Diagnostic Engineer 176.pdf

www.castleprocess.com

VibrationMonitoring

Systems

TemperatureMeasurement

Equipment

Rental

Service &Calibration

Consultancy

Training

FREE Seminars

Solutions forCondition Monitoring,Predictive Maintenance& Diagnostic Engineering

Diagnostic EngineeringT H E J O U R N A L O F T H E I N S T I T U T I O N O F D I A G N O S T I C E N G I N E E R S

ISSN 0269-0225 No. 176 March/April 2011

T H E O F F I C I A L M E D I A P A R T N E R O F T H E I D EPlant&Works

Engineeringwww.pwemag.co.uk

See page 7 for more…

Diagnostic FC_Layout 1 24/03/2011 12:49

The UK’s new Maintenance and Plant Asset Management exhibition.

Coming soon, the new Exhibition Pack with full details.

17 – 19 APRIL 2012 NEC BIRMINGHAM

ContactRoberto Tondina on: t: 01732 370348 m: 07886 119897 e: [email protected]

Sarah Galbraith on: t: 01732 370342 m: 07790 228262 e: [email protected]

Darrell Moffatt on: t: 01252 781826 e: [email protected]

visit www.maintenanceuk-expo.com

Perfect FitThe

DFA Media Ltd . Cape House . 60a Priory Road . Tonbridge TN9 2BL . tel: 01732 370340 . [email protected]

P&AM 2012 Brochure - Light bulb_Layout 1 21/01/2011 12:12 Page 1

Diagnostic Engineeringis published by DFA Media Limited onbehalf of The Institution of DiagnosticEngineers

Registered Office16 Thistlewood RoadOutwood, WakefieldWest Yorkshire, WF1 3HHTel: 44 (0) 1924 821000Fax: 44 (0) 1924 821200E-mail: [email protected]: www.diagnosticengineers.org

President:Dr.David Adams PhD., MIPM(SA), FIDiagE

Chairman:Steve Reed MIDiagE

INSTITUTION OFFICERSCompany Secretary/Treasurer:Andy Garnor MIDiagE

Vice-Chairman:Chris Gilbert MIDiagE., MIOA

Executive Officer:Bill Parker MIDiagE

Membership Selection Officer:Chris Gilbert MIDiagE, MIOA

Council Members:Jeff Casciani-Wood FIDiagEMalcolm Hedley-Saw MIDiagERob Gardiner MIDiagEJeremy Frances Delvarr MIDiagE

Articles, photographs, manuscripts andother contributions for publication to:The EditorDiagnostic EngineeringDFA Media LtdCape House, 60a Priory Road Tonbridge TN9 2BLor by e-mail:[email protected]

ISSN 0269-0225

Diagnostic Engineering is free ofcharge to members of the Institutionof Diagnostic Engineers. It is also available on subscription.For details contact Head Office.

The views expressed by contributors are their ownand are not necessarily those of the publishers, theeditor or the Council of Management of theInstitution of Diagnostic Engineers. Whilst everycare is taken to ensure that the contents of theJournal are accurate, we can accept noresponsibility for these, or for the effect of errorsor omission. Likewise, while every care is takenwhen accepting advertisements, we cannot acceptresponsibility for the contents of these or forunsatisfactory transactions. We will howeverinvestigate any complaints.

THE

IN

STIT

UTI

ON OF DIAGNOSTIC EN

GIN

EE

RS

��

EDITOR’S COMMENT

www.diagnosticengineers.org 00Diagnostic Engineering March/April 2011 1 0

Editor’s commentThe next time you use your diagnostic skills on a faulty television set, youmight justifiably be inclined to swear about the elusiveness of the fault. RayPressnell’s member contribution says instead, why not take a coffee break andconsider how the technology began, and imagine how it developed to itspresent solid state. Such appreciation might inspire you to locate that fault in aless harassed, and more logical and peaceful manner. There are many peoplewho feel that they could not survive happily without the trusted ‘goggle box’sitting proudly in the corner of the room. Yet, since human creation we havehad nothing like it in our lives. Until, that is, one intrepid inventor decided that itcould, should and indeed would happen. Scotsman John Logie Baird createdthe first of ‘everything’ in television. Whilst it is true that he does not receive therecognition for his remarkable pioneering, without his input television would bemany years behind in progress. He had none of the electronics that we have,yet demonstrated actual pictures on a screen.This month’s issue of Diagnostic Engineering also takes a look at one of the

simplest tools in the diagnostic toolkit must surely be a set of feeler gauges.Steve Reed MIDiagE MIDGTE explains how they require very little maintenanceother than rust prevention and if correctly used they maintain their originaldimensions. He highlights that those of a certain age would surely have used aset in order to keep the old car running in the days of DIY repairs - setting suchthings as valve clearances, ignition points and sparkplug gaps.Have you ever had problems with transmission chain jumping or climbing its

sprockets? A common cause of chain climbing or even jumping its sprockets isexcessively worn sprockets, or worn chain, or both. Worn sprockets will alsocause chain to wear rapidly, so it’s important to replace it and check thecondition of the sprockets before fitting new chain. David Turner, of RenoldChain, looks at the causes and the solutions.Meanwhile John Sayer FIDiagE asks the question what happens when

Surgeons and Engineers collaborate and get it wrong? This will no doubt get allof us thinking.These are a just a few of the highlights in this month’s issue of Diagnostic

Engineering. Please remember to send in your contribution for consideration -the success of your magazine depends on your active involvement and is youropportunity to shape the future of the Institution of Diagnostic Engineers.

Aaron Blutstein MIDiagE Editor Diagnostic Engineering

Aaron Blutste

Comment_Layout 1 24/03/2011 14:46 Page 1

A�new�

mark�of�assurance

For more information:

Membership:

Bill Parker (IDE) 01924 821000

Commercial:�

Roberto Tondina 01732 370348

��

� ��

THE

IN

STIT

UTI

ON OF DIAGNOSTIC EN

GIN

EE

RS

��

IDE Accreditation wp_Layout 1 22/03/2011 11:53 Page 1

Editor: Aaron Blutstein BA (Hons) MIDiagETel: (01732) 370340e-mail: [email protected]

Advertisement Manager: Roberto TondinaTel: (01732) 370348e-mail: [email protected]

Display Sales Executive:Sarah GalbraithTel: (01732) 370342e-mail: [email protected]

Internal Sales Executive: Alistair McKayTel: (01732) 370347e-mail: [email protected]

Production Manager & Designer:Chris DavisTel: (01732) 370340e-mail: [email protected]

Reader/Circulation Enquiries: Capsule Publishing Services LtdTel: 0845 602 7390e-mail: [email protected]

Customer Liaison: Ewa FibakiewiczTel: (01732) 370340e-mail:[email protected]

Finance and Credit Control: Clare JacksonTel: (01732) 370340e-mail: [email protected]

Sales Director: Ryan FullerTel: (01732) 370340e-mail: [email protected]

Publishing Director: Ian AtkinsonTel: (01732) 370340e-mail: [email protected]

Published by: DFA Media Limited, Cape House 60a Priory Road Tonbridge Kent TN9 2BLTel: (01732) 370340Fax: (01732) [email protected]

Printer: Garnett Dickinson, UK

PAGE 1

Editor’s comment

PAGE 4

Institution of DiagnosticEngineers Code

PAGE 5

News

PAGE 6

Member contributions

John Sayer FIDiagE asks the question - what happenswhen Surgeons and Engineers collaborate and get itwrong?

Knock, knock... by Douglas Wragg FIDiagE

Logie Baird’s contribution by Ray Pressnell FIDiagE.

The Importance of a Feeler Gauge in 1945 by SteveReed MIDiagE MIDGTE

PAGE 12

Industry comment

How do you teach faultfinding skills? Alan Smith,managing director of Advanced Maintenance Servicesgives his personal perspective

Have you ever had problems with transmission chainjumping or climbing its sprockets? David Turner, ofRenold Chain, looks at the causes and the solutions.

PAGE 17

Directory

Inside this issue: March/April 2011

PAGE 5

PAGE 8

PAGE 12

COVER STORY PAGE 7

CONTENTS


Diagnostic Contents_Layout 1 24/03/2011 14:47 Page 3

11. To promote the education and training of personswhether resident in the United Kingdom orelsewhere in all matters relating to diagnosticengineering and allied technologies.

12. To establish and maintain contacts with personsand/or organisation concerned with theemployment of diagnostic engineers andconsultants.

13. To arrange consortia of specialist diagnosticengineers to perform specificadvisory/consultancy projects as required.

14. To develop the science, practice and business ofdiagnostic engineering and allied technologies.

15. To encourage and improve the technical,financial, business, managerial and generalknowledge of all persons engaged in the practiceof fault and failure diagnosis, conditionmonitoring, post-mortem examination,accidentinvestigation and allied activities.

16. To compile and classify information andparticulars relating to the expert servicesrendered by members of the Institution.

17. To disseminate information and particularsrelating to the expert services rendered bymembers of the Institution.

18. To stimulate efficiency in diagnosis and to elevatethe position of those connected therewith inskilled practical employment.

1 9. To foster intelligent appreciation of the facilitiesexisting for the provision of education andresearch.

10. To facilitate the exchange of information, ideasand practice by the publishing of suchinformation as shall be of interest to diagnosticengineers.

11. To render advice and aid in the exploitation ofinventions and to make known their nature andmerits.

12. To assist in obtaining employment and to helpengineers and others to find competent staff.

Definition

A ‘Diagnostic Engineer’ shall be any person capableof contribution to the art or science of determiningthe existence of a problem in a machine, plant,system or structure and/or appraising the cause(s) ofa failure which may have taken place and/orassessing the condition or vulnerability of suchmachine, plant, system or structure either during useor while under development.

Interpretation

It is accepted that through a diagnostic capability or aspecial knowledge of a failure and deteriorationmodes, reliabilities and hazards a person will be ableto contribute to a satisfactory assessment of thecauses of a defect and able to contribute to theidentification of remedial action to cure the defectand prevent failure.

Motivation

Employers are invited to recognise that persons whohave joined have shown distinguished interest indeveloping and extending their technical skill.

Rewards

Prizes up to £500 in value are offered annually forthe best brief accounts of interesting diagnosticcases.

Activities

The Institution shall arrange and subsidise:

� Regular Newsletters to members

� Regular notices of services available from memberswill be (distributed free of charge to members) tointerested parties. These notices will also bedisplayed at times on the Institution’s web page.

Certificate

A Membership Certificate is issued to all members.

01 4 Diagnostic Engineering March/April 2011 www.diagnosticengineers.org

THE OBJECTIVES OF THE INSTITUTION

THE

IN

STIT

UTI

ON OF DIAGNOSTIC EN

GIN

EE

RS

CELEBRATING

30�YEARS

1981�-2011

IDE Code_Layout 1 22/03/2011 11:51 Page 4

NEWS

www.diagnosticengineers.org Diagnostic Engineering March/April 2011 5

Many of our readers will remember the yearsJosephine Mullins served our Institution.In recognition of those years Council, in

consultation with her family, is introducing anew award. The Jo Mullins Young EngineerAward. This award is to help support andencourage the younger generation to furthertheir education and training in engineeringdisciplines.It is hoped the first recipient of this award will

be announced and presented at our AGM laterthis year.

To be eligible a candidate has to benominated by a Member. So who do youknow?

Open to:� Male or female.� 18 to 25 years olds.� Engineering student.� Scope of engineering course - NVQ or similarto formal university degree.

If you would like to nominate a candidate to

receive this award in 2011 simply write to the Award Selection Officer at our registered address. The letter should brieflydescribe the candidate’s career to date and whyyou think he or she is a suitable recipient.Please also describe what form of support will best be of benefit to your candidate.(Books, equipment, Educational financialsupport).

The closing date for receipt of sponsorednominations is 1st of September 2011.

Dear Editor,

I am particularly impressed with John Sayer’s article “Doctors ofIndustry”, IDE journal No.175. It is a masterpiece and well worthy ofa Collacott Award. The strongest points are on page 10 where he carries over from

page 9 the position of the automotive engineer’s diagnostic tools.Equally strong is the medical profession reliance on the body healingitself (particularly “bed rest”). He is so right that there is ultimately noself-healing mechanism. The nearest might be the temporarypatching by self sealing fuel tanks as developed for fighter aircraftand (later) Concorde after the Paris disaster.“Scrap and replace” arose from the need to create sales derived

from the policy of “built-in obsolescence”. Hence deliberate inclusionof wearing parts, soon withdrawn from availability after the warranty

period has expired. This, of course, tied up with new models so thatas soon as brought, the equipment is obsolete. This is certainly thecase with computers, as John Sayer has written about before.I saw a cartoon in our local Shell oil stores just recently. It

showed a frustrated customer pointing to a component on a shelfbut being told by the salesman that since the computer showed“no stock”, he was not allowed to sell it. I’ve experienced a casewhere, again, the part I wanted was on the shelf, but I did not havethe updated catalogue part number because the hard copycatalogue did not exist any more - only disc, accessed through thestore’s computer and agency coded. I modified another bearing bysleeving - job done.

Yours sincerely Dr Robert A. Kisch

LETTER TO THE EDITOR

The search is on

IDiagE Chairman’s FishingChallenge 2011Competing for the Stuart Reed Challenge Trophy Decoy Lakes Coarse Fishery, Near Peterborough – Date: 10th June 2011The excellent Decoy complex has built a reputation as one of the top competition carp waters in thecountry and deservedly so. For sheer consistent sport on waters ideal for club and open matches, and thesport at this complex is so good throughout the year that Angling Times often choose to use the lakes totest new match, pole, feeder and waggler fishing tackle.The lake we will be fishing is ‘Elm’, where meat and hemp down the edge of long pole and banded

pellet shallow. Absolutely full of fish, take plenty of bait. One fisherman (therefore may not be 100% true!)said: “I fed 6 tins of meat and 3 of hemp down the edge alone and only fished it for 3 hours.”There are large catches to be had in all lakes, and the facilities are pretty good too.

Location address: Decoy Lakes, Decoy Farm, 351 Drybread Road, Peterborough, Cambridgeshire PE7 2AD – Telephone: 01733 202230

RULES: Barbless hooks only; Anyone caught using barbed hooks will be asked to leave; Size 12 hooksmaximum; Keep nets and landing nets supplied by the lakes; Only one rod to be used at any one time; Allday tickets landing nets only; All fish to be netted with landing nets; No silk Braid or Dacron; Men’s toiletsprovided in building, Ladies near house. No litter. No cans or tins. No animals. BAITS: Due to increased demand, fresh maggots will be available at Decoy (if pre-ordered). No boilies,blood worm or joker, nuts, sticky magg. Ground bait to be used in feeders only, no frame feeders. Floatingbaits on hook only.Book your place now phone: 01924 821000

News_Layout 1 24/03/2011 14:48 Page 5

6 Diagnostic Engineering March/April 2011 www.diagnosticengineers.org

MEMBER CONTRIBUTIONS

Q: What happens when Surgeons andEngineers collaborate and get itwrong?

A: It’s up to diagnostics to sort it out!

Like a piece of exquisite Art Deco ormore a kin to something one wouldexpect to find adorning the bonnet of aluxury car. At first sight the ‘metal hipreplacement’ would seem to have morein common with fine art than that ofbrutal surgical mechanics - but once inplace, baring any unfortunatecomplication, it works and goes on towork well for years.

‘Dubbed the greatest success inOrthopaedics in the 20th Century’ Thecomplex design of the prostheticimplant that form the two majorcomponents of the repair had to takeinto account the vast strains and wearencountered and therefore one mustmarvel at the working simplicity of thoseoriginal bone joints that in turn haveinspired engineers with unique andoften completely unassociated designanswers.

But like everything in life joints wearthrough use and age or can becomediseased, in turn this can inflict cripplingpain on the patient. So, it is no surprisethat they opt for such drastic surgerywhen it can mean the differencebetween ending their days withextremely limited mobility and sufferingor gaining a new lease of life and activity.

Despite the strength of the joint theother major hurdle had to be that theload bearing surfaces have to survivewithout oiling instead relying on boththe construction itself and the body’snatural fluids and little more. So thesurface faces have to be extremelyrobust and hard wearing so as not to failearly, after all once a patient is no longercrippled they’ll want to regain activitiesand those activities will in turn add wearto the joint.

There had to have been acollaboration between surgeons andtheir experiences and the expertise ofengineers and plastic/metallurgists inorder to get this design right.Nevertheless the surgery itself mightfind a mechanic more at home than asurgeon when the tools involved areseen - the whole process being a one

way ticket once started as there’s littlechance of turning back what with thecutting and grinding of bone andphysical hammer blow insertion of themain element. The tolerances of boththe recipients body and the materialsused having to be just right in allrespects.

So, it comes as a bit of a surprise tolearn ‘that the one thing this design ofcomplex engineering beauty andsurgical skill failed to take into account,leaving diagnostics to spot andhighlight,’ was that metals used innewer implants through wear and/orbody contact could in fact potentiallypoison the patient.

Earlier designs of hip replacementwere reliant on metal into a polymerbased hip cup joint, but the polymercups were shown to wear quickly andfail far sooner than expected so a morereliable metal into metal cupreplacement was sought. The newmaterial chosen for its strength anddurability was cobalt-chrome alloy, nodoubt this was thought to be so hardand when polished with such smoothfacing surfaces that decay through wearwould be negligible. But DiagnosticEngineers at Newcastle Universitybecame involved following reports ofthose conducting testing of patients. Thepatients had complained of groin painfollowing prosthetic hip replacementimplants. Testing showed that the metalions of cobalt and chrome found in theblood were of high enough a level to beof great concern. Such metals arenaturally found in the body in minuteamounts but the levels detected farexceed what can be thought of as safe.The diagnostic engineering researchshowed that the one ‘joint fits all’ typemechanics had failed to take intoaccount the build and sex of the patient,which resulted in misalignment andaccelerated wear in the vast majority ofpatients.

With the quandary of what to doabout this so a voluntary recall forreplacement joints was established.

It would seem that worldwide some93,000 patients have had the newerthe metal alloy hip replacements andnow they will all need to be contactedand offered this traumatic decision(many have already have been

contacted), after all surgery isn’tsomething to go into lightly even whenyou feel very unwell, although then youmight at least see it as a no optionchoice. But when the initial correctivesurgery you have already undergonefeels to work extremely well and you aresuffering no obvious side effects, surelyit has to be a much harder choice tomake.

That aside many millions of hipreplacement surgeries have helped givemassive relief, so this article should notbe looked upon totally negatively.Instead the role of the DiagnosticEngineer in discovering and reportingthe problem should be betterhighlighted and acknowledged as nodoubt they will go on to assist inresolving this and future problems.

Inspired to writeBy John Sayer FIDiagE.

Members Contributions 1_Layout 1 24/03/2011 14:55 Page 6

COVER STORY


Monitoring and maintenance in processindustries has never been as importantas it is today. The competitive advantageto be gained through effective plannedmaintenance and rapid fault diagnosiscan be the difference between making aprofit and not!

It is also true that now has neverbeen a better time to invest in thetechnology, which offers so much morefor so much less. Whether you arelooking at basic temperature monitoringor full diagnostic vibration analysis, it hasnever been simpler or more cost-effective to do.

To leave maintenance issues tochance is to risk everything!

Castle Group Ltd is offering a newpackaged service, which can delivertailored solutions based on individualscenarios. Whether in-house training,monitoring systems, diagnosticmeasurement services orinstrumentation rental, working withCastle Group will deliver a combinationof products and services that willcomplement your systems and methodsof working. You might even like to havea permanent support service so thatwe’re always there in the background tokeep things moving along as theyshould.

Whoever is in charge of managing theimplementation of a system forcondition monitoring or any form ofdiagnostics will want to be in control ofexactly which systems and training theybuy into. It may be that the productiondirector wants all systems and expertiseto be in-house so that everything isclose to hand if needed. Alternatively, itis possible to contract in many of theservices required to run a successfulsystem. Castle Group offers a servicethat can be tailored to fit in whateverlevel of support is required.

Tailoring systems and support issimple and should always be a majorpart of the equation. It is simple enoughto install a condition monitoring systemusing vibration sensors, but theinformation must be dealt with in theright way and in a timely fashion, sotraining may be arequirement oftheimplementationprocess. Whenlooking atdiagnosticvibration analysis,this is also aservice that canbe provided in

house with the right training. Analyserscan also be hired if necessary to keepcapital purchases at bay.

With 40 years of experience withmonitoring and analysis equipment,Castle is well placed to deliver onprocess monitoring and maintenanceissues. We have a range of products andservices through which we can deliversupport and solution provision.

Everything you do in production linemaintenance can have a profound effecton profitability, which is why we alwayswork on the basis of saving you moneyor helping you increase profits. Weusually find the investment needed ispaid for in very short order!

Look out for Castle’s FREE half dayseminars, which can be found atwww.castlegroup.co.uk, following thelink for FREE legislation seminars.

Castle Group Ltd

Castle Group LimitedSalter Road, Scarborough, North Yorkshire YO11 3UZ UK

Tel: +44(0)1723 584250, Fax: +44(0)1723 583728

email: [email protected]

Internet: www.castlegroup.co.uk

Cover Story_Layout 1 24/03/2011 14:53 Page 7



Let me reassure right from the outset,that I am not going to tell you a “knock,knock” joke - that would be unforgivable.

Mind you, having said that, the onewhich I liked most of all went on

“whose there? Martini. Martini who?Martini hands are frozen!”

There, and I said I would not do that -so many apologises - one does tend toget carried away sometimes.

Germane to this case is a story, whichI have heard on a number of occasionsfrom differing sources, although I do notknow whether it is entirely true orapocryphal.

It concerns a captain of industry whowas the head of one of the big carmanufacturers. He had turned round thefortunes of the company, introducedTotal Quality Management, and had theworkforce pulling in the same direction,and set for great things.

Apparently, he organised a slap-upbanquet for the companies whichsupplied his company with parts andaccessories, and the great and the goodfrom those companies attended withalacrity. It was a sumptuous affair,wonderful food and great wines toaccompany it.

At the conclusion of this mammothrepast, when the guests were in to brandyand cigar mode, their host stood up andsaid “Gentlemen, please follow me.” Thisthey did in to another huge room, where,to their horror, ranged around the roomwas a display showing the parts whichtheir respective companies made, thedefects with the products and the cost tothe company in consequential damagecaused by these parts.

I imagine that it was a sobering - nopun intended - experience to thoseassembled.

The message delivered to them wasthat in future their companies would beliable for consequential damage causedby defects in their products, and that ifthey still wished to supply part to thecompany, they would sign a contract tothat effect.

If that is indeed a true story, then itshould be a source of inspiration.

The case that we are now going tolook at has a parallel in regard to theknock-on effect.

I was contacted by a fairly largecompany who made engine

components, amongst which wasincluded crankshaft pulleys.

They had received a report of a ratherstrange alleged failure of one of these ona French car, and would I go andinvestigate. My pleasure, I assure you, asI enjoy nothing better than a pilgrimageoff to the West Country.

When I arrived at the garage in thecharming village of Slowe-in-the-Uptayke,I was greeted with great enthusiasm andcourtesy - “we read all your articles” wasthe greeting.

Feeling somewhat flattered and with asort of warm feeling inside, it was timeto go to work and see what hadhappened.

This particular type of crankshaft pulleyincorporated a vibration damper -nothing new there, as that idea is as oldas the hills.

The design was that the pulley camein two parts, an inner and an outersection of the pulley, and these werelocked together by a shim which wasinserted between the two halves uponassembly.

In this case, the shim had twistedslightly, leaving a “tail” of metalprotruding out between the two halvesof the pulley.

As the pulley rotated, a centrifugalforce was exerted on this tail, and over aperiod of time, more of the shim wasbeing drawn out of the pulley.

It readily follows that the more “tail”present, the greater the centrifugal forceexerted, until, inevitably something hasto give.

That was exactly what had happenedin this case - as the tail grew, it reached apoint where it started to hit the timingcover on the engine, producing a regularnoise, which would have increased involume as the tail grew still further.

It reached the point where the end ofthe piece of metal became entangled inthe cam belt, and became wedgedbetween the cam belt and the crankshaftpulley. This caused the belt to jump atooth on the crankshaft, and one toothon the crankshaft timing gear roughlyequated to 10o of crankshaft movementand therefore 5o of camshaftmovement. As this was a diesel engine,this was sufficient for the valves and thepiston crowns to meet each other.

Mercifully, this occurred as the driver

was slowing down to stop because ofthe unusual noise from the engine.

The net result was that there was littleor no damage to the engine, and wheneverything had been carefully checked,the engine was re-assembled, but with anew front pulley.

One of the questions that was put tome by the manufacturer was “if there isa defect, what can we do to rectify it?”

Upon mature reflection, myrecommendation was that one methodof overcoming this problem was insteadof using a strip of shim stock, to use asleeve or continuous cylinder, which isan absolute fit and therefore there wouldbe no possibility of one bit of itappearing above the surface of thetorsional vibration damper.

Not only that, but there would be noknock-on effect, and no consequentialdamage.

Knock, knock...By Douglas Wragg FIDiagE.




The next time you use your diagnosticskills on a faulty television set, you mightjustifiably be inclined to swear about theelusiveness of the fault.Instead, why not take a coffee break

and consider how the technology began,and imagine how it developed to itspresent solid state. Such appreciationmight inspire you to locate that fault in aless harassed, and more logical andpeaceful manner. As sophisticated as itnow is, television is not yet even 100years old. There are many people whofeel that they could not survive happilywithout the trusted ‘goggle box’ sittingproudly in the corner of the room. Yet,since human creation we have hadnothing like it in our lives. Until, that is,one intrepid inventor decided that itcould, should and indeed would happen.Scotsman John Logie Baird created thefirst of ‘everything’ in television. Whilst itis true that he does not receive therecognition for his remarkablepioneering, without his input televisionwould be many years behind inprogress. He had none of the electronicsthat we have, yet demonstrated actualpictures on a screen.His creations included mechanical

television transmission and receiving,colour television, recording (recognisableimages at 30-lines scanning with a 6-per-second field rate, on 78 rpm videodiscs - and in the years 1926 to 1928!),3D television, etc. It is worth expandingupon another of his amazing firsts: atransatlantic television broadcast. It wasBaird and his chief engineer, Ben Clapp,who carried out that world’s first. UsingBen’s amateur radio station G2KZ, theytransmitted live television pictures acrossthe Atlantic very early in the morning ofFebruary 09 1928. Ben had travelled toNew York in late 1927 to makereception arrangements with radioamateur Robert Hart at his Hartsdalehome.Video signals were generated in

Baird’s studios in Long Acre, London,and relayed by landline to Ben’s Surreyhome. The Ham radio stationtransmitted Baird’s signals out across theAtlantic on a 45-metre wavelength at apower of 2kw. The station’s logbookrecorded 58 test transmissions beforereception results were deemed goodenough for a demonstration. This demowas made later that same morning.Pictures included Baird’s ventriloquist

dummy (‘Stooky Bill’), Baird himself, andPress Association journalist William Fox.Harold Smith, who manned Ben’stransmitter, entered in the log that thestation ‘closed at 0438 GMT’ (around2338 NY time on Feb 08). It has beensaid that he does not deserve theaccolades for invention of the systems.This because, ‘they’ say, his efforts‘contributed nothing to the ongoingdevelopment of high-definition electronicsystems of the medium’. That seemsrather pompous. The Wright Brothers’planes, the first motorcar, the first train,the first jet airliner, and most other ‘firsts’are not to be seen in operation today.Does that mean that their inventorsshould be forgotten or, worse, derided inthe way Baird has been? Of course not!To get the matter in perspective, Baird, aperpetually ill man, produced the world’sfirst television pictures in 1924, with thefirst public demonstration in Selfridges inApril 1925. After a few years of furtherdemonstrations of his devices, by 1928,he was marketing the world’s firstdomestic television receiver, his 30-line‘Televisor’. Models costing between £20and £150 gained orders at such asLondon’s Selfridges Store prior to actualtransmissions of programmes.The BBC was reluctant to transmit

Baird’s rudimentary signals, but finallyhad to capitulate to public demands. Theworld’s first television broadcasts dulybegan on 30 September 1929. Theycould not be called the most attractivepictures to be seen. Filling a screen sizeof only 2 inches wide and 4 inches high,they were actually quite difficult to see.Despite the shortcomings, by 1932some 500 Baird Televisors, and anunknown number of homemadeversions (kit and self-design) were indaily use by the British public. Butcircuitry progress was obviously neededto give the new medium the widerpublic interest it richly deserved. TheBush Radio manufacturing companyachieved some progress. They produceda 30-line self-contained receiver with apicture measuring 9 inches by 4 inches.Sadly, for them, it was not a wise

commercial decision to release this newreceiver onto the market, despite itstechnological advancements. Britain’sEMI was, at the same time as Baird,developing a higher definition system fortransmission on vhf. One of the featuresof the associated and revolutionaryreceivers was the use of larger, fully

Logie Baird’s contribution

By Ray Pressnell* FIDiagE.



evacuated cathode ray tubes. These arestill the major component of mosttelevision receivers on the world market.Significantly, an EMI official said that atthe time, ‘they considered that the crt asa display device was only an interimmeasure. We didn’t really believe thatthis huge vacuum envelope, acumbersome sort of thing, would last.’Well, it’s lasted over 70 years, and showslittle sign of being immediately displacedon a large scale! Most important of all inthe development of television was EMI’scamera, since it made live television apracticality. Remarkably, the camera hadto be developed in secret.The twoinventors, J D McGee and WF Tedham,had failed in attempts to persuade theirsuperiors to the cause. The firstexperimental version was produced in1932, and further developmentsproduced a camera tube with excellentdefinition. Called the ‘Emitron’ it wasconsidered far superior to similarlyprincipled ‘Iconoscopes’ then available.Invented by Russian born AmericanVladimir Zworykin in 1923, theiconoscope was at an earlier stage ofdevelopment than the proven Emitron.Both types have long since beensuperseded by developments in cameratechnology. In the August 1936 BritishRadio Show, seven manufacturersdemonstrated their television receivers.They were shown in a darkened booth,with curtains ensuring that only theirscreens, and no manufacturers’ names,were visible. Of the sevenmanufacturers, the BBC’s Controller of

Engineering ranked Baird’s receiver asfourth in quality. It was EMI’s system(rated second at the show) that waschosen to pioneer televisionbroadcasting on the 2nd November1936. Their vastly superior Emitroncameras tipped the scale their way, andthese cameras remained in service intothe 1950s. The BBC from AlexandraPalace (affectionately known as ‘Ally-Pally) in London subsequently made theworld’s first public high definitiontelevision broadcasts on that date. Theywere monochrome, and used a 405-linestandard in the vhf band. Thesebroadcasts were of course pre-dated bythe less-acceptable BBC 30-linebroadcasts of 30 September 1929,though these former broadcasts couldrightly be termed ‘exploratory’.GEC/German co-operation enabled aclosed-circuit system to operate in Berlinin March 1935. This was viewed only inpublic viewing rooms, with no receivershaving been sold to the German public.Using just 180-lines, it was obviously notintended as a public broadcast system,but rather as a demonstration of theimproving television skills of Germanengineers as a result of British/Germanco-operation. To say that Bairdcontributed nothing to the developmentof high-definition television is more thana little from the truth. He was the first toprove beyond a shadow of doubt thattelevision was highly feasible. Hismechanical system paved the way to thefuture. It stimulated interest, and awe,amongst the public around the world,

and inspired commerce to producemore efficient systems. His immensepersonal drive and ambition gained himthe notice and finance he needed. Heembraced the coming age of electronicsand cathode ray tubes. He developedlarger viewing screens, and better picturedefinition through increased scanninglines. He was in the forefront wheretransmission and reception wereconcerned. His views and achievementswere respected and were instrumental inpushing the whole commercialenterprise forward. His ideas were ofimmense value to the subsequenthigher-definition systems. He surelydeserves the full accolades that are dueto the true inventor and promoter of theidea of television. Since those headydays, billions of pounds and dollars havecontributed to the development of thesuperb systems we now watch. Noinfluence is possible on theprogramming that we endure. However,it is hoped that the above will bring abetter appreciation of the technicalaspects. Just remember this: In the1960’s the fault rate for televisionreceivers was stated as ‘two faults perreceiver per year’. Now it’s being statedas ‘one fault per receiver per five years’.Won’t that rare fault that might enrageyou seem so insignificant after all? Enjoyyour coffee!

* This article was first published inJournal No.129 March/April 2003 andis re-printed with the kind permissionof Ray Pressnell FIDiagE.

One of the simplest tools in thediagnostic toolkit must surely be a set offeeler gauges. They require very littlemaintenance other than rust preventionand if correctly used they maintain theiroriginal dimensions. We of a certain agewould surely have used a set in order tokeep the old car running in the days ofDIY repairs - setting such things as valveclearances, ignition points and sparkpluggaps.It therefore came as quite a surprise to

find that the following report describing amethod of extending the length of feeler

gauges should be of interest to such agroup of distinguished persons of thatperiod.Checking the clearance of turbine

blades was crucial for reliable andefficient operation of gas turbines and jetengines. Clearances were taken betweenrotating blades and the stator andbetween stationary blades and therotating components. When the gapswere too small the possibility of adestructive rub would occur due to thereduction caused by either thermal orcentrifugal growth of the components. If

the gaps were too large then theefficiency of the machine would bereduced as the gas stream would passover the blade tips and the potentialenergy wasted.Today many sophisticated methods

are employed to set and check blade tipclearances turbine blades are alsomanufactured to very fine tolerancesusing the latest machining and castingprocesses. During the 1940’s turbineblades were finished and polished byhand so it was absolutely necessary tocheck this clearance of every blade

The Importance of a Feeler Gauge in 1945By Steve Reed MIDiagE. MIDGTE.




regardless of access problems. Whether the device described below

ever went into commercial production Idon’t know. When I was taking blade tipclearance readings in the 70’s we usedlong series feeler gauges manufacturedby Moore and Wright which were aboutthree feet long if my memory serves mewell.When Engineer A.J.Birch produced this

report during the month of August 1945two things were not a problem to theauthor, the first being the classification ofCONFIDENTIAL and the other theCIRCULATION.We as readers of this report in the

21st century would ask, a) Why wouldsuch a simple device be confidential andb) Why would the very best of Britain’sengineers and distinguished persons beat all interested in such a device. To introduce you to a few of those on

the circulation we have :Dr D.M. Smith Chief Engineer GasTurbine Dept. Metropolitan-Vickers. Elect Co.LtdMr W.F.Saxton Chief Engineer Armstrong-Siddely Motors Ltd.Mr F.W.Owner Chief Engineer (1947)Bristol Aeroplane Co. Ltd.Mr E.S. Moult Chief Engineer De Havilland Engine Co.Ltd.Mr A.G.Elliott Chief Engineer / Vice President Rolls-Royce Ltd. DerbyDr A.A. Griffith Chief Scientist Rolls-Royce Ltd. DerbyMr H. Sammons ( Retired as MD 1960)D.Napier & Son Ltd.

Mr H. Constant (Head of Pystock)Director, National Gas TurbineEstablishment.Dr S.H. Hooker Chief Engineer Rolls-Royce Ltd. BarnoldswickDr A.E. Watson Technical DirectorJoseph Lucas Ltd.

The titles attached only give smallevidence to the achievements of thesemen. Others A/Cdre. F Whittle and Dr HRicardo require no introduction howeverin 1945 both were directors of Powerjets(R&D) Ltd.Powerjets (R&D) Ltd a government

owned company formed in April 1944following the nationalisation ofPowerjets.(Frank Whittle’s originalcompany) comprising the old PowerjetsWhetstone facility and the gas turbine

section of the Royal AircraftEstablishment Pyestock together withflight testing at Bruntingthorpe, severalheavy bombers and a couple of Meteorjet aircraft. Employing approx. 1500personnel between the two main sites.During 1945 the year of this report,

Powerjets (R&D) Ltd was a member ofthe Gas Turbine Technical Advisory andCoordinating Committee (GTTACC) andas such was obliged to divulge allreports, data, and information to therepresentatives from the aircraft industry,engine manufacturers, ministrydepartments and the admiralty all fellowmembers of (GATTACC)As wartime restrictions and security

was strictly adhered to everything wasclassified thus A. J. Birch’s feeler gaugeholder became Confidential.

www.diagnosticengineers.org 00Diagnostic Engineering March/April 2011 11



INDUSTRY COMMENT

I sometimes wonder if people are bornwith the ability to diagnose engineeringproblems and trying to teach it ismission impossible. Not everybodycould become jet fighter pilot, or aworld-class pianist, so why should Iexpect it of our future electricians andengineers.

We all have our little niches in life andbreaking out into new pastures is not anoption.This sad view is only after trying to

train our apprentices to grasp the simplelogic involved in faultfinding. First some

background as to my past. My owntraining was on warships in Portsmouthdockyard. The results from school were poor

except for the science subjects, whichcovered magnetism, electrical, leversand pulleys etc. These were lookedforward to.On taking the dockyard entrance

exam I was pleased to find that my98% pass mark in science had carriedme through.Having such a broad canvass of

sectors from dockside cranes to aircraft

carriers was truly exiting. They say yourschool days are the best but myapprenticeship days working on multimillion pound “toys” were better.It soon became apparent that “its

always been done that way” attituderuled the day.

Some snotty nose, know nothingapprentice (as was my label), was notgoing to change anything.I was moved through different

sections, large ships, small craft, frigates,submarines, dockside cranes and yardmains, working on switchgear and cablejointing up to 33KV. You spent 3 to 4months in each section. Most were keento move me on and give the trouble tosomeone else. It did much as to thefurtherance of my training.I soon learnt that a fitter that had

worked at the same bench for 50 yearsdid not take kindly to a 18 year oldknow-it-all telling him there was a betterway to do a job. My people skills leftmuch to be desired.After 5 years I completed my

apprenticeship and found a niche job asa Diagnostician in the yard servicessection. I was one of a small group whowere called on to sort out problems onlarge fridge units that took over thecooling duties of warships in refit. Otherplant I looked after was floating cranesincluding a captured German 250 tonbeast.If it wasn’t for the Aircraft carrier

Victorious needing an urgent refit,commandeering all newly qualifiedtrades on board, I would have still beenthere.My diagnostic skills would have sunk

to pulling in cables from the front to theback of a very big ship. I left and joinedan industrial heating company, again,fault finding on oil and gas burners.My fledgling company was started in

the 3 day week (1973) and soon grewto needing more staff.It soon become apparent that I could

only stretch myself over so many jobsand the staff I had were not able to sortout any technical difficulties from themachines that they were installing.Site installation crew are a different

breed from shop-based personnel. Yes

Born to diagnose?How do you teach faultfinding skills? Alan Smith, managing director of Advanced

Maintenance Services gives his personal perspective.

Industry Comment 1_Layout 1 24/03/2011 15:03 Page 12

INDUSTRY COMMENT

www.diagnosticengineers.org 00Diagnostic Engineering March/April 2011 13

they are still electricians or pipe fitters,but their focus is to get the job doneand get back home asap.

Trying to change their mindset intocarrying out diagnostics on misbehavingmachinery did not appeal to them. Idefiantly needed their “let us at em”attitude in getting difficult installationscompleted so it would be better not torock the boat too much.

I tried to recruit ex apprentices thatwere being laid off from the closing(was saved later) dockyard. The theorywas that they would have done thesame training as me, therefore couldsort out the faults, same as me.

The whole thing ended in disaster.The lads had spent most of their time

in college, as there was not the work inthe ‘yard’. What was worse theyaccepted that they knew nothing andwere content to let life wash over them.Even better, they had top marksawarded to them in their exams ‘to helpthem get a job’.

It was then that the realisationdawned over me, if I wanted techniciantype staff we had to take on apprenticesof our ow (bit slow at taking these‘corporate’ decisions).

How do you select the right person?Interviews are all right to see ifcandidates can present themselves ascreditable, but as for identifying anyspark of passion or common sense, theyfail me.

Also going by qualifications gave apoor conversion rate of reaching theirsecond year. One lad had so manyGCSE results that I was blinded by themand gave him the job. It lasted about 6weeks before he found working was toohard, and was expected to learn thingsand he got his hands dirty.

It took about 10 years of 1 in 10success rate before I saw a patternemerging.

If you took a school lad on as aSaturday labourer for 3 weeks, and senthim out with the trades people, it wassoon very obvious what they werecapable of.

If they were bitten by the interest bug,they had to ask if there were anyvacancies for full time work when theyleft school.

The ones that had no interest neverasked, so excluded themselves.

The ones that did ask were told thatyou needed some reasonable resultsfrom school, so make the effort beforeyou leave.

After a few months they had to jumpthrough more obstacles when theywanted to be an apprentice.

I found that the more they had tofight for the job the more value it hadfor them. This then reflected in theeffort they put into keeping their hardwon apprenticeship.

This theme is continued into theirtraining. If they ask a lazy question, likehow many amps in a KW or how muchcurrent will a 2.5mm cable take, they donot get the answer. They are remindedthat they have covered it in college andlook at their course work. If youanswered every question they get intothe routine of “ask Alan”. Well Alan willshow you the path to the answerinstead (they really hate me for it).

A saying they hear often is, ‘at schoolyou were taught, at work you learn’. Thedifference is your own input on thesecond one.

One Saturday lad, with noqualifications at all, brought in his craft &design school project. It was an intruderalarm he had made for his mum. Hesheepishly produced this battered alloybox and demonstrated how the alarmelectronics worked. I asked why it wasfolded so badly.

He had been excluded from schooldue to behaviour problems and hadfinished off the project at home, with nofolders or guillotine. He had used thekitchen door as a folder. That showedme that with no one pushing him, he

completed that project for his ownsatisfaction and the pride in presenting itto his mum.

He got the job and re-sat his schoolexams that he was excluded from.

His crowning glory was to beapprentice of the year at our localcollege and I took great satisfaction instanding up to applaud him when hewent up to collect his prize.

Unfortunately I could not help butturn round and rib the head of trainingfor Southern Electricity, “this is the oneyou did not want”.

When you see progress like that itmakes up for the ones who fell by thewayside.

That apprentice stayed with us formany years before being tempted witha job as leader of the maintenancesection of a large packaging company.

Some of my staff think I will blow afuse if we lose someone who we havespent a lot of time and effort training.

Not at all, it’s a free world, very bigand needs exploring. I say to all of them,you are welcome to stay on completionof your apprenticeship, but you willalways be ‘the lad’ in the eyes of the‘old timers’ and remembered for allthose jobs that went wrong. Go to anew job and you go in as the ‘man’, fullyqualified and full of confidence.

The icing on the cake for me is when


INDUSTRY COMMENT


you see them some years later and theyask for their job back. Often we do reemploy them.

Points that I consider essential tomaking a diagnostic engineer:Anger at not knowing something.Anger can be an invaluable tool to have.If not being able to solve a problem justwashes over you, how are you going todrive yourself to go the extra mile infinding out what you need to solve yourdilemma. Many a time I have screamedat someone for making a noise ordistracting me in the middle of acomplex job.

Determination not to be beaten.I suppose this is pride getting its twopennyworth in. How low will you feel ifyou walk away without fixing it. It’s aboutthis time that you question why youever took the job on in the first place.

Question what people are telling you.I still get caught occasionally, byaccepting someone’s word that “thecontactor’s alright , I’ve just checked it”only to find out an hour later it was afaulty contactor.

Try not to pre-empt where the fault is,based on what was wrong last time. By

all means keep that previous fault inmind but do not let it exclude otheravenues of thought.

Verify any theories to prove / disprove them.When the brain is in full swing it’sthrowing out lots of “it could be”.Sometimes an eager customer will siton your shoulder, watching andmumbling that he is surprised that yougo down so many blind alleys. Youshould go straight to the fault and fix it istheir view, funny thing is that they can’tfix it with their approach. I find this typeof customer will say those infuriatingwords “is that all it was, we could havefixed that”.

Double check yourself don’t be rushedby others needs. I had been called by the commercialdocks to a German freighter whosemain engine refused to start. I had justunloaded my toolbox from the car whenthe pilot came up to me demanding toknow how long before it’s fixed. “Therethree more ships waiting for this jetty, somove this one” he ranted. The last thingyou want is someone else’s problemsloaded onto you, just when you need aclear head.

Keep a watchful eye on the blindingobvious.How many of us have rushed into acontrol cabinet, meter in hand, only tofind the wall isolator turned off.

My own red faced blunder was on anold supply ship. It was delivered toPortsmouth by a transit crew who shut itdown and went home.

When the new crew took ownership,they kept getting failed starts on theauto engine management system. Iwent through all of the interlocks theprevented main engine running. Coolingpumps on and up to pressure, gearboxoil pump running. Priming pumprunning. Overheat not tripped, overspeed not tripped. There was a onepair cable that was open circuit, It wasnot on any drawings, so we laboriouslytraced it from the engine room, upthrough the galley, behind panelling incabins, up to the bridge.

There, on the engine control consul“emergency main engine stop”. Two ofus had spent all day to reset a stopbutton.

Why do I do it, it’s like a drug, withoutthe side effects, but with the addiction.

When I see a ship sail or a machineproducing its goods, it’s a kick so say: “Ifixed that”.


ENG

INEE

RING

FOC

US

[email protected] Engineering Focus

When a leading budget retailer decided tomove to a larger warehouse and distributioncentre, it was determined not to significantlyincrease its material handling costs.Fortunately for 99p Stores, technology offeredby HOPPECKE INDUSTRIAL BATTERIES hasenabled it to make the most of its materialshandling fleet, saving it thousands of poundsover the length of a five-year contract. HOPPECKE sales director, Gus Whyte,explained: “We worked closely with thecompany to install a new Trak Air HighFrequency charger system, capable ofcharging 32 batteries at any one time andincorporating a ‘call forward’ function thatsignals to operators which battery is to beused next.”t| 01782 667305 e| [email protected]| www.hoppecke.co.uk

NEW BATTERY SYSTEM

Pipe coupling manufacturer TEEKAYCOUPLINGS LTD is supplying itspatented fire-protected pipe couplingsto the Queen Elizabeth Class AircraftCarriers - the largest vessels to enterservice with the Royal Navy, it wasannounced.Teekay Axilock-FP Pipe Couplings havebeen selected for joining steel, coppernickel and GRE plain end pipes on theQEC project. Joining plain end pipeswith Teekay Couplings avoids the need for welding, flanging, threading or grooving the pipe. Theuse of Teekay Couplings instead of traditional steel flange sets will considerably reduce thespace, weight, time and cost of the installed pipework system.t| 01494 679500e| [email protected]| www.teekaycouplings.com

FIRE-PROTECTED PIPE COUPLINGS

FLUKE is offering a Fluke Ti32 and FlukeTiR32 free lens promotion, running until 30April 2011. These two thermal imagers aresaid to provide a combination of ruggedness,ease of use and superior image quality. Thechoice of a free additional telephoto, or wideangle, lens (recommended list price over£1000) to purchasers of a new Fluke Ti32 orTiR32 Thermal Imager, enables an even widerrange of application areas where the thermalimager can be used. The Fluke Ti32 Industrial Thermal Imager isdesigned and priced to deliver unprecedentedperformance for troubleshooting andpreventive maintenance of electricalinstallations, electro-mechanical equipment,process equipment, HVAC/R equipment andmore.t| 0207 942 0700e| [email protected] w| www.fluke.co.uk/ti

FREE LENS PROMOTION

NEW STATIONARY CAMERA

OPTRIS introduces the second generation of the optris PI thermal imager. The optris PI is based on a new, small detector with 160 x 120 pixel which can allow a betterlocal resolution of the device under test.Thermal processes of very small objectsstarting from 50 µm can be presented.Precise measurements can be performedstarting from 0.5 mm. Exchangeable highprecision lenses allow adjustment of themeasurement distance and object size.The software optris PI Connectrepresents the temperature merits withup to 120 Hz (8 ms per picture).Measurement results can be captured,analysed afterwards and then filed.t| +49 (0)30 500 197 21e| [email protected]/[email protected]| www.optris.com

Using diagonal fan technology to increase theworking back pressure, RITTAL’s newTopTherm fan and filter units provide anincreased and more stable airflow, even withcontaminated filters. Diagonal air flow offersa greater spread of air within the enclosurethus reducing the possibility of hot spots andhas the effect of requiring fewer maintenanceintervals for the replacement of filter mats.For quick installation and servicing the newgeneration Rittal TopTherm fan and filter unitsrequire no tools. It is possible to fasten intothe enclosure, modify the airflow direction,change the electrical connections andorientation as well as replace the filter matsall without tools.t| 01709 704000e| [email protected] w| www.rittal.co.uk

FAN AND FILTER UNITS PROVIDE INCREASED STABILITY

Offering exact planning reliability EPLAN Pro Panel allows the definition of a virtual 3D prototypeof the mounting layout - independently of the electrical or fluid schematic. Mounting panels,housings or enclosures can be dimensioned optimally so that the costs are reduced. Consistentdata for all the participating engineering disciplines ensure that the workflow towards theproduction is also efficient. Last but not least EPLAN Pro Panel provides added value to thecomplete engineering process.Designing on the basis of theEPLAN platform is supported fullyin both electrical and fluidengineering. This applies tomounting panels that are plannedwith EPLAN Electric P8 as well asfor hydraulics units designed withEPLAN Fluid. t| 01709 704100e| [email protected]| www.eplan.co.uk

VIRTUAL 3D PROTOTYPE

With access to the new RittalXpress websiteat www.rittalxpress.co.uk it is possible tosearch for a suitable product and receive anoutline quotation for a standard or modifiedRITTAL enclosure within minutes. RittalXpresswas developed to identify which products areavailable via the seven day modificationservice and create a quick and easy to useinterface for configuration on line. Choose byapplication, size, IP rating, part number ormaterial, which can be mild steel, plastic,aluminium or stainless steel. The RittalXpresswebsite has a level of intelligence that onlyallows the selection of accessories to suit thechosen size or type of enclosure, along withthe inclusion of any holes required. t| 01709 704000e| [email protected]| www.rittal.co.uk

ONLINE QUOTATION FORENCLOSURES WITHINMINUTES

A new condition monitoring servicefor large induction motors, that candetect potential motor failure well inadvance, has been introduced byABB. Called ABB MACHsense-P, theservice can spot trouble withbearings, rotor winding defects,imbalances, internal misalignmentsand voltage abnormalities, providing

an early-warning to plant engineers, thereby saving considerable costly downtime. The serviceprovides accurate diagnosis; reports quickly, with a summary delivered on-site; includesintegrated analysis for current, voltage and vibration; rates defects clearly by severity;recommends specific repairs; considers machine design in judging defect severity; reducesunplanned downtime; and issues early warnings, allowing time for planning maintenance.t| 01224 592123 e| [email protected] w| www.abb.com

EARLY-WARNING SERVICE

15_IDE_0411_NEW PS 0109 24/03/2011 15:07 Page 1

INDUSTRY COMMENT

A common cause of chain climbing oreven jumping its sprockets is excessivelyworn sprockets, or worn chain, or both.Worn sprockets will also cause chain towear rapidly, so it’s important to replaceit and check the condition of thesprockets before fitting new chain.Look at the faces of the sprocket’s

teeth. Any wear will be seen as apolished worn strip, about the pitchcircle diameter (PCD), on each of theteeth as shown in diagram 1.If the depth of the wear, X, has

reached a value equal to 10% of thedimension Y, then the sprocket hasreached the end of its life and needs tobe replaced. It’s worth pointing out thatlow cost, poor quality sprockets on mostindustrial applications are a falseeconomy. A good quality sprocketshould last through the life of severalchains before anything like the amountof wear shown here will have occurred.If you’re fitting new chain don’t forget

to correctly lubricate it. The lubricationthat’s on the chain when it comes out ofthe box is only sufficient to preventcorrosion during transit and to aid initialbedding in.If neither the chain nor the sprockets

have worn then check the chain isn’t

excessively slack. If it is then adjust thecentre distances to increase tension.This adjustment should result in theslack strand of chain having acalculated degree of movement basedon the horizontal centre distance of thedrive.This distance, A, in horizontal drives, is

calculated by dividing the horizontalcentre distance, C, by factor K, whichhas a value of 25 for smooth drives and50 for shock drives. For vertical drives Ashould be approximately equal to halfthe chain pitch P. Care should be takento avoid over tensioning.Other ways of removing slack from

the chain include using a jockeysprocket or, if it’s permissible to do so,

the chain itself could be shortened.If there is no sign of wear or excessive

slack in the chain then it’s possible thatthere is insufficient wrap around thedrive sprocket. Particularly for large ratiodrives it’s possible that the driversprocket may not have enough teeth toabsorb the working tension. If the drivecannot be altered the solution is to fit ajockey sprocket to increase wrap.A final check is to look for a build up

of foreign material in the sprocket toothgap. If any is present then clean thesprockets teeth so that the chain canonce again engage correctly.

For further information please visit:www.renold.com


Chain jumping its sprockets?Here’s the solution.Have you ever had problems with transmission chain jumping or climbing its sprockets?

David Turner, of Renold Chain, looks at the causes and the solutions.

Diagram 1

Diagram 2


CONDITION MONITORING

CONDITION

MONITORING

Condition monitoring systems and servicefrom the experts. A wide range of systemsincluding Portable and On-Line, operatingfrom one common OMNITREND softwareplatform.

On-Line systems

• Plug and Go monitoring for all typesof machines, compact and affordable,provides comprehensive machine datatrending and spectrum analysis.• Custom designed systems to meetspecific measurement requirements fornon standard machines and systems.

Portable systems

VIBSCANNER and VIBXPERT machinetrending and analysis systems forcomprehensive data trending and FFTanalysis of machine condition.VIBROTIP machine condition trendingsystems for routine monitoring ofmachine data and condition

Tel: 01543 417722Fax:: 01543 417723eMail: [email protected]: www.pruftechnik.co.uk

To book your space NOWContact: Alistair McKay on:

Tel: 01732 370347e-mail: [email protected] EVALUATED VIBRATION

ANALYSIS NOW A REALITY

Takes the hard work and time out of analysing spectra, by giving ‘real information’ of the health and condition of your plant and not just data. Displays the values of Lubrication, Bearing Condition, Imbalance, Misalignment, Gear Mesh, Looseness etc, in a manner that everybody understands, even on a Green, Yellow and Red scaling.

Laser shaft alignment with “easy Laser”, the easiest and fastest system ever, for every machine alignment, including shaft to shaft, fl atness, straightness, camber, train drives, offset drives, roll parallelism, thermal growth, belt drives etc. it’s up to you.

SPM INSTRUMENT UK LTDSuite 12, Hardman Business Centre, New Hall Hey Road, Rawtenstall, Rossendale, Lancs BB4 6HHContact: Stan JacksonTel: 01706 835331 Fax: 01706 260640Web: www.spminstrument.co.uke-mail: [email protected]

Condition MonitoringSolutionsWe´re committed to maintaining yourcritical machinery. Making maintenancea profitable part of your company iswhat drives us.

Timely failure prediction and detection iskey to cutting operating costs. For overthree decades, we´ve contributed toimproved reliability for customers in allbranches of industry and in every cornerof the world. Let us assist you in yourpursuit of mechanical reliability: we havethe methods, the equipment and thesoftware to offer cost-efficient conditionmonitoring solutions tailored to yourspecific needs, backed up by trainingand worldwide support.

CONDITION MONITORINGCONSULTANTS

CONDITION MONITORINGCONSULTANTS

Condition MonitoringSystems & ServiceOPTIMISE YOUR PLANT & MACHINERY & PREVENTEXPENSIVE DOWNTIME

Full service online & offline conditionmonitoring solutions now availablefrom the bearing experts:

Vibration analysisOnline vibration & temperature monitors

Portable, off-line data collectors

Sophisticated online monitoring systems

Acoustic Emission monitoring

Thermographic imaging

Oil Analysis

Installation & commissioning of CM systems

Complete aftersales service

Schaeffler (UK) LtdTel: 0121 351 3833 Fax: 0121 351 7686 Email: [email protected] web: www.schaeffler.co.uk

MachineMonitoringSystems Ltd

Condition Monitoring andAsset Reliability Services

Condition Monitoring Services fromthe UK's leading provider offering*Vibration/Thermography/Oil/Ultrasonic/Partial discharge

*ISO18436 BINDT approved training *Specialist Motor testing *Balancing *Hand/Arm vibration testing

UK wide coverageMMS LtdT: +44 (0) 1869 250801E: [email protected]: www.machinemonitoring.co.uk

� ��

LASER ALIGNMENT

LASER ALIGNMENT

shaft alignment

machine bores

roll parallelism

pulley & belts

flatness

straightness

dynamic movement

Tel: 01543 417722Fax:: 01543 417723eMail: [email protected]: www.pruftechnik.co.uk

LASER

ALIGNMENT

From the inventors of lasershaft alignment - systemsand service for : -

SPM Instrument UK Ltd.Suite 12, Hardman Business Centre, New Hall Hey Road, Rawtenstall Rossend-ale, Lancs BB4 6HH

Laser Measurement and Align ment Systems for every need:Belt transmission alignmentShaft alignmentBore alignmentDynamic measurementsGeometry measurement systems for parallelism, straightness, fl atness, squareness, spindle direction etc.

Tel: 01706 835331Fax: 01706 260640Website: www.spminstrument.co.ukE-mail: [email protected]

TEMPERATURE SENSING

Leaders in temperature measurement

Europe’s leadingmanufacturer of

industrial temperaturesensors and

thermocoupleconnectors

thermocouple cables thermocouple connectors temperatureinstrumentationtest instruments

Certificate No. 4746

Labfacility LimitedBognor Regis

tel: +44 (0)1243 871280Sheffield

tel: +44 (0)1909 569446www.labfacility.co.uk

[email protected]

THERMOGRAPHICTRAINING

THERMOGRAPHY VIBRATION MONITORING

VIBRATION BALANCING

Vibration Analysis (machinery troubleshooting &diagnostics, Conditionmonitoring) Dynamic Balancing(of rotating & reciprocatingmachinery) Applications throughout allaspects of industry; � Manufacturing � Machine Tool� Oil and Gas � Motor Sport� Waste Management � MarineDynamic & Static Balancing; � Spindles � Flywheels � Fans � Turbines� Rotor assemblies � Crankshafts � Propshafts

Tel: 01869 345535Mob: 07774 468726

Email:[email protected]

www.vibrationfree.com

Vibration Free

� � � ��

PRODUCTS & SERVICES

Acoustic Associates:

Tel: 01733 896346

Web:

www.aasussex.co.uk

EA Technology

Tel: 0151 3394181

Web:

www.eatechnology.com

Castle Group

Tel: 01723 584250

Web:

www.castlegroup.co.uk

Interface CM

Tel: 01246 431010

Web:

www.interfacecm.com

Aidtech Ltd.

Tel: 01159 325305

Thermascan

Tel: 01234 219421

Web:

www.thermascan.co.uk

D E P&S Pages_NEW_PWE_P&S_0608 22/03/2011 11:46 Page 2

close to you!

obc_IDE_0411_obc_IDE_0411 24/03/2011 12:47 Page 1

Diagnostic Engineer 176.pdf

Documents

Transcript of Diagnostic Engineer 176.pdf