ems nov/december 2007

Powering the RAF

Reach for the skies

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

ISSUE 2

PAGE 24

NOV/DEC 2007

INDUSTRY NEWS

GUIDE TO BUYING

IMPROVINGRELIABILITY

w w w . e n g i n e e r i n g m a i n t e n a n c e . i n f o

Maintenance Scheduling

Condition Monitoring

Environmental Management

Pneumatics

For more information quote EMS Enquiry No. 101 on IBC

RUMBLE,HISS,RUMBLE,HISS,SILENCEI’ve lost count of the number of factories I’ve worked inor visited over the last two decades. What I will neverforget is the noise and smell. Luckily, for the employees,both noises and smells are diminishing due tolegislation, modern machinery, improved processes andbetter working practices.

Regarding noise, common sources included the rumble of aircompressors and hiss of leaking pneumatic circuits. When thecost of oil was a fraction of today’s record breaking price andthe only footprint discussed in magazines like this related tosteel toe-capped work boots, such noise was tolerated.

Things have changed. Questions need to be asked. Given thefinancial and environmental cost of compressing air, is thathiss an air cylinder venting or a damaged pipe joint?

Turn to page 30 for advice on improving the efficiency ofpneumatic systems, from listening for leaks with the latestinstrumentation to feeding waste compressor generated heatback into the facility’s central heating system.

Staying with compressed air, I recall a customer asking me tovisit a robot that was performing erratically. I had helpeddesign the machine and was worried about its welfare. Oninspection I was concerned by the water venting from thepneumatic solenoid valves.

The lessen learned was simple. If a compressor fails and youhire a temporary replacement, make sure it is piped-inbefore, not after, the water trap. Otherwise, like magic, yourpneumatics will become hydraulics. Expensive!

Jon Barrett, EDITOR

9PAGE

29PAGE

19PAGE

15PAGE

7PAGE

4PAGE

PLANT

CALIBRATION

INDUSTRY NEWS

CONDITION MONITORING

FACILITIES MANAGEMENT

HEALTH AND SAFETY

Published sixtimes per yearby EMS

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© 2007 EMS

Editor: Jon [email protected]

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www.engineeringmaintenance.info THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

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

INDUSTRY NEWSHighlighting what’s happening in maintenance

CALIBRATIONCalibration frequency? Let analysis decide

PLANTRoundup of the latest plantproduct announcements


Insurance against expensive machine breakdowns


Tracking down the hidden costs of WEEE

HEALTH AND SAFETY

ATEX dust zones: check motor compliance

�� For more information quote EMS Enquiry No. 102 on IBC

It is not uncommon for reliabilityand maintenance improvementinitiatives to fail to deliver: butwhy? Common causes include:� Lack of top management

understanding, leadershipand long term support

� Mobility of management� Short-sighted, cost focused

initiatives, instead of longterm, reliability focused

� Politics and disjointedorganisational goals andobjectives

� Confusing the organisationwith new names on wellknown concepts

� Not understandingimprovement initiatives areprocesses without end

� Process driven by disciplinedthoughts and actions bypeople

� Technology is secondary tobehaviourIn his book Good to Great

(ISBN 0-06-662099-6), JimCollins uses the famous essay‘The hedgehog and the fox’ byIsaiah Berlin as a comparisonbetween good companies andgreat companies. The bookinvestigates what greatcompanies share in common.In summary, great companiesknew one thing they can bethe best in the world at. Thenthey did this for a long time.The study was based on a 30-year period. All greatcompanies made breakthroughimprovements in financialperformance and sustainedtheir results. Great companiesare described as hedgehogs,good companies as foxes. Foxcompanies often changedplans and tried to outsmart themarket with short terminitiatives. Their leaders wereglamorous and well known.Leaders of great companieshad much lower visibility.

Great companies typicallyworked with disciplinedimplementation for fifteen-years before making asignificant positive financialbreakthrough in performanceand sustained this performancefor fifteen years and beyond.

So how does this relate toreliability and maintenanceimprovements? The followinggraph describes the differencebetween the hedgehog and foxapproaches. The majority oforganisations I know are foxes,the most successful arehedgehogs. A Tappi Solutionsmagazine survey showed only16 per cent of companiesviewed maintenance programsas long term improvementprograms (hedgehog).

Hedgehog organisationsfind things they need toexecute well. They spend timeidentifying best practices. Thenthey execute disciplinedthoughts and actions accordingto their best practices. For along time (typically three toseven years) they implementand execute best practices in adisciplined manner and cometo a point when significantresults are generated after a breakthrough. Someorganisations see thisbreakthrough after three toseven-years. A key is that newmanagers are requested tocontinue implementing thebest practices, not new ideas.

The fox approach confusesorganisations and people don’tbelieve the latest initiative is forthe long term. The consequenceis lack of true, enthusiasticcommitment: vitally importantfor success.

The hedgehog approachstabilises organisations to focuson continually improving theright things. An organisationmust focus on long-term

sustainable results (not justcutting costs) and see whatresults it achieves. In resultsoriented organisations, resultsare prioritised as follows:1. Quality, volume,

production, throughput 2. Cost to manufacture this

quality volumeThis focus improves

reliability performance, withthe increased reliabilityreducing manufacturing costs.Reliability performance isdefined as ‘overall productionefficiency (OPE) which includesTotal: Quality Performance,Time Performance and Speed Performance.

Most organisations do notdo this. Instead they focus oncutting maintenance costs.Consequently, maintenancecosts temporarily go down,then increase more than the

earlier savings. Also, reliability drops and losses can be substantial. This hasbeen proven many times,especially in economic downturns. The root cause is oftenshort-sightedness and, what Dr Deming described as one of the most serious industrialdeceases: ‘the mobility of top management’.

� Reader Reply Number: 300

3www.engineeringmaintenance.info Nov/Dec 2007 EMS

Why do many reliability andmaintenance improvementinitiatives fail to deliver expectedresults. Hedgehog or Fox?Christer Idhammar, president Idcon Inc

Christer Idhammar is a world renownedexpert in reliability and maintenancemanagement best practices. He startedthe Idhammar group of companies inSweden in 1972 and Idcon Inc in USA in1985. In 2002 he received theEuromaintenance Incentive award(EFNMS) for outstanding internationalcontributions to improve reliability and maintenance in industries worldwide. He is the author and co-author ofseveral books and hundreds of articles.He can be reached at [email protected]

Fox organisations try new tricks. Perhaps it started when a new managerimplemented ‘planned maintenance’. This lead to short term improvements sothe next manager implemented ‘predictive maintenance’. Again, the results wereshort term. This caused the company to skip to ‘total productive maintenance’,then ‘condition based maintenance’ (CBM), then ‘asset management’ (AM), then‘reliability centred maintenance’ (RCM), then ‘value driven maintenance’ (VDM).Most initiatives were initiated by management changes.

4EMS Nov/Dec 2007 www.engineeringmaintenance.info

Two new MIG/MAG weldingpackages have been introducedby Esab, comprising the OrigoMig L305 or L405 step-controlled power sources andthe Origo Feed L302 or L304wire feed units. Each packageincludes a PSF welding torchand a 1.7, 5.0 or 10mconnection set with three wirefeeder mounting options:wheel kit, suspension bracket,or mast and counterbalance.Typical applications will be inthe vehicle industry, householdand furniture industry andgeneral steel fabrication.

Both the Origo Mig L305 andL405 casing offers protection toIP23 for indoor or outdoor use.The L305 offers ten voltagesteps and a 60 per cent dutycycle of 190A/24V, while theL405 has 40 voltage steps and

Somethingto celebrateTo celebrate 25 years ofinnovation in infraredtechnology, ThermoteknixSystems hosted a two daysales meeting at its headquarters in Cambridge. Sales agentsfrom Egypt, India, Philippines, Singapore, China, Indonesia,South Korea, Lebanon, South Africa, Pakistan, Malaysia andHong Kong attended the event, which included productpresentations and demonstrations from key Thermoteknixpersonnel. The conference culminated in a gala dinner to whichall sales agents, staff, key customers and suppliers were invited.

In addition to its silver anniversary celebrations, Thermoteknix was also celebrating being named as smallinnovative company of the year at the Innovation and DesignExcellence Awards (iDEA).

� www.thermoteknix.com � Reader Reply Number: 302

CML Innovative Technologies (CML-IT) is now manufacturingits LED light engines in Europe, reducing both the lead timeand the number of air miles required for shipping. Productionof the LEDule product has moved from Costa Rica to plants inGermany and Czech Republic, with local manufacturesignificantly shrinking the carbon footprint of the LED devices.Shorter lead times for European customers could also help toencourage the switch away from incandescent lamps, whichhave already been banned in Australia and California.

Designed to offer a low power, long life replacement forincandescent lamps, the LEDules feature one, three, four, eight,nine or 14W power with a consistent unit-to-unit colourtemperature. Colours include cool white, warm white, blue,cyan, green, amber and red, with a new RGB version, featuringred, green and blue LEDs, for subtle mood lighting applications.Units are supplied with LED, lens, driver circuitry, heatsink andpackaging, with several different fitting options available.

Suitable for general lighting applications, LEDules can be usedas spot-lights for point-of-purchase and display case lightingor for general illumination applications such as architectural,landscape or task lighting. LEDules can also be customised forspecific applications.

� www.cml-it.com � Reader Reply Number: 303

a 60 per cent dutycycle of 365A/32V.

Voltage settingsand inductanceadjustments are made on thepower source, with controls forwire feed, 2/4 stroke andburnback time located on thewire feeder for easy access. TheOrigo Feed L304 has additionalcontrols for creep start, spotwelding, inching and gas purge.

Various accessories areavailable for the MIG/MAGwelding packages including adigital V/A meter and atransformer for CO2 heating. � www.esab.co.uk� Reader Reply Number: 304

ONE SPANNER, MANY USES

Last month's EMS prize draw winner isutilities operations and maintenancemanager at GSK Dartford, Del Pailes, who has received £100 in Argos vouchers.The prize was sponsored by HolroydInstruments, which manufacture a rangeof condition monitoring instrumentationfor use by maintenance personnel. Theseare in use both in the UK and overseasand said to offer ease of use as well andeffective operation, even on machineryrotating as slowly as 0.25rpm.

The Thermoteknix team celebrate 25 years inbusiness as well as being named small innovative

company of the year at the iDEA awards

LED lighting goes green

INDUSTRY NEWS

Available exclusivelyfrom Buck andHickman, Roebuck'snew universalspanner set isclaimed to fit allknown nuts and boltsincluding spline,12point, square, starand six-point. TheUniwrench set ismanufactured frompolished chrome-molybdenum steel, featuring one straight U grip with a non-slipsurface and a 15deg angled ring grip. Its open-end, non-slipdesign also allows users to remove damaged fasteners includingnuts and bolts that are up to 70 per cent rounded off. The metricset includes: 8,10, 11, 12, 13, 14, 15, 16, 17, 18 and 19mm sizes,all with a lifetime warranty from Roebuck.

� www.bhinone.farnell.com � Reader Reply Number: 301

Roebuck's Uniwrench is claimedto be the only set of combinationspanners required for any job

CML's environmentally-friendly LEDules are now manufactured in Europe,cutting air miles and lead times

ON WINNING FORM

MD of Holroyd Instruments,Trevor Holroyd,prepares to send theArgos gift card to lastmonth's winner Del Pailes of GSK

Packaged for reliabilityEsab's new weldingpackages feature an IP23 casing forreliable operationindoors or out


INDUSTRY NEWS

At 30 years old, the boiler make-upwater treatment plant at E.ON’s Isleof Grain power station was beginning to look its age so E.ONappointed Elga Process Water to refurbish the equipment.

The station hosts two oil fired 690MW units giving a totalgeneration capacity of 1,380MW. High purity water issupplied to the boilers by an ion exchange plant, consistingof two streams of cation exchange, anion exchange andmixed bed polishing, each capable of delivering up to400m3/h of boiler make-up water. The three metre diametervessels are fabricated from carbon steel and lined withrubber to protect them from the acidic conditions inside.

Grain’s plant chemist, Pete Kingbrooks, said: “Between Mayand September the demand for electricity is lower and thestation output is reduced. That means we can run with onlyone of our ion exchange streams available, carrying outplanned maintenance on the other.”

Both the cation and mixed bed exchange units, werescheduled for re-lining and Elga Process Water’s task was toremove the ion exchange resins to a temporary store, cleanand re-line the vessels with rubber, spark test to ensure theintegrity of the lining, reload the resins, hydraulically testand re-commission the units.

� www.elgaprocesswater.com� Reader Reply Number: 307

Get in the groove forrugged wire feeding

Elga Process Water was called in torefurbish the boiler make-up watertreatment plant at E.ON’s Isle of Grainpower station

Makeover fortired plant

Esab's Origo Feed 302, 304 and 484 units featuregrooved-wheel feed mechanisms for reliable wire feeding

A new infrared thermometer has been launched which canoperate at ambient temperatures up to 250°C without cooling. The non-contact Optris CT hot sensor, developed by Micro-Epsilon,is said to represent a genuine leap forward in its sensor class,allowing temperature measurement from –40 to 975°C. Thisperformance is made possible with new detector materials,mechanical design and high temperature cabling.

Potential applications include ovens, dryers, heat treatmentlines in the metal and glass industries, paper, plastic, textilesand semiconductor manufacturing.

The technology can help process engineers optimise energyconsumption, speed and product quality, by reducing processtemperature once products reach their desired temperature. The CThot’s narrow beam optics enable oblique aiming, which meansusers can measure thick or light fabrics using the same sensorwithout calibration adjustment.

New treatment lines are often built inside compact machines tooptimise process efficiencies. In such applications, sighting tubes fortemperature sensors can no longer be positioned outside the processchamber. Compact, non-contact, infrared sensors are thus requiredinside the chamber itself. The CT hot, with its compact head andcooling-free design, is engineered to fit such restricted spaces.

Micro-Epsilon Optris’ general manager, Ulrich Kienitz, said: “Intextile or fabric drying processes, for example, companies canposition multiple CT hot sensors along the inside of an oven ordrying machine, which is typically around 30m in length. Thesensors are able to monitor the temperature of a complete sheetor strip of fabric. By analysing the data from the sensors andlooking for unusually high temperature gradients and fluctuations,operators can gauge the humidity of the material and change theprocess operating conditions such as speed.”

� www.micro-epsilon.co.uk � Reader Reply Number: 305

Mecaplastic, the Midlands-based supplier of traysealing and thermoforming machinery has launched anew partial tooling concept designed to let customerschange tray sealer tools in less than five minutes.

The partial construction allows 80 per cent to remain in situ, withonly four key elements changed during the process. Themechanism comprises lightweight, easily manageable pieces,with all tooling accessible for cleaning and maintenance. The onlyequipment needed for tool changing is a standard screwdriver.

The system is interchangeable between the semi-automaticS1000 and in line S2000/S3000 tray sealers. It is also modifiedatmosphere packaging (MAP) compliant.

� www.mecaplastic.com � Reader Reply Number: 330

The new non-contact Optris CT hot sensor allows temperature measurementfrom –40 to 975°C in ambient temperatures up to 250°C, without cooling

Rugged construction makesEsab's latest wire feeders suitablefor harsh industrial environments.Suitable for use with step-controlled welding power sources,the Origo Feed 302, Origo Feed304 and Origo Feed 484 allfeature galvanised steel housingsas well as electronic controls andgrooved-wheel feed mechanismsfor superior welding.

A choice of feed roller diametersmeans the units can be used withwelding wires up to 1.2, 1.6 or2.4mm diameter. The smallestrollers offer a two-wheelconfiguration, while the twolarger rollers feature a four-wheelconfiguration. Flexible mountingoptions mean the feeders can bemounted on a mast with acounterbalance, on wheels or ona hanging bracket.

When the feeders are used witha water-cooled gun, the EsabLogicPump (ELP) automaticallyprevents overheating. Feederscan also be connected to Esab'sMiggytrac and Railtrac kitsthrough a remote outlet, forsimple mechanised welding.

To keep ownership costs as lowas possible, units are designed forsimple maintenance with anaccessible feeding mechanism soworn parts can be exchangedeasily. Customers can purchaseadapters to allow wire spools of440mm diameter to be used, orthe feeders can be used withEsab's Marathon Pac bulk cabledrums. Interconnection cables areavailable in 1.7 to 35m lengths.

� www.esab.co.uk


COOLING FREE THERMOMETERS REACH 250°C

Tooling change in five

COOLING FREE THERMOMETERS REACH 250°C


for a sensor’s required accuracyand the time during which itpreviously maintained thataccuracy. Sensors found to behighly stable need not be re-calibrated as often assensors that drift.

The History Trend Option,available as standard in CMXEnterprise and as an add-on inCMX Professional, is a utilitydesigned for viewingcalibration history data. Data isdisplayed graphically and isavailable in numeric format.

The function helps usersplan optimal calibrationintervals. Once implemented,maintenance personnel, forexample, can analyse aninstrument’s drift over acertain time period. HistoryTrend displays numerically andgraphically the instrument’sdrift over a given period. Usingthis information, engineers canmake decisions andconclusions regarding optimalcalibration intervals and

instrument quality regardingmeasurement performance.

Users already familiar withCMX may confuse the functionwith the standard CalibrationResults window. However, theHistory Trend window letsusers view key figures ofseveral calibration eventssimultaneously, letting themevaluate the calibrations of aposition or device for a longertime period compared with thenormal calibration result view.

For example, users get anoverview of how a particulardevice drifts betweencalibrations and also whetherthe drift increases with time.Also, the engineer can analysehow different devices are suitedfor use in a particular area ofthe plant or process. Reportingis straightforward and the usercan tailor reports to suit theirindividual needs, using theReport Design tool.� www.beamex.com� Reader Reply Number: 309

In this article, Beamex demonstrates

how plants can improve their efficiency

and reduce costs by performing

calibration history trend analysis

Calibration frequency? Let analysis decideManufacturing plants need to be confident theirinstrumentation products, like temperature sensors andflow meters are performingcorrectly. If sensors drift, theconsequences can be disastrous.

Most plants have amaintenance plan whichensures all instruments arecalibrated appropriately.However, with increasingdemands and cost issues, thetime and resources requiredfor calibration checks can bescarce. This may lead toinstruments being prioritisedfor calibration, with thosedeemed critical receivingregular checks, while thosedeemed less critical, calibratedless frequently or not at all.

Plants can improve theirefficiencies and reduce costsusing calibration history trendanalysis, a function availablein Beamex’ CMX calibrationsoftware. Using this function,the plant can analyse whetherit should increase or decreasethe calibration frequency forall its instruments.

Cost savings can beachieved in several ways. First,by calibrating less frequentlywhere instruments appearstable according to theircalibration history. Second, bycalibrating critical instrumentsmore often, ensuring they arechecked and corrected beforedrifting out of tolerance.

Beamex’ area salesmanager in Finland, Pertti Mäki,said: “The largest savings fromusing the History Trend Optionare in the pharmaceuticalssector, without doubt, but all

industry sectors can benefitfrom using the software tool,which helps companies identifythe optimal calibration intervalsfor instruments.”

The trick, said Mäki, isdetermining which sensorsshould be re-calibrated after afew days, weeks or even yearsand which can be left forlonger periods withoutsacrificing quality or safety.Doing this, he said, letsmaintenance staff concentratetheir efforts where they areneeded, thus eliminatingunnecessary calibration effortand time.

Mäki continued: “When anengineer buys a particularsensor, the supplier provides atechnical specification thatincludes details on what themaximum drift of that sensorshould be over a given timeperiod. With CMX’s HistoryTrend Option, the engineer cannow verify that the sensor heor she has purchased, actuallyperformed within the specifiedtolerance over a certain timeperiod. If it hasn’t, theengineer now has data topresent to the supplier tosupport his findings.”

The History Trend functionalso means a plant can comparethe performance of differentsensors from differentmanufacturers. Thus, setting upa new line, maintenancepersonnel can use thisfunctionality to select the sensorthat best suits the process.

Calibration software likeCMX can also help whenplanning calibration operations.Calibration schedules account

CALIBRATIONThe History Trend Option lets usersanalyse an instrument’s drift over time

History Trend user-interface

• Save money by planningwork more efficiently

• Spend more time beingproductive

• Keep track of parts

• Reduce Paperwork

Tel: 01732 871417Fax: 01732 [email protected]

• Visual Planning for Maintenance and Health & Safety

• Information at a glance

• Complete system£150 + P&P and VAT

VIBRATIONISOLATION

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

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Surveys- Ex-stock Delivery- Selection Service- Special Design Service

EUROVIB ACOUSTIC PRODUCTS LTDGoodwood House, 86 Holmethorpe Avenue,

Redhill, Surrey RH1 2NLTelephone: (01737) 779577 Fax: (01737) 779537

[email protected] www.eurovib.co.uk

www.elcomponent.co.ukt 01279 503173 f 01279 654441 e [email protected]

Unit 5, Southmill Trading Centre, Bishop’s Stortford, Hertfordshire CM23 3DY

aM&T Sub-Metering SystemsFlexible cost-effective metering for all utilities and every type of business. We have the hardware, software, networking and installation skills to supply the package you need, on time and on budget.

alarm signalling

Power Quality AnalysersHigh performance instruments for the most demanding energy and powerquality analysis applications designed and built to the highest quality standards.Supplied complete with the latest windows software.

Energy Data LoggersEasy to use portable data loggers forelectricity and general utility monitoring.Safe, non-invasive.

(3 phase analysers)

Power Factor Correction

fast payback and real savings.

For more information quote EMS Enquiry No. 105 on IBC For more information quote EMS Enquiry No. 106 on IBC



PLANT MANAGEMENT

Eurobond Adhesives claims Penloc threadlockers, retaining compounds andstructural adhesives are essential tools in amaintenance engineer’s tool box. Therange offers anaerobic and two-parttoughened acrylic bonding solutions formaintenance tasks.

ZT Threadlocker is a low strength yellowacrylate designed to work in temperaturesfrom -55 to 15°C. It cures to handlingstrength in five to 20-minutes and be fullyfunctional in 45-minutes. Breakaway torqueis 12Nm. VF is the high strength grade with30.5Nm breakaway torque.

R2 is a self-hardening resin retainingcompound, designed to secure bushes,bearings and other cylindrical parts.Interference fits can be strengthened or

replaced by slip fits without loss of strength.Mechanical locking devices such as wedges,pins and adjusting springs can also beeliminated. R2 has a medium shearstrength allowing dismantling with ordinarytools. It can withstand temperatures from -55 to 200°C. Typical uses include bearings,splines, keys and oil seals.

1-1 is a two-component toughenedacrylic structural adhesive. It cures tohandling strength in five-minutes, with fullcure in one-hour. It resists temperaturesfrom -55 to 125°C. Typical tensile shearstrength values of 276kg/cm2 can beachieved on steel to steel applications.

� www.eurobond-adhesives.co.uk


STICKY MAINTENANCE SOLUTIONS

RW Greeff has introduced Dow Corning’sMolykote L 1428, a new syntheticlubricant formulated to resist oxidationand thermal degradation, whilemaintaining stable performance andlubricity over a wide temperature rangeand under heavy loads. It also suits hightemperature bearing applications.

L 1428 is designed to help lowermaintenance costs, reduce chain drag andwear, extend oil-drain intervals and

prevent process interruptions. The oil iskosher approved and NSF F2 designated(certified for food-grade applicationswhere no contact is expected withfoodstuffs). The company states theproduct has extremely low volatility andwill not form carbon deposits or smoke.

� www.rwgreeff.co.uk


SMOKE FREE LUBRICANT

Fluid Dynamics International states thatdowntime and maintenance costsassociated with sludge formation in zincphosphate-based paints have been reducedby installing Magstream magnetic fluidconditioners. Magstream has alsominimised problems with clogged spraynozzles and reduced flow rates due to pipeencrustation. Consequently, the consistencyof phosphate coating has improved.

The company claims Magstream’seffectiveness has been proven in paintspraying plants for over 20-years, withcompanies such as Jaguar, Hoover, Servisand Massey & Ferguson, Sanyo, Brotherand General Motors. The product uses rareearth magnets encased in a stainless steel

tube and orientated to optimise polarity.The financial savings from installing

Magstream are also said to be significant.In one automotive application, sludgeformation and disposal was reduced by 75per cent, while the spraying systemcleaning frequency was extended from sixweeks to 12-weeks. Pipe work no longerneeded caustic cleaning to remove sludgeencrustations and the electricalconsumption of pumps reduced accordingly.Resulting efficiency improvements in heatexchangers also enabled more precisecontrol of phosphate temperature.

� www.treatwater.com


Remove the drudgery of sludge


PLANT MANAGEMENT

Abbeychart’s new Nuert Mini-Pump isdesigned to provide a compact, quiet andreliable solution where space limitationsprevent standard pumps and a lower flowrate is required.

Technically similar to standard models,the pump boasts fewer components andlower cost. The company states it can bematched with a small motor to replacevibration pump units, while offeringhigher performance and long service life.Measuring 49 by 75 by 86mm the pumpcan be installed in any position.

These self-priming rotary vane pumpsare offered with five flow rates between

50 and 270 lit/min at 1,400rpm, with orwithout normal or balanced by-pass foradjusting maximum pressure.

An optional built-in 100 mesh stainlesssteel filter removes particles down to150μm. Working life is further extendedwith self-lubricating internal components,low start-up torque and a one-piecepolished stainless steel rotor shaft.

Specifications include 18 barmaximum working pressure andmaximum fluid temperature up to 50°C(standard) and 90°C (special).� www.abbeychart.co.uk� Reader Reply Number: 313

SMALL BUT PERFECTLY FORMED

A new Multikwik utility sink, launched byHunter Plastics, is designed to provide afunctional solution for providing practical handwashing facilities for workplaces. The sink is asingle piece moulding making it easy-to-clean,hygienic and virtually maintenance-free.

The sink eases the task of installing handwashing facilities required by the Healthand Safety Executive. This requires everyworkplace to provide washing facilities withhot and cold water close to all workstations.

With a ten-year strength guarantee, thecompany states the sinks will withstand therigours of continual use without deteriorating,even when sited outside. Chip-proof andresistant to boiling water, frost and mostchemicals, the sinks are tested to 150kg andwill not rust due to their plastic construction.

Two versions of MultiKwik utility sinksare available. The cleaner station featuresan integral splash panel, while the washstation also has a grid, drainer, soap dishand hooks. Both are available in a granitefinish and are supplied with plug andchain, waste fittings and overflow.

� www.hunterplastics.co.uk� Reader Reply Number: 316

The efector octavis bearing condition monitorfrom ifm is now available as a master unitwhich can monitor up to four separatelocations. The central unit can also now beprogrammed via Ethernet. The stainless steelvibration pickups (placed up to 30m away)feature IP69K for arduous environments.

Efector octavis continuously monitors amachine’s operating condition. It is designedto detect rolling element bearing failuresand shaft imbalance conditions on criticalplant equipment such as pumps, motors,mixers, compressors, fans and spindles.

� www.ifm-electronic.co.uk� Reader Reply Number: 314

Remotemachinemonitoring

Sensitive applications such as food,electronics and medicine, require purecompressed air. Activated carbon filters andadsorbers have a limited capacity to removeoil and it can be difficult to decide when tochange elements. Oil vapour concentrationin suction air is subject to considerablefluctuations and overloading can damagefilter elements. Sudden oil break-throughcan cause high consequential costs.

For higher process security incompressed air treatment, Beko Instrumentshas developed measuring instruments forsupervising the oil content. Oil Control reactsto the changed remainder oil rates in thestreaming compressed air. Residual oilcontent is measured using ion exchange. Thesolution is unaffected by moisture content,is independent of changing flow conditionsand features adjustable alarm values.

Centralised and decentralisedcompressed air monitoring, shut-off andbypass is possible with Oil Control, withusers able to verify oil content in any partof system. Using Oil Control, factories canprotect production processes against high oilentry, thus avoiding repair and waste costswhile guaranteeing compressed air quality.

� www.bekotechnologies.com� Reader Reply Number: 315

How much oil?

That sinkingfeeling

Unless you’re a Meerkat, it isn’t always

possible to stand around watching for

danger. And anyway, if you are

responsible for heavy duty industrial

machinery, you’ll know that the danger

signals are usually hidden until it’s

too late.

There is, however, an alternative way tomaintain constant vigilance.

Proactive preventive condition monitoringfrom INA FAG – it’s just as sensitive insidean industrial environment as the Meerkatis out in the wild.

Our condition monitoring products aredesigned to watch for the tell-tale signs ofdanger – particularly increased / unevenvibration or rises above temperaturenorms – in industrial machines. Thismeans you can take corrective actionbefore any real problems occur. Rangingfrom simple bolt-on monitors to highlysophisticated online systems, ourcondition monitoring equipment helpsyou to prevent emergency shut-downsand to plan your maintenance routinesmore efficiently and cost-effectively.

For further details of our conditionmonitoring products and services call0121 351 3833 or visit our web site atwww.schaeffler.co.uk and click on theCondition Monitoring and MaintenanceProducts link.

Schaeffler (UK) Ltd

Tel: 0121 351 3833 Fax: 0121 351 7686 E-mail: [email protected]

Web: www.schaeffler.co.uk

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A workshop has been organised to show how scheduling and optimisation tools

can help ensure the right person, does the right job, at the right time

Meeting service level agreements

MAINTENANCE SCHEDULING

Delegates to Mac EU’s workshop will see how resource scheduling and optimisation tools can benefittheir organisations


designed to help maintenanceorganisations allocate the best person, to perform the most critical work, withinprescribed SLA timescales.

In scheduling resources to workassignments, Smart Schedule can beconfigured to consider a wide range offactors including work criticality,work/resource locations, resource skillsrequirements, existing workload, holidaysand others. The weighting given to theseduring optimisation can be tailored to suitparticular environments and maintenancemanagement systems.

Smart Schedule has a visual userinterface that supports the automatic colour-coding of tasks as they are assigned, startedand completed. Alerts can be configuredto flag where tasks are reaching their SLAcommitments and their colour changedaccordingly. The dispatcher or supervisorcan then intervene and re-schedule or re-prioritise work though a simple drag-and-drop process, thus maximisingthe opportunity to meet the SLA.

During the workshop, attendees will beshown how a resource scheduling andoptimisation tool can benefit anorganisation and how it works. Further,delegates will see how the tool can interactwith asset management systems such asIBM’s Maximo Asset Management system.

To attend the workshop, register byemail at [email protected] or the webwww.macseu.co.uk. After successfulregistration, delegates will receive furtherinformation. The workshop starts at 10amand will be held at Mac EU, 45 to 47Station Road, Gerrards Cross, SL9 8ES.Spaces are limited.

� www.macseu.co.uk


Maintenance professionals have, for manyyears, accepted their responsibility to ensurethe assets they are responsible for areavailable when needed and meet necessarycompliance standards. Increasingly, however,the world of maintenance organisations isshifting from asset centric to servicecentric, with performance based contractsand service level agreements that can bedifficult to meet or even measure.

Also, in recent years, industry has seenincreasing workforce mobilisation and anadoption of mobile technology. In themaintenance arena, companies are nowseeing technicians with PDA-based workinstructions, using telecoms and wi-fi

network communications to receive workand feedback completion.

Meeting these new developments andchanging environments results, most ofthe time, in more pressure onmaintenance processes, labour productivityand ultimately profitability. Fortunately,organisations do not have to solve thisproblem alone. Resource scheduling andoptimisation tools are available ascomplimentary solutions to supportmaintenance management systems.

Macs EU has organised a free workshop(5 December) to introduce maintenanceprofessionals to Smart Schedule, a resourcescheduling and optimisation tool from Syclo


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company’s assets are protected. Riskassessments should be carried out regularly to see what effect breakdownswould have on critical, bottleneckmachines and equipment. The severity andlikelihood of breakdowns on particularmachines are assessed and given acorresponding risk value. Those with thehighest risk scores are given priority by themaintenance team and should beprotected by condition monitoring.

Companies can protect plant withoutcondition monitoring or predictivemaintenance systems by, for example,holding stock of components such asgearboxes and bearings. When a breakdownoccurs, the component is immediatelyavailable. However, as Hartigan points out:“As well as the obvious increase in stockholding costs, the company also runs therisk of the stock deteriorating or becomingobsolete over time. We would recommend

By using the latest condition monitoring systems and services, manufacturing

companies can reduce unforeseen breakdowns. Schaeffler UK’s managing director,

Kate Hartigan, explains

Condition monitoring:insurance against breakdowns

When owning and managing high valueitems like cars or homes, most people arecomfortable paying insurance premiums. So,surely manufacturing companies need toensure their high value capital goods areadequately insured against unforeseenbreakdowns? After all, lost production couldequate to tens of thousands, even hundredsof thousands, of pounds per day.

Although the cost of machinecomponents like bearings and motors issmall compared with the total machineprice, the cost of production downtime andconsequential losses resulting from acomponent failure, are often significant.

Take a steel or aluminium manufacturingplant. The typical cost of productiondowntime is £100,000 per day. Similarly, lostproduction in a paper mill equates to around

£15k per hour. Total maintenance costs for atypical food or beverage manufacturer arearound 15 to 20 per cent of total costs. Thepharmaceutical sector spends similaramounts on maintenance.

Naturally, every manufacturing companyhas a maintenance department. However,due to time and resource constraints, themaintenance team may become reactive,fire fighting problems as they occur, with nopredictive maintenance systems, littlepreventive maintenance and often nomaintenance strategy at all.

There should be no excuses for thistoday. There are many technology safeguardswhich, when compared with the cost of lostproduction, are relatively inexpensive. Moreenlightened manufacturers are usingcondition monitoring and predictivemaintenance systems, including bearingvibration monitoring, acoustic emissionsmonitoring and thermography, to protectplant and machines.

Schaeffler UK’s managing director, Kate Hartigan, said:“Manufacturing ormaintenance managersneed to justify anyexpenditure on conditionmonitoring systems andservices, to their financedirector or MD. We wouldsuggest using a riskmanagement approachwith questions like ‘whatwill it cost the companyin lost production if I losethat critical machine forfive hours?”

One of the financedirector’s responsibilitiesis to ensure the


Schaeffler UK’s managing director, Kate Hartigan,argues condition monitoring should be consideredas insurance


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As a result, the customer preventedunforeseen breakdowns and the cost ofconsequential damage. Less than a yearafter installing the new systems, thecustomer projected the following results:

Annual costs before introducingcondition monitoring:� Five chock/roll neck repairs, each

costing €21,000 = €105,000� Five unscheduled roll changes, each

taking 7 minutes: €35,000� Total: €140,000� Total CM project costs by comparison:

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system, around €40,000.

� www.schaeffler.co.uk


that customers reduce the risk ofunexpected failures, by implementingsuitable condition monitoring systems onrotating plant and machinery. Don’t think ofthis as capital outlay, but as insuranceagainst the risk of possible lost production.

“By installing a predictive maintenancesystem, the customer picks up a problemearly. During the next convenient downtimeperiod, the maintenance team can thenremove and replace a bearing with minimumdisruption costs and also avoid the risk ofbreakdown damage to the equipment.”

Condition monitoring also helpsprevent maintenance teams replacingcomponents unnecessarily and possiblyintroducing new, unrelated problems.Manufacturing maintenance staff can useCM systems to predict when failures arelikely to occur and plan replacement duringproduction shutdowns.

Hartigan continued: “In too manycompanies, parts are changed on a timebasis rather than on a condition basisbecause the maintenance team considersthis to be the safest option. However, thisintroduces a further risk, becausewhenever there’s human intervention,problems can occur.

“Most companies work in a breakdownculture which is reactive rather thanproactive. Rather than boasting about howrapidly they can repair or replacecomponents and get a machine back intoproduction, maintenance teams need to beasking themselves ‘how can we prevent theproblems occurring in the first place?’ CM isthe most effective solution.”

If a manufacturer plans to achieve 100per cent production schedule adherence,predictive maintenance is critical.Unforeseen machine breakdowns simplycannot be tolerated. Similarly, overallequipment effectiveness (OEE), totalproductive maintenance (TPM) and theoryof constraints (TOC) performance will sufferif unforeseen breakdowns occur thatdisrupt production.

Praxis, a partnership betweenSchaeffler UK’s maintenance and conditionmonitoring specialist FAG IndustrialServices (F’IS) and Corus NorthernEngineering Services, gives customersaccess to a range of condition monitoringproducts and services. The range ofhandheld and fixed systems includes:vibration monitoring systems; acousticemissions monitoring; endoscopy; thermalimaging equipment; and contract patrolmonitoring services.

Training services are offered so customers

can understand equipment, analyse resultsand take appropriate corrective action. Thefocus is on training customers to takecomplete ownership of condition monitoringstrategy and implementation.

Steel and aluminium productionIn one materials production application,extreme operating conditions associatedwith hot wide strip mills resulted in a shortservice life for the work roll bearings.Unexpected shutdowns and costly resultingdamage had to be avoided. Schaeffler’s F’ISteam installed permanent conditionmonitoring of the work roll bearings usingits FAG DTECT X1 vibration monitoringsystem. This included integration into thecustomer’s software, remote monitoring,data evaluation; customer training; and theidentification of bearing defects.


��


For more information, contact:Ian Taylor, Business Development Engineer

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Your plant maintenance picture isn’t complete without us

Condition monitoring helps maintain output, efficiency and profitability by providing a detailed and accurate assessment of plant assets




Hidden costs of WEEE

WEEE may be touted as a supplier cost, but unless organisations get their asset

registers in order, it will also create a significant cost for UK business, insists Real

Asset Management’s managing director, Keith Dolby

www.engineeringmaintenance.info Nov/Dec 2007 EMS

19


The implications of the Waste Electrical and Electronic Equipment(WEEE) Directive seemed to have passed unnoticed by themajority of UK businesses. And why not? The legislation statesfirmly the onus of disposal rests with suppliers and distributors.

However, endemic poor asset management means thisburden will pass directly to the bottom line. With upwards of 10per cent of registered assets no longer in existence and the lackof component level recording of electrical and electronic assets,businesses will struggle to identify original suppliers and providea full audit trail to disposal.

The result will be expensive WEEE compliant disposal,potential fines for failure to provide an audit of asset disposaland attendant negative publicity.

Supplier burdenThe green bandwagon is rolling strongly across the UK andEurope, with politicians of all parties united in their bid to attract

the environmentally sensitive voter. Businesses too are keen topublicise their green credentials, from carbon offsetting toorganic goods.

Such policies have a firm economic footing. Green strategiesappeal to voters and consumers alike: but only if the potentialcost is viable. Over burden the general public with cost orexpectation and it will take more than a picture of an endangeredpolar bear to reenergise widespread environmental concern.

So, it is no surprise that the WEEE Directive was carefullyframed to place responsibility with suppliers and distributors ofelectronic and electrical equipment. The directive aims tominimise the impact of electrical and electronic goods on theenvironment by increasing re-use and recycling and reducing theamount of WEEE going to landfill.

It seeks to achieve this by making producers responsible forfinancing the collection, treatment and recovery of wasteelectrical equipment, while obliging distributors to allowconsumers to return their waste equipment free of charge.

However, such policies assume a level of asset management farbeyond that achieved by the majority of UK business. Unlesssupplying a like-for-like replacement, suppliers will only removeand dispose of equipment they delivered in the first place. Howmany UK businesses can accurately identify the location of theirWEEE equipment within the organisation, let alone confirm when itwas purchased and from whom? Yet without such information, justwhich company do they expect to handle the disposal for free?

Lost assetsThe asset registers of most UK businesses are appalling. In manycases, a full physical audit not only reveals that at least 10 percent of recorded assets no longer exist but only 40 per cent ofregistered assets can typically be easily identified. The rest havebeen moved and/or upgraded without record.

This means that on an average 2,000 item asset register,around 200 items have been disposed of but are still recorded asin use. While this may not matter to the finance team which has

How many UK businesses can accurately identify the location of their WEEE equipment?

For more information quote EMS Enquiry No. 117 on IBC20EMS Nov/Dec 2007 www.engineeringmaintenance.info

already depreciated these assets to zero, itwill certainly matter when the organisationis asked to prove the items were disposedof in line with the WEEE Directive.

The figures are worse for WEEEequipment. With prices for suchequipment currently so low, fewindividual items reach the typical£1,000 to £1,500 minimumcapitalisation threshold, so arenot required to be held individuallyon the asset register. Instead, financedepartments opt to consolidate suchpurchases into one single entry.

Furthermore, most companies typicallyswitch supplier regularly to reflect changesin pricing and availability. Yet, while theseitems are recorded as one bulk purchasethey are highly unlikely to be disposed ofsimultaneously. Equipment breaks, isrefurbished and moves locations:information that cannot be recordedwithout an individual asset number.

So, when disposal is due, just how is acompany going to identify and prove theoriginal supplier? Without such knowledge,

the liability will beon the organisation to

arrange and pay for WEEEcompliant disposal.

Asset managementPenalties for failing to meet the WEEEDirective are not insignificant. If foundguilty of an offence, producers,distributors and operators can be liable toa fine of up to £5,000 per offence onsummary conviction in the MagistratesCourt or an unlimited fine imposed by theCrown Court. Company directors andmanagers can also be prosecuted, inaddition to the company itself, if theyconsent to, or participate in the offence, orif their neglect led to the commission ofan offence by the company.

If organisations are to avoid the twofold costs of fines and/or expensive WEEEcompliant disposal with one of themultiplicity of firms recently set up to

support thisburgeoning marketthey need to create an accurate, detailed asset register.

First step is a full audit. It is likely anycompany conducting a full audit during2007 to identify missing assets will begiven leeway by the authorities. After thatdate any ‘missing’ assets will be deemedto have been disposed of withoutfollowing the proper procedures since thecompany will have no valid certificate. Thefinance director will be faced with theunpleasant choice of admitting the

FACILITIES MANAGEMENT Upwards of 10 per cent ofregistered assets no longer exist

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23


company has no accurate picture of itsown assets or accepting a fine. Neitheroption will amuse the shareholders.

Once the full physical audit has beenconducted, organisations then need to putin place strong procedures for assetdisposal. Linking the asset register to adocument management system willensure a scanned WEEE certificate can belinked to a disposed asset, providing therequired audit trail. Each asset can berecorded alongside the supplier’s nameand email address, enabling swift suppliercontact when disposal is due.

Critically, the creation of an accurate,up to date asset register can also deliveran immediate return on investment,including a reduction in insurancepremiums. Recording the cost of assetdisposal will also improve a company’sunderstanding of the total cost of eachasset and the true financial implications ofthe WEEE Directive.

Compliance overloadUK business is already complaining aboutexcessive red tape, which is perhaps one

of the reasons that the introduction of theWEEE Directive in July 2007 has been soeffectively downplayed. However, a beliefthat the onus of WEEE is firmly onequipment suppliers could be anexpensive mistake.

There are many reasons for anorganisation to clean up its asset register,

but without doubt those organisations thatpersist in inaccurate and bulk recording ofWEEE assets will rapidly discover the truecost of this green initiative.

� Real Asset Management

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Equipment breaks, is refurbished and moves locations

24

ENERGY MANAGEMENT

EMS Nov/Dec 2007 www.engineeringmaintenance.info

Take-off for boiler upgrade

Fuel efficiency, reduced cycling and extended life are three of the stated benefits

of Wellman Robey’s Ygnette boilers, recently selected for an RAF replacement and

upgrade project

A UK Royal Air Force base has orderednine Ygnette hot water boilers fromWellman. The boilers will replace andupgrade existing Wellman Robey Ygnetteboilers originally installed in 1977. Theorder comprises three 2,500kW LPHW (4.5 bar g) and six 800kW LPHW (10 bar g)boilers, all fitted with dual-fuelmodulating burners supplied by Wellman’sburner company, GP Burners.

The manufacturer states its Ygnetteboiler is known for its performance on allfuel types. The horizontal, three-pass,wet-back, reverse flame design features alarge furnace for efficient combustion.Combustion products are reversed to passthrough convection tubes forming thetube pass and then discharged into a rear

outlet box provided with chimneyconnection for horizontal or vertical outlet.The stated benefit of this design is nearperfect combustion with maximum fuelutilisation, high operational efficienciesand low running costs.

Modulating burner controls helpimprove boiler operation by monitoringwater temperature to produce acontinuous control signal that determinesfuel input. Reductions in watertemperatures trigger an increase in firingrate, which helps optimise efficiency andminimise emissions. Precise air/fuel ratiocontrol is essential to minimise excesscombustion air and reduce heat losses inexhaust gases.

Modulating burner output helps

improve boiler temperature ortemperature control, thus increasing fuelefficiency. Additional stated benefitsinclude higher turn-down ratios, less plantcycling, extended boiler life, extendedrefractory life and less burner downtime.

Wellman Robey’s Mike Winnall said:“We are delighted to be awarded theorder for the replacement boilers by theRAF and we are confident that theYgnette range of boilers fitted withmodulating burners will offer the clientmaximum energy savings and a systemto serve them well for the next 30 yearsand beyond.”

� www.wellman-robey.com


The RAF boiler order comprises three 2,500kW and six 800kW systems

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27

ENVIRONMENTAL MANAGEMENT

According to system developer,Manchester-based Ener-g Efficiency, itsnew Virtual Energy Manager will give abig boost to bottom line performance,while cutting carbon emissions. Thecompany’s managing director, Paul O’Brien, said: “The technology can helporganisations of all sizes, from SMEs tomulti-nationals, to manage and takecontrol of their energy use and beginevaluating their carbon footprint.

“Crucially, it uses plain English and‘dashboard’ visual displays thateveryone in the workforce can readilyunderstand. It’s simple to use, yet thetechnology is so advanced that itautomatically manages the optimumenergy output to suit various areas –from warehousing to offices.”

The Virtual Energy Manager is saidto be the first system to combineautomatic meter reading and a buildingenergy management system. It isbacked by an energy savings guarantee,which provides money back shouldconsumption reduction not reach agreedefficiency targets.

The powerful internet-based systemis designed to managing every part ofan organisation’s energy use 24/7. It

provides: actual consumption metering(day-by-day and hour-by-hour); instantsaving assessments; quick, easycalculations of emissions performance;optimum comfort levels; integratedcontrol of plant services; and an alarmto report issues such as unusual energyusage peaks.

Mr O’ Brien added: “The need tomanage energy and reduce carbonemissions is increasing. The display ofenergy certificates will shortly beneeded in public buildings, and otherproposed legislation includes theintroduction of a Carbon ReductionCommitment that will see many publicand private sector organisationsneeding to calculate their carbonfootprint and manage their energy useto reduce their footprints.

“In both cases the need for highquality, accurate energy data andeffective energy management is clear.Virtual Energy Manager is designed foreveryday use and will quickly tell usersthe status of their site and theirperformance against target. Within afew seconds the energy ‘dashboard’provides easy-to-understand informationat a glance. Interactive maps help

identify and locate sites needingattention and simple icons quicklyhighlight actual performance.”

Designed for organisations of allsizes, the system is equally at homemanaging one site or hundreds,automatically adjusting as a businesschanges. Sites can be added orremoved, while individual meters andsites can easily be benchmarked againsteach other.

Paul O’ Brien concluded: “Knowledgeis power and empowering managers isa key feature, with customers choosingwho has access. Experience shows thatwaste can be driven out moreeffectively by providing knowledgeabout energy use to mangersthroughout an organisation, fromdirectors to shift supervisors.

“When it comes to managingenergy, different people are alsointerested in different things. Someneed to know financial data, othersmore technical information. VirtualEnergy Manager provides it all from asingle, easy-to-operate platform.”

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ATEX dust zones:check motor compliance

While industries like petrochemical are used to ATEX conformity, Deritend is warning

that motors without correct certification are likely to be used in the recently defined

ATEX zone 20 to 22 dust conditions


General manager of Deritend’sWolverhampton motor repairand rewind workshops, DaveHawley, takes up the story:“There are many companiesthat are now subject to ATEXregulations for the first time,due to the inclusion of dustladen atmospheres. They maybe aware that explosions andfires caused by dust can beequally as devastating as thosecaused by explosive gases andvapours, but not whatconstitutes a risk and how toaddress it. Compliance as far asdust and electric motors areconcerned is actually relativelysimple and the motorparameters required are notextreme, but there is a genuineneed to know within industry.”

Previous regulations forexplosive atmospheres did notaccount for risk of explosioncreated by dust. There havebeen several large explosionsinvestigated in recent years inareas such as crop storage,food processing, coalprocessing and plastics that arenow attributed to dust. Bothatmospheric and settled dustcan pose a problem and arenow included in the newregulations.

Most industries used todealing with explosive gasesand vapours (typicallypetrochemical) are unlikely toneed to make many, if any,changes regarding the newdirectives. Companies in thissector will also know what

type of new motor they needand that an approved repairershould be used to certify arepaired motor. Companies notusing motors certified by thesupplier or repairer are liableshould anything go wrong,under ATEX 137. Industriessuch as paper, processing, foodpreparation, textiles,woodworking, plus companiessupplying machines into thesesectors, are likely to beincluded for the first time andrequire the most information.

Zone classification is theresponsibility of the companyon whose premises machineryis operating. It is also theresponsibility of any companymanufacturing machinery orrepairing machinery that maycreate a risk or is designed foruse in a risk area.

Zone classification depends

on the type of hazard presentand duration that machinery isexposed. For examples,explosive gases such ashydrogen and vapoursproduced by petrol are zoned0, 1 or 2 based on thefrequency of presence andconcentration. Dust ladenatmospheres created byactivities such as compositewoodworking and flourproduction are zoned 20, 21and 22 based on level ofexposure. Settled dust is alsoincluded, which depending ontype and amount, can fall intoany of the three categories.

Areas to look out forwhere motors are at risk ofcausing a problem in the newdust zones are: conveyors,mixers, extractors, fans andpumps. Atmospheric dust isthe most dangerous,

something as simple as flourcan cause powerful explosions.Extraction equipment shouldbe used and motors working inthis environment require ahigher level of enclosuresealing of IP65 and acontrolled maximum surfacetemperature of 125°C.

Settled dust is a wider riskthan atmospheric dust andtends to cause fires started byexcessive heat, thesmouldering temperature ofcommon dust as varied ascocoa or paper is generallyover 200°C and so motorsealing to IP55 and amaximum surface temperatureof 125°C are adequate. It isimportant to note that neitherof these motors are EEx typerated and thus less costly.

Motors must have full certification paperworkavailable from themanufacturer for inspection,when requested. Also motorsmust carry correct identifyinglabelling, including a re-assessedCE mark conforming to thenew regulations. This is whypurchasing a quality new motorfrom a knowledgeable supplieror a rewind from a reputablefirm is essential for peace ofmind and ultimately people’ssafety. Older certified motors do not need to be re-certified, but the repairer does.

� www.deritend.co.uk


29

HEALTH AND SAFETY

Several large explosions investigated in recent years are now attributed to dust


Start with compressor sizing. A system’snominal compressed air requirement isdetermined by all of the consumers: tools,machines and processes. Thus, compressorsize should be based, not on the total airusing equipment, but usage at any giventime. The golden rule is size the compressorto the largest air-using equipment only.

To be certain, carry out a compressedair audit, such as Atlas Copco’s AIRScan.This gives a true picture of how muchcompressed air is being used and howmuch energy is wasted producing it. Thesurvey pinpoints areas of energy drain.Analysis of usage patterns shows wherethe system could be improved regardingefficiency, flexibility and costs.The audit is applied in two stages.Consultant engineers conduct an initialdiagnostic check to determine thecompressed air system’s efficiency,including pipework. The second phase is a complete system appraisal, whichmeasures, audits and reviews all elementsof the compressed air system. As the

procedure is non-intrusive, it does notcause shut downs or interruptions.

Variable speed compressorsThe survey may recommend installingvariable speed drive (VSD) compressors. In 80 per cent of installations, air demandshows important fluctuations, while in 70 per cent of installations, load cycle liesbetween 40 and 80 per cent.

Energy savings averaging 35 per centare the main characteristic of integratedVSD compressors, derived from anintegrated frequency inverter that variesthe compressor motor speed to matchoutput to demand. Traditional regulatorscan not track demand pattern variations,wasting energy as a result.

VSD smoothes a compressor’s airdemand profile, eliminating pressureovershoot and saving energy. Other VSDbenefits include: up to 22 per cent total lifecycle cost savings: pressure flexibility;pressure stability; no starting current peaks;high power factor; and EMC-compliance.

Atlas Copco offers 24 VSD stationarycompressor models, ranging from 7kW to 900kW, including oil-free versions andworkplace models, with integrated airand condensate treatment equipment.

Energy recoveryMost electrical power used by screwcompressors is transformed into heat, but upto 94 per cent of heat can be recovered. Awell-planned investment in energy recoverycan payback within one to three-years.

The available heat from a water-cooled,oil-injected compressor (preferably above30kW) can be recovered as hot water.Connecting it to a boiler’s return circuithelps reduce heating costs of washroomsupply, radiators and process operations. Inthe case of air-cooled compressors, hot aircan be ducted for direct space heating.

Air dryingEnergy-efficient procedures should also beapplied to producing moisture-free qualityair. Atlas Copco’s MD adsorption dryer andoil-free screw compressor combination isdesigned to reduce demand regardingpower consumption and compensation forpressure drop. Compressor heat is used toregenerate the dryer rotor, which needsonly 120W for rotation. No electricalheater or purge air is involved and closecoupling minimises pressure drop.

Intelligent controlIn applications comprising multiplecompressor installation, intelligent remotecontrol and monitoring can also helpreduce power costs and optimise thesystem for minimal pressure band andmaximum energy savings.

Atlas Copco’s AIRConnect is anaftermarket service that links compressedair installations to a 24/7 internet-basedmonitoring system. It is designed toprovide increased compressed air systemavailability and reliability and allowsservice optimisation: the right service atthe right interval.

Hardware monitors the devices in the

Maximising energy savings

PNEUMATICS

The largest proportion of a compressor’s lifecycle costs is energy consumption.

What’s more, 30 per cent is thought to be wasted. Thus, it is essential

operators measure, control and reduce energy losses. Atlas Copco explains

System audits can includesonic leak detection


compressor room and providesinternet access. AirConnectsoftware includes aconfiguration program forcompressor room layout andmeasurement points duringcommissioning. AIROptimizerprovides hardware andsoftware for energy

optimisation. The agreementincludes hardware andsoftware, maintenance costsand an annual AIRScancompressed air audit.

An initial audit isperformed to determinepotential savings and, as aresult, many operators find the

savings exceed their previousmaintenance costs.

Aftermarket servicesThe underlying principlebehind all practical issues ofcompressed air production ismanagement and control of airgeneration costs. That means

all-embracing service contractsthat extend to on-going auditsof energy efficiency, air leakageand air quality. All these factorsrelate to the implementation ofcost-effective measures toremedy problem areas theaudits reveal.

Atlas Copco offers a choice of service plans, with options for inspection,preventative maintenance and total responsibility.Effective, plannedmaintenance of a compressedair system is a majorcontributor to optimumperformance from equipmentand the control of energy costs.

� Atlas Copco

� 0800 18 1085

� www.atlascopco.co.uk


PNEUMATICS

The largest proportion of a compressor’slifecycle costs is energy consumption

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

ANNUAL BUYER’S GUIDE

Company Website Email Contact Telephone Number

Boilers

Byworth Boilers www.byworth.co.uk [email protected] 01535 665225

Certuss Steam Generators www.certuss.co.uk [email protected] 0121 3275362

Boiler Hire

Wellman Robey www.wellman-thermal.com [email protected] 0121 543 0000

Bolt Securing Systems

Nordlock Ltd www.nord-lock.co.uk [email protected] +44 (0)1980 847129

CMMS

Cayman Venture www.cayman.co.uk [email protected] 0191 2963816

Productivity Europe www.productivityeurope.org [email protected] 01234 215867

Idhammar Systems Ltd www.idhammarsystems.com [email protected] 0117 9309300

Compressed Air

Atlas Copco www.atlascopco.co.uk [email protected] 0800 181085

Gardner Denver www.gardnerdenver.com [email protected] 01452 338116

Condition Monitoring

Elcomponent Ltd www.elcomponent.co.uk [email protected] 01279 503173

Holroyd Instruments www.holroyd-instruments.com [email protected] 01629 822060

Proviso Systems www.proviso-systems.co.uk [email protected] 01777 817536

Monitran www.monitran.co.uk [email protected] 01494 816569

Schaeffler www.ina.co.uk [email protected] 0121 351 3833

SPM Instrument UK Ltd www.spminstrument.com [email protected] 01706 835331

Data Acquisition

Metrum www.metrum.co.uk [email protected] 0118 973 3000

Health & Safety

Integrity&Compliance Management www.icm-uk.com [email protected] 01779 474748

Lubrication

ATS Electro-lube (UK) ltd www.ats-electro-lube.co.uk [email protected] 0191 491 4212

Planned Maintenance

T Cards Direct www.tcardsdirect.com [email protected] 01732 871417

Thermography

Flir www.flir.com [email protected] 01732 221245

Fluke www.fluke.co.uk [email protected] 020 7942 0700

Hawk-IR www.hawk-ir.com [email protected] 01642 497000

Training

National Fluid Power Centre www.nfpc.co.uk [email protected] 01909 504700

Vibration Analysis

Hansford Sensors www.hansfordsensors.com [email protected] 0845 6801957

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info


EENNQQUUIIRRYY??F R E E P R O D U C T I N F O R M A T I O N S E R V I C ECCOOMMPPLLEETTEE AANNDD FFAAXX TTHHIISS PPAAGGEE BBAACCKK TTOO 00220088 77111133115533

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Sept/Oct 2007

PLANT MANAGEMENT

❏ Artificial Intelligence/Expert Sys

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ENVIRONMENTAL

❏ Dust/Fume Extraction

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HEALTH & SAFETY

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ENERGY MANAGEMENT

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