 10 maintenance and engineering managers interviewed by easyFairs ahead of the 28 February – 1 March NEC exhibition say they expect their budget to remain the same or increase over the coming year. Additionally, over a third (36 per cent) said that improving plant productivity is the main driver behind their maintenance spend. This is welcome news given that 55 per cent of respondents are planning to tackle the economic slump through added investment in predictive maintenance technologies that will extend plant longevity, improve efficiency and avoid catastrophic, costly plant failures. However, easyFairs found opinion divided when it came to views on the board’s attitude to maintenance; 8 per cent said they saw it as expensive, while 8 per cent believed their bosses considered it as good value for money. Nearly two fifths said their respective boards saw maintenance as an invaluable part of the business, but one fifth said directors saw it merely as a “necessary evil”. easyFairs UK & Ireland Managing Director Matt Benyon said: “Businesses are still finding it tough, but many realise that cutting back on maintenance budgets is false economy. There’s a wealth of advanced, affordable technology on
show at MAINTEC 2012 that can deliver significant efficiency savings and help protect machinery and equipment.” Now in its 37th year, easyFairs MAINTEC 2012 is the UK’s leading exhibition dedicated to showcasing the latest asset management solutions, and offers maintenance managers an opportunity
to source the predictive maintenance technologies to help them tackle the tough economic climate. Matt added: “There’s a lot going on at this year’s show. We’ve launched a new hazard prevention area called HAZEX, plus have put a real emphasise on predictive maintenance technologies, which will come as pleasing news to those who took part in the survey.” Indeed, and in addition to utilising predictive maintenance systems, the research showed that training (45 per cent), energy management (42 per cent), and inventory/spare parts management (39 per cent) were other popular ways respondents planned to boost profits. Additionally, more companies are responding to the recession by focusing on contracting and outsourcing: of those surveyed over half (55 per cent) do not outsource maintenance and asset management at the moment, but contracting and outsourcing was ranked top priority for them over the coming months. Other key findings included that 70 per cent said the board uses productivity to measure plant performance, followed by downtime (61 per cent) and running costs (42 per cent). And encouragingly, 41 per cent said that the current climate had not forced them to postpone planned investment in major new equipment.MAINTEC 2012 takes place from Tuesday 28 February to Thursday 1 March 2012 at the NEC, Birmingham.
Maintenance Key To Improving Plant ProductivityMaintenance budgets are set to remain buoyant
and focus on improving plant productivity, even in
these times of austerity, research from MAINTEC
2012 show organiser easyFairs has revealed.
For more information or to register for the show please visit www.easyFairs.
com/MAINTECUK, and for stand bookings and exhibiting enquiries contact
Jerry Dawson on +44 (0)20 8843 8823 or email [email protected].
32 engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
Instead of utilising a valve mechanism
to close off steam, the highly efficient
GEM steam traps use the patented
venturi orifice design to effectively drain
condensate from the steam system and
maximise energy and water conservation.
As the GEM steam traps have no moving
parts to wedge open or fail they provide a
permanent solution to steam trapping and
condensate return problems. GEM steam
traps also improve product processing
by enhancing the quality of steam and
reducing equipment repairs, downtime
and replacement costs. Available in a
wide range of sizes for a cross section
of applications, and with optional filter
where applicable, the GEM steam traps
provide companies with a fast payback in
increased equipment reliability, water and
energy savings of up to 30%.
TEI’s flue gas condensing heat recovery
economisers can reduce the energy
consumption of an industrial boiler by up
to 18% by capturing the waste heat in the
flue stream and converting it to hot water.
Thermal Energy International Inc. is an
innovative technology company providing
custom energy and emission reduction
solutions. The company’s award winning
energy recovery, conservation and
bio-energy solutions provide significant
financial and environmental benefits to
customers.
Thermal Energy International produces a range of GEM venturi orifice steam traps to suit a range of applications.
Thermal Energy International Raises The Bar On
Thermal Efficiency On Stand C8 At Maintec 2012Thermal Energy International Inc. (TEI) will be exhibiting its range of awarding winning energy efficiency products on stand C8 at the NEC Birmingham from 28th February to the 1st March. TEI’s products include its GEM venturi orifice steam traps and its flue gas condensing heat recovery economisers .
About Thermal Energy International Inc.Thermal Energy International Inc.
is an innovative clean technology
company providing a variety of
award winning energy efficiency,
emission reduction, water
efficiency and bio-energy products
and solutions to the industrial,
commercial and institutional
markets worldwide. Thermal
Energy’s products include; GEM®
- Steam traps and condensate
return systems, FLU-ACE® - Direct
contact condensing heat recovery,
and Dry RexTM - Low temperature
biomass drying systems.
Thermal Energy International
Inc. is also a fully accredited
professional engineering firm,
and offers advanced process and
applications engineering services.
FLU-ACE®, GEM®, DRY-REX®,
THERMALONOX®, and THERMAL
AUD® are trademarks of Thermal
Energy International Inc.
For more information, visit:
www.thermalenergy.com &
www.gemtrap.com.
33engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
E24
D14
F10
D1
D3
D12
C2
B2
E3
C8 C7
C3F7
B15
D5
D8
D21
C15
A14
B14
F9
F5
C10
C20
A11
F21
A7
A12
B7
F11 B8
E13
C9
B5
E19
A2
A6 B9
C17
A25
E11
A19
F18
E15
B4
B6
E8
F20
A21
F14
F25
F16
B10
F22
A3
D7
B11
C14D11
E21
A17C13
F4
C21
A4
E1
A2a
C18
F2
F15
B25
A5
B1
F1
B14a
B21
A15
D22
E9
C16
B3
B13
D23E23
B22C19
B18
E7
A22
A18
B26
B17
C17a
B12
A26
D17
A1a
F12
D6
C5
C23
A1b
B19
A1
D13
D19
B16
B19a
E25
D20
F8
D18
F6
Maintec 2012 Floor Plan
Exhibitor list on pages 34 & 35
Maintec Preview
Adash 3TP Ltd A25AESPUMP Ltd B14aAlpine Components B10Ambersil (CRC UK Ltd) B4Antech Hydraulics (NTZ Filtration) A12AV Technology Ltd C20BCAS F4Bel-Ray Company Inc. E8BELGRAVIUM A1bBINDT - The British Institute of NDT F12C-Cubed Ltd/Jenton Group B5Castle Group Ltd D22Censol Ltd A4CEPSTRA (UK) LTD A15Clean Air Group D13Cobalt Conveyors E25Control Freq GSM C19CorDEX Instruments F5
Crimson Industrial Vision Ltd A2Des-Case Corporation D12DP Doors & Shutters Ltd C16Dust Control Systems Ltd F9
Dustcontrol UK Ltd E15
EA Technology E21Easylaser / Damalini AB A19ERIKS STOREROOM SERVICES B9
ERIKS UK Ltd A6
Facilities Management Association E23Flexilube Ltd B6FLIR Systems E3Flowcrete UK Ltd A14Fluke (UK) Ltd F7Flux Pumps International (UK) B18Gardner Denver Ltd F1Gemini Data Loggers (UK) Ltd B16Hansford Sensors Ltd C7High Voltage Partial Discharge C21Hire Torque Ltd C3Holroyd Instruments Ltd F22Icetech UK B1
Idhammar Systems Ltd C15IFM Electronic Limited B2IGS UK LTD A1Infor C10Inpro-Seal C17Institute of Infrared Thermography A2aIPEC Ltd B13IPS International Ltd B11Jacob UK Ltd D7Jena Rotary Technology F16John L Lord & Son Ltd (Specialist Flooring) D6Jungheinrich (UK) C5Jungheinrich (UK) C23KRR Prostream C13Kuwait Petroleum International B7Lighthouse (UK) Ltd A17Llumarlite Ltd B3LOBO Systems Ltd F25Losomat UK B12MACS EU Ltd E9Maintenance Connection UK LTD E13Mattei Compressors F6MEPCA B17
Metrum Information Storage Ltd A7Michell Instruments Ltd D21Micropoly Europe Ltd B25MIDLAND GROUP TRAINING SERVICE E19MONITION LTD - Fixturlaser UK A3
Exhibitor List | Maintec 2012
Jan/Feb 2012engineeringmaintenance.info34
35engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
Maintec Preview
MSL Group A26OCIP Energy Ltd D23OPTRIS GmbH E1Pickerings Lifts F15Plate & Locate F18PMI Software Ltd E11Prevost UK Ltd F2Probe Technical Recruitment F21Process Industry Informer B26PRUFTECHNIK Ltd D1
Quartzelec Ltd D17
R. STAHL D18Radir Ltd C2RMS Ltd F20Ro-Dor Ltd D5
RRC Training A18S.E.M.CO D19
SAFELIFT ONSHORE A1a
SCHAD AUTOMATION E7Schaeffler UK Ltd D3
Shire Systems Ltd D11
Sira Test & Certification D20
Siveco UK Ltd C9SMARTAG LTD C14
Softsols Group D8SPM Instrument UK Ltd A21
SRI
B19aSRO Solutions LtdC18Technical Training SolutionsA11Tempus MTAS LtdB15
Teseo UK F14Testo Limited B8THE INSTITUTE of ASSET Management F8
Thermal Energy International C8
TotalMobile A22TR Floor Systems B21Valveforce B14Walrus Pumps UK Ltd B22WD40 Company B19Western Business Publishing C17aWymark Ltd F11XETEC A5
More Maintec Preview On Page 36...
36 engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
Maintec Preview
New to the show this year will be
the VISIO PRIME Inspector – a 6mm
dia. Video Endoscope with 4-way
articulation specifically designed for
industrial inspections or machinery, pipes
and tubes, and other hard to access
equipment. The VISIO PRIME Inspector
will deliver high quality images, allowing
minimal dismantling to inspect the area
of interest. Weighing in at less than 1kg,
this highly portable, battery powered unit
has the ability to go anywhere and makes
an ideal inspection tool when you need to
get to those hard to access areas.
With a complete range of Video
Endoscopes, the Crimson Industrial
Vision is able demonstrate systems to
suit every application, from a simple video
inspection camera to the premium fully
articulating, long range endoscope for
detailed inspection. Also on show will be
a range of FLIR Systems Thermal Imaging
cameras, including the latest i7 and
E-Series. As a special offer at Maintec,
if you buy a FLIR E or T series camera
after visiting us on Stand A2 at the show,
we will include an Extech BR250 Video
Borescope free of charge.
New Video Endoscope for Maintec 2012
Inspection camera Specialist Crimson Industrial Vision will be
bringing its range of Thermal Imaging cameras and Remote
Visual Inspection products to MAINTEC 2012.
There will be 30 learnShops
(seminars) running over the three
days, with speakers from major
brands such as Britvic, Siemens, and
Schaeffler, all revealing their secrets
to help those visiting succeed in
2012.
“In today’s challenging economic
climate, it is even more important
to introduce an effective condition
monitoring (CM) regime that enables
engineers to keep their machinery
running efficiently,” says Ian Pledger,
Field Service Engineer for Schaeffler
UK, and who will be the first speaker
to start the learnShops programme.
Ian continues: “We talk to many
industry professionals who are
considering CM for their facility but
who are not sure at first how best
to go about it, or feel that CM may
be too complicated or costly. With
actual case study examples, we can
demonstrate that it is possible to
start off slowly with a few techniques
and then develop them over time to
suit their plant equipment and their
maintenance budgets.”
EXPERTS TO REVEAL WINNING MAINTENANCE
TECHNIQUES AT MAINTEC 2012
easyFairs has attracted a wealth of maintenance specialists,
all willing to share their winning techniques and vast
experience with visitors of the MAINTEC 2012 show, taking
place from Tuesday 28 February to Thursday 1 March 2012
at the NEC, Birmingham.
37engineeringmaintenance.infoJan/Feb 2012
Maintec Preview
Maintec Preview
38 engineeringmaintenance.infoJan/Feb 2012
Health & Safety
This has never been clearer as more and more innovative Draeger ideas are becoming viable commercial offerings and state-of-the-art equipment for the very best in personal protection. As part of this total solution offering, Draeger has opened a number of dedicated Safety Centres across the UK. Located in Aberdeen, Blyth, Gatwick and Plymouth, additional Centres are also currently being discussed
In charge of this initiative is Brian Hesler, ex Fire Chief at Northumberland Fire and Rescue Service, who brings first hand experience of the need for effective training and first class equipment. Developed to meet business demands and serve its customers better, these Centres are intended to bring Draeger closer to its customers. Combining sales and service from experienced personnel, they also offer a wide range of training courses and access to the complete range of Draeger gas detection and respiratory protection products on a short or long term rental basis.
Draeger’s Aberdeen Safety Centre, for example, has been proven to offer a very successful formula. Opened 18 months ago, it has just been granted approval to double the size of its facility to offer more training and other services alongside additional storage. As well as assisting and supporting fire and rescue services, this facility also supports general industry and, of course, Aberdeen’s core oil and gas industry which operates in both upstream and downstream market areas. Offshore safety inductions, for instance,
have been carried out for up to 35 people a day prior to rig shutdowns.
Located just 20 minutes from the harbour, the Centre is run by Kenny Durward who has extensive experience in rental, service and maintenance as well as the marine, oil and gas industries. In addition to service, maintenance, face fit testing and a range of training courses, including OPITO approved H2S awareness training, this Bridge of Don site is also finding that the rental side of the business is extremely buoyant. Whether planned or in an emergency, plant and rig shutdowns require the use of different personal protective equipment over differing time frames. Offering fully maintained and certificated equipment for rental over short, medium and long term periods, Draeger ensures that essential equipment is available immediately. On-site training can also be provided at the time of rental if required.
In the north of England, the Blyth Safety Centre combines a centralised administrative base with repair workshops, services, lecture areas and confined space training facilities. Welcoming customers from all over the UK, it echoes Aberdeen’s commitment to meeting customer needs with more choice and more experience in training, service and the sale or rental of equipment.
Other specialist personnel, each bringing their own particular knowledge and experience to dedicated areas of the business, as well as these new facilities, have joined Brian’s team. Peter Silk,
formerly a technical advisor to Firebuy and Assistant Divisional Officer with the London Fire Brigade (LFB), manages the new Southern Safety Centre at Gatwick. Now operational, Gatwick ,in addition to the range of services offered by Aberdeen , also offers test facilities for chemical protection suits as well as calibration and repair of thermal imaging cameras, and test and certification of compressed air cylinders.
Peter will also be responsible for the running of another new Safety Centre in Plymouth, looking after the needs of Cornwall, Devon, Somerset and the south west. Modelled on Aberdeen and covering all areas of industry, the Plymouth Centre offers the full range of services and, like each of the other facilities, can accommodate Draeger’s mobile confined space trailer and mobile display vehicle.
Representing a significant capital investment and employing around 50 people so far, these Safety Centres are at the forefront of a new era in Draeger customer service. Additional Centres are currently being discussed, as is the potential to work with partners in joint facilities. Also under development is an innovative E-learning platform which is set to take online training to a completely new level.
Brian concludes “We are still growing, still recruiting and still looking at ways to become even closer to our customers. The development of these Safety Centres was the result of in-depth customer discussions and listening to industry feedback. We are fully committed to meeting our customers’ needs and, in so doing, believe that we can help to ensure the utmost safety for those customers. A total solution offering is the key to our success and, we believe, the key to a safer future.”
Draeger Safety Centres – Now Across The UKOne of Draeger’s greatest successes is being able to offer
its’ customers “a total solution” rather than just “a product”.
For further information contact
Customer Service, Draeger Safety
UK Limited, Ullswater Close, Blyth
Riverside Business Park, Blyth,
Northumberland, NE24 4RG.
Tel: 01670 561200,
fax: 01670 356266,
www.draeger.com.
40 engineeringmaintenance.infoJan/Feb 2012
Humidity Calibrators
The temperature compensated
control probe provides higher
accuracy over the range of
measurement. Newly designed
electronics is incorporated within
the heat/cool circuitry and a more
efficient peltier mechanism, has been
incorporated for faster response and
temperature stability. The number of
ports in the chamber door has been
increased to accept 5 probes with
diameters of 10mm, 12mm, 15mm
The M2000SP-XR Humidity GeneratorOne System…Three Functions
High Accuracy Calibration of Instruments Over Full
Operational Range The field proven M2000SP-XR with new
solid state electronics for high accuracy and performance
over the full operating range of humidity and temperature.
and 18mm. NVLAP Accredited
calibration of control probe. System
tested for performance at ICH
guideline parameters to meet
accuracy and long term stability
requirements. Typical response time
is 3 minutes for 70%RH step change.
Production and Volume Calibrations
at Ambient Temperature
The chamber size of the M2000SP
standard system is 2 liters. For
calibrations of multiple data loggers
or sensors the chamber
capacity must be
increased. The
M2000SP-XR, using
the 12 port external
chamber, provides the
increased calibration
capabilities through the use
of a chamber with
internal dimensions
of 250mm x 200mm
x 100mm (h x w x
d). Nine (9) horizontal
ports have sufficient
separation
to prevent
interference and
to maximize
number of
transmitters for
insertion within the
chamber. Three (3) top ports are
for instruments with long probes
(250mm) or reference standards
to verify internal readings. Clear
chamber door for visual observation
of instruments with digital displays.
Calibration of Chart Recorders
with Embedded Sensors Using
Programmed Procedures
For fast, accurate calibration of
battery operated chart recorders
having the RH/T sensors embedded
within the recorder housing. The
internal blower of the M2000SP has
been modified for a more efficient air
flow, both within the internal chamber
and the external chambers. The
large external chamber has internal
dimensions of 300mm x 250mm x
150mm (h x w x d). Accurate RH
calibrations over the range of 10-
90%RH, at ambient temperature,
can be done more quickly than when
using larger chambers. A typical 3
point RH calibration can be done in
less than 1 hour after temperature
has stabilization. The internal
chamber conditions are verified using
a reference instrument calibrated
by an NVLAP Accredited laboratory
according to ISO/IEC guidelines and
17025 procedures. Through the
use of pre-programmed calibration
procedures , the required calibration
cycle can be done automatically.
Kaymont Consolidated Industries
Tel: (631) 951-9100
Fax: (631) 951-9109
180 Oser Avenue, Suite 200,
Hauppauge, NY 11788
41engineeringmaintenance.infoJan/Feb 2012
Level Measurement
Hardness Test Solution
SiloPatrol® level sensor can improve silo inventory control and plant safety
Monitor Technologies’ SiloPatrol® smart weight and cable-based level sensors are effectively utilized to improve inventory control of powders and bulk solids stored in vessels.
The sensors measure the material inventory level
automatically and on-demand without the need for plant
personnel to climb silos, which helps to increase plant
safety. SiloPatrol can also be interfaced with optional
operator interfaces.
The SiloPatrol® uses time-proven weight and cable
techniques and includes Hall Effect sensor technology,
state-of-the-art sealed bi-directional optical sensing, a
split-compartment enclosure design, isolated outputs and
other valuable features to produce a rugged, reliable and
accurate measuring system designed for the harshest
and most dynamic conditions.
For more information:
Please visit www.monitortech.com, e-mail monitor@
monitortech.com or call 1-630-365-9403 for more details.
43engineeringmaintenance.infoJan/Feb 2012
Induction Heat Treatment
Infrared Thermometers
Our standard infrared thermometer started back in the 1970s with the System 1, some of which are still in operation today. System 4 our latest range of infrared thermometers has evolved to be suitable for a wide range of applications, ranging from steel and glass to cement and road stone. We are now able to meet the majority of special customer requests for temperature ranges to meet their exact application requirements. Please visit our website:www.landinst.com for further details.
Land Instruments International - Over 60 years of providing temperature measurement solutions
Land Instruments InternationalEmail us on [email protected]
Call us on +44 (0) 1246 417691Visit us at www.landinst.com
LAND has been at the forefront
of infrared (non-contact)
temperature measurement for
over 40 years.
44 engineeringmaintenance.infoJan/Feb 2012
Editors Choice
How CMMS Software Can Improve Your Chance Of Successful Implementation
80% of CMMS Implementations fail
80% of CMMS Implementations
fail is a term that can be found in
many articles. Those failures can be
described in many ways, e.g. where
the budget overruns, where only 20%
the software is eventually utilised
(then sometimes regarded as a great
success), or where the changing of
the original to the planned business
process simply failed. The reasons for
the latter can be attributed to difficult
selection processes, incomplete
requirement identification and/or a
lack of implementation management.
Rigid CMMS software
Rigid CMMS software with a lack
of possible customisation can be a
significant reason. Another factor
is that the software does not have
sufficient features, or in fact the
opposite where it
has far too many features and is
simply too difficult to operate. Failure
to operate in a manner that suits
the “way we do things”, means you
have not achieved workforce and
management commitment, and all
efforts are on trying to use the new
system in the same manner as the
old, the result being shelfware and
not software. But what if the software
could operate in both old and new
manners? Is that possible?
Possible solutions
Possible solutions can be found in
CMMS software that offers modules
as your system grows, therefore
allowing continuous improvement.
Many suggest that configuration or
customisation of the system is the
only way forward, but this can prove
to be expensive, but not anymore.
The new solution
The new solution is in modern
software creation technology. The first
step is to consider software that has
all the possible features you would
ever want but has 80-90% of them
turned off
or invisible. The second and more
important requirement is that menus,
screens, dialog boxes and wizards
are flexible. Flexible means they can
be configured, and even for different
users, but take care, don’t abuse this
capability. This allows a step-by-step
process in moving from an existing
duplicate system to a new improved
system. Indeed in many cases it can
be the opposite, i.e. a need to reduce
the number of fields on the screen
or better still screens in the process.
In either case that’s continuous
improvement, introducing a new field
on the screen, month by month.
And the argument of web versus a
network system is over. Do both with
the one system.
Contact Xetec on:
By Phone:Manchester, M22 5XB: +44 161 408 7777Bray, Co Wicklow: +353 1 442 9997 By E-mail:[email protected] or [email protected]
45engineeringmaintenance.infoJan/Feb 2012
47engineeringmaintenance.infoJan/Feb 2012
Heat Exchangers
Spare Management Software
• Hygienic, Double Tube-Sheet Exchanger for the Pharmaceutical Industry.
• Shell and Tube to all TEMA Classes and Types.
• Electric heaters certified for use in Explosive Atmospheres, Ex d IIA T3, other gas groups and temperature class are available.
• Condensers. • Re-boilers and Evaporators.• Atmospheric Vaporisers
(Longitudinal Fins).
Logichem Process EngineeringLogichem Process Engineering (LPE) offers a wide range
of Heat Exchangers – manufactured and supplied in
various materials and designed with the most advanced
process, thermal and mechanical software. All of LPE’s Heat
Exchangers comply with the TEMA and ASME codes.
For more information,
contact:
Mr Ignatius Herbst
(Managing Director)
Email:
Or visit us at:
www.logichemprocess.com
LPE’s Heat Exchanger range includes:
An Explosive Proof Syngas Ex d Heater.
PARTS-PUBLISHER is a customisable standard
software that enables equipment manufacturers
and operators to assemble, distribute and
automatically update parts and service information.
The application delivers all parts and service
data – such as parts catalogues, maintenance
manuals, technical specs and sales collateral – pre-
filtered according to serial number, product line or
configuration/trim package. PARTS-PUBLISHER
catalogues employ an intuitive user interface
that provides a synchronised view of assembly
drawings or 3D models and associated parts lists,
including detailed information such as pricing, part
Solutions for Parts and Service InformationUse PARTS-PUBLISHER to automate
parts catalogue creation, improve parts
identification, streamline parts ordering
and reduce mis-orders
For more information please visit:
www.docware.com
Demo catalogues and videos online!
description, service bulletins etc. Built using industry
standards, the product integrates seamless with key
business applications such as ERP, PLM or CAD.
Buyers Guide
Jan/Feb 2012engineeringmaintenance.info48
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Buyers Guide
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Buyers Guide
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