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February 2013 | Issue 10
4-6
16-17
30-35
Industry Latest News
Health & Safety
The Hazex/Maintec Show Preview
Halifax Fan LtdReports TwoRecord Years
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INDUSTRY LATEST NEWS
HEALTH & SAFETY
DUST AND FUME EXTRACTION
ATEX EQUIPMENT
THE HAZEX/MAINTEC SHOW
PREVIEW
EXPLOSION PROOF PRODUCTS
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Stands 47 and 48 will feature a comprehensive
selection of ABB equipment utilising a variety of
measurement techniques, including laser, zirconia
and FT-IR spectrometry.
Products on the stands will include the LS25
laser gas analyser. Enabling in-situ monitoring in
stacks, pipes, process chambers and other similar
applications, the LS25 uses tuneable diode laser
absorption spectroscopy (TDLAS) to measure
concentrations of various gases including oxygen
and ammonia in gas streams. Offering a very fast
ABB to highlight emissions technology and know-how at AE 2013
ABB will be exhibiting its latest range of air and gas analysers at the Air Quality and
Emissions (AE) Show at the Telford International Centre (13-14th March 2013).
response time, the LS25 is especially suited to
applications with fast changing conditions such as
municipal waste incineration where the composition
of gases may be subject to rapid changes.
Other equipment on display will be ABBs new
Endura AZ10 zirconia oxygen and StackFlowMaster
instruments.
For more information, email
[email protected] or call
0870 600 6122 ref. AQE 2013.
HES August 2012HES December 2012HES February 2013
Based on customer requirements new cost
saving innovations and improvements have been
implemented into the manufacture of Rittals TS
8 enclosures.
The following updates will start to take effect
from December 2012 onwards. Tool free
adjustment of the mounting plate depth;
additional markings every 100mm in the vertical
sections for positioning of rails; TS 8 punched
pattern on the door frame for easier installation
of equipment; simple mounting plate earthing
from the front to negate the need to remove
the rear panel or mounting plate and a low
tack baying seal for easier re-adjustment where
neccesary.
All benefits have been introduced for quick and
easy assembly of Rittals TS 8 enclosure, which
can realise customer savings in both time and
costs.
Rittal Introduce New TS 8 Updates
For more information follow the link below:
http://www.rittal.co.uk/information/TS8UpdateFlyerFINAL.pdf
Eef Comment On Lofstedt Progress Report
This report signifies welcome progress on restoring
a proportionate and balanced approach to health
& safety legislation. However, government must
ensure that in the rush to clear the stock ofregulations government doesnt remove measures
that business finds helpful.
Furthermore, having made welcome progress at
home, the UK government must now lead efforts
at EU level to ensure the forthcoming review of
health & safety Directives ensures that we only
see regulation from Brussels where there is clear
evidence it is needed and, whose impact on
business has been thoroughly assessed.
Commenting on the report on the progress of the Lofstedt Report
recommendations on health & safety, Terry Woolmer, EEF head of Health &
Safety Policy, said:
Finnish utility Teollisuuden Voima
Oyj (TVO) said that, based on recent
progress reports from the Areva-
Siemens consortium constructing the
plant, it is preparing for the possibility
that the start of the regular electricity
production of Olkiluoto 3 nuclear power
plant unit may be postponed until 2016.
Last year it said that it would be delayed
beyond 2014.
Construction of Olkiluoto 3 started in May
2005, with completion originally scheduled
for 2009. However, the project has suffered
several setbacks. TVO announced in
December 2011 that it anticipated the 1600
MWe Areva-designed EPR reactor would
begin commercial operation in August
2014, some five years later than originally
planned.
In July 2012, the company declared that
the plant unit will not be ready for regular
electricity production in 2014. Noting
that Areva-Siemens are constructing the
plant under a fixed-price turnkey contract
and are therefore responsible for the time
schedule of the project, it requested the
supplier provide an updated schedule and
completion date.
TVOs senior vice president, Jouni
Silvennoinen, said in a statement: We have
not yet received an adequate schedule
update. He added, Additionally, the
instrumentation and control (I&C) design
has not proceeded as planned, and
therefore the plant completion may be
further delayed.
Finnish utility says Olkiluoto
3 nuclear plant faces further delays
Latest Industry News
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HES August 2012HES December 2012HES February 2013
Coromill 316 Exchangeable-Head Milling System Is
Now Available With Internal Coolant
The CoroMill 316 exchangeable-head milling system is a truly versatile
system for milling operations. It can be applied for high feed face milling,
slot milling, helical interpolation, shoulder milling, profile milling and
chamfer milling of components in material groups from ISO P to ISO S.
For more information and a closer look at
the CoroMill 316, visit
www.sandvik.coromant.com/productnews
Mine Explosion Kills Eighteen In Northern Russia
From March 1st this high performance system is
available with internal coolant holes.
The machining of such materials as Heat Resistant
Super Alloys, Titanium and Stainless Steels often
requires the use of coolant for temperature control
and chip evacuation during cutting. Re-cutting of
chips and chip jamming often lead to poor surface
quality, damage to the cutting edge and toolbreakage.
By offering an internal coolant solution, with
precise positioning of coolant holes to optimize
the effect of the coolant jet, CoroMill 316 is able to
outperform existing solutions with external coolant,
guaranteeing superior chip evacuation and a secure
cutting process.
The CoroMill 316 system allows machine shops
to quickly, easily and accurately switch between
various operations such as cutter type, radius
variation, teeth frequency, geometry and grade.
CoroMill 316 end mills are even suitable for five
axis milling of flanks which often require taperedtools for stability at longer tool reach.
On February 11 the Russian Interior
Ministry said nine people had died
and eight more could be trapped
under rubble at the Vorkutinskaya
coal mine in the northern Komi region
after a gas explosion. Later in the
day, Interfax said the death toll had
increased to 18, with 10 brought to
the surface.
The blast, at a mine owned by a division of one
of Russias largest steel producers, Severstal,was caused by a build-up of methane gas, the
Ministry said in a statement.
A total of 259 miners were working underground
when the explosion took place and the majority
have made it back to the surface, according
to the Emergencies Ministry, with some
accompanied out by rescue workers.
Initial reports had said around two dozen miners
were working in the shaft where the explosion
took place.
The mine, in the northern city of Vorkuta, is part
of the coal mining division of the Russian steel-
making giant Severstal, whose mills it provides
with hard coking coal concentrate.
According to AFP it has been operational since
1973 and has an output of 1.8 million tonnes of
coal a year, with total coal reserves estimated at
40 million tonnes.
Methane gas explosions remain a frequent
occurence in the coal mining industry in Russia,
despite recent drives to improve safety.
In 2010, 68 people were killed in twin methane
blasts at Russias biggest underground coalmine, the Raspadskaya mine in the Kemerovo
region of Siberia.
CoroMill 316 exchangeable-
head milling system is now
available with internal coolant
The CoroMill 316 exchangeable-head milling
system is a truly versatile system for milling
operations. It can be applied for high feedface milling, slot milling, helical interpolation,
shoulder milling, profile milling and chamfer
milling of components in material groups
from ISO P to ISO S.
From March 1st this high performance
system is available with internal coolant
holes.
The machining of such materials as Heat
Resistant Super Alloys, Titanium and
Stainless Steels often requires the use of
coolant for temperature control and chip
evacuation during cutting. Re-cutting of
chips and chip jamming often lead to poor
surface quality, damage to the cutting edge
and tool breakage.
By offering an internal coolant solution,
with precise positioning of coolant holes
to optimize the effect of the coolant jet,
CoroMill 316 is able to outperform existing
solutions with external coolant, guaranteeing
superior chip evacuation and a secure
cutting process.
The CoroMill 316 system allows machine
shops to quickly, easily and accurately
switch between various operations such as
cutter type, radius variation, teeth frequency,
geometry and grade. CoroMill 316 end
mills are even suitable for five axis milling of
flanks which often require tapered tools for
stability at longer tool reach.
For more information and a closer look atthe CoroMill 316, visit
www.sandvik.coromant.com/productnews
Latest Industry News
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9 HES February 2013
Walsall Ltd had over one hundred years of UK
heritage dating back to the early days of Walsall
Conduits PLC, which once dominated the world
of electromechanical explosion protection. Today,
Pepperl+Fuchs UK manufacturing is located
in the companies new 60,000 sq ft facility in
Wednesbury, just off the M6 J10. A complete
range of mechanical explosion protection products
and customised solutions are manufactured in the
West Midlands for customers throughout the UK,
examples of our portfolio are highlighted below:
Enclosures & Terminal Junction Boxes
Pepperl+Fuchs mechanical explosion protection
products are based around high quality enclosures
in the increased safety, intrinsic safety and
flameproof protection classes. The range provides
several different options of enclosure dependant
upon the project application and specification
required, with a variety of sizes and materials
available including stainless and mild steel, as well
as glass reinforced polyester (GRP). All products are
manufactured to the same exacting levels of quality
which Pepperl+Fuchs has been associated with for
over 65 years.
Local Control
Using Pepperl+Fuchs manufactured enclosures, a
comprehensive range of multi function local control
stations and control panels are also available.
Standard and customised local control stations
in glass reinforced polyester and stainless steelenclosures are complemented by Exd IIC Local
Control Stations utilising cast iron enclosures.
Exd Customised Enclosure Solutions
Pepperl+Fuchs has a huge amount of knowledge
and experience in creating customised Exd
enclosure solutions to meet the specific project
requirements of our customers. These bespoke
solutions allow the hazardous area mounting of
a wide range of industrial products which do not
have Ex approval. Components such as PLCs,
intrinsic safety barriers, starters, and transformers
can be mounted in an Exd enclosure which then
allows them to be located in a zone 1 certified area.
The enclosures are typically manufactured in cast
iron, aluminium and stainless steel materials with a
wide range of sizes and orientations available.
Solutions can also be engineered to customer
specific requirements using combinations of the
product range. A typical example would be an ASM
type Exd enclosure containing industrial equipment
close coupled to an FXL type Exe enclosure via
a line bush. The Exe enclosure is used to house
control functions and terminals therefore allowing for
easier installation.
Certification
As a global supplier to a wide range of industries
and applications, all Pepperl+Fuchs products are
certified to a variety of international standards
including the latest ATEX and IECEX guidelines.
Our products are used in a variety of applications
from oil platforms to pharmaceutical plants
and everything else in between; therefore we
ensure certification allows usage in gas and
dust environments as well as a wide range oftemperature extremes.
The equipment product construction standards
make provision for different methods or types
of protection, two common methods plus a
combination of both are as follows:
Increased Safety (Exe)
Increased safety (Exe) protection is based on the
premise that an explosion will not occur if a spark
cannot occur. Increased safety protection can only
be used for equipment that does not include spark
or heat producing components in normal service
and where increased safety measures have been
implemented to further reduce these risks. An
Exe enclosure need only meet a rating of IP54 to
prevent water ingress leading to electrical fault and
sparking. A simple example would be a terminal
junction box.
Flameproof (Exd)
Many types of industrial equipment such as PLCs,
contactors and MCBs can be certified using the
flameproof concept. The external enclosure of
flameproof equipment is designed to withstand
an internal explosion. The enclosure joints permit
the products of combustion, and the resulting
expansion of gases, to be relieved through the joints
and not to permit that explosion to transmit through
to the external atmosphere. In many instances
a combination of both Flameproof and Increased
safety in the same solution, rather than an Exd
enclosure on its own, can provide reductions in
cost, space and weight.
Hazardous Area Certified Enclosures - A Solution
For Every Application
Pepperl+Fuchs the worlds leading manufacturer of intrinsicallysafe explosion protection and electronic sensors acquired UK based
Walsall Ltd to increase expertise and capacity in the manufacture of
mechanical explosion protection products for use in hazardous areas
and harsh environments.
Telephone: +44 (0)161 633 6431
Email: [email protected]
Group Website: www.pepperl-fuchs.co.uk
Hazardous Area Enclosures
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HES August 2012HES December 2012HES February 2013
Detect Heat & Overheat Before There Is Fire Or Explosion
Detect Heat and Overheat (and Fire) and
report/alarm from 60 385C
in Engine-rooms, Wind generators, Power Plants,
Ovens, Generators, Dryers, Trains, Gas turbines,
Heating rooms, Factories, Inventories and many
more. Reliable 2- or 4-wire N/O or N/C switches,
FM approved, connect to your existing alarm
system or take the comprehensive LICO HDL
& Stand-Alone or intermitting Alarmpanel HDL
to secure life and your values by in advance
monitoring.
LICO Mecatronic S.R.L. Str.Bucinului
Nr.2B / 19 RO-540526 Targu-Mures
Romania
Tel. +40 365 807 497
Fax: +40 365 434 999
Email: [email protected]
LICO Hungaria Kft Raba u. 4
H-2030 Erd, Hungary
Tel + 36 23 520 113
Fax + 36 23 520 115
email: [email protected]
LICO Electronics GmbH Klederinger Str. 31
A-2320 Kledering Austria
Tel + 43 1 706 43 00
Fax + 43 1 706 41 31
email: [email protected]
Learn more by visiting:
www.prevent-a-fire.eu
or www.fenwal-direct.eu
A World First At MAINTEC
It takes a proven method of inspection and not
only extends its scope of application into explosive
environments but also adds in RFID technology so
that findings can be tagged to a location and trends
easily documented.
The world launch platform for this development is
the CorDEX Instruments stand at the MAINTEC
CorDEX Instruments, the UK manufacturer
of instrumentation and equipment for
hazardous environments, is introducing a
new intrinsically safe product at MAINTEC
2013 that is a well suited for anyone involved
in predictive maintenance.
show. The company will also be showcasing several
other products in its popular range of handheld
inspection and NDT devices for operation in
hazardous areas.
Visitors are invited to test drive CorDEX
Instruments other ATEX certified products including
the ToughPIX series of digital cameras, the
LaserMETER 3000XP laser distance meter and the
UT5000 intrinsically safe ultrasonic thickness gauge.
The companys IW Series Intelligent IR Windows
with locking mechanism and multiple identification
system will also feature.
Tel: +44 (0)1642 454373
Email: [email protected]
http://www.cordexinstruments.com/
Latest Product News
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HES August 2012HES December 2012HES February 2013
Halifax Fan Ltd, based in Brighouse enjoyed sales
growth of 30% in 2000/11 and followed that up with
a record 43% growth over the last twelve months.
Established in 1965 to serve the local textile
industries, Halifax Fan designs and manufactures
a wide range of industrial fans and has grown
to be a global player with offices and factories
in China, Hong- Kong, Thailand and Sydney
Australia. Managing Director Malcolm Staff, Fan
technology hasnt changed much over many years
but their application is essential in a great many
industries. We saw the opportunity to strengthen
our position simply by making our products more
reliable and more efficient, reducing their total cost
of ownership. It was also clear that the main growth
Halifax Fan Ltd Reports Two Record Years.
While the global economy is still struggling
and major UK high street chains are failing,one Yorkshire based traditional engineering
company reports two bumper years.
market was the Far East, particularly China, where
power stations and petrochemical plants were
being built widely and that to enter that market,
we needed a local base. In 2006 we opened a
modest manufacturing facility in Shenzhen, just over
the border from Hong-Kong and this has grown
to span three factory units totalling some 4,000
m2. Crucially, from the outset, we focussed on
embedding our UK quality practices in the Chinese
plant and invested in staff training to ensure that
product quality and reliability is constant regardless
of which plant our products are built in.
The petrochemical and oil industries particularly
demand fans built to the highest safety standards
and Halifax has developed a particular expertise in
this sector, even to the extent of in-house testing
and certification to these standards. This has
resulted in repeat orders such as the two year
contract to supply 50 hazardous area fans per
month to a US oil sector company and a single
order for Halifaxs biggest ever fan worth almost
$1m.
All of this has required a continuous investment
in computer based design and manufacturing
technology, moving software and communications
to the cloud and extensive personnel training and
most significantly, apprenticeships and graduate
sponsorships to overcome the UK shortage of
skilled engineers. Plans are in place for further
growth globally so this one UK company that has
got on its bike and found success where other
less bold companies have struggled to weather the
recession.
For more information on halifax fans,
please contact:
t:+44 1484 475 123
W: www.halifax-fan.com
Industrial Fans
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Thermal oil specialist Global Heat
Transfer is calling for the food and
pharmaceutical industries to ensure they
use compliant food-grade (FG) thermal
fluids in heat transfer applications.
The company believes that, although the use of FG
fluids is a regulatory requirement imposed by several
bodies including the FDA and NSF, it is one that
many manufacturers are entirely unaware of.
If there is any possibility that an oil or lubricant could
come into contact with food products, a certified
FG fluid must be used to safeguard consumer
health. Failure to use FG oil in a food application
can result in the loss of the manufacturers top tier
accreditation if the EFSIS (the European Food Safety
Inspection Service, part of SAI Global Insurance
Ltd.) learn that an inappropriate product is being
used.
Non toxic, clear in appearance and odourless, FG
oil is extremely important in the food processing
industry as it is a regulatory requirement and a
sound financial investment. FG oil is designed not
to contaminate food so, should a minor spillage
occur, there would be no need for products to be
recalled. Furthermore, Globaltherm FG performs
better than none FG products in FG applications
as it maintains carbon in suspension rather than
depositing it and therefore helps to reduce carbon
build up.
Global Heat Transfers FG oil is a high efficiency
heat transfer fluid specifically developed for non-
pressurised, indirectly heated, liquid phase heat
transfer systems that require
bulk temperatures up to
326C (620F), as are used
in food processing plants,
pharmaceutical operations
and other FG applications.
Globaltherm FG thermal
fluid from Global Heat
Transfer is fully H1 certified
by the US Food and Drug
Administration (FDA). It also
holds NSF (National Science
Foundation) International
HT1 approval.
Made from a mixture of pure heat transfer
hydrocracked base oils, Globaltherm FG thermal
fluid has excellent thermal oxidation stability
allowing operation at high temperatures for
extended periods, which can be extended when the
oil is maintained and monitored properly. It is non-
hazardous, non-toxic and odourless, which means
it requires no special handling and is not considered
a controlled substance under United States OSHA
(Occupational Safety and Health Administration),
Canadian WHMIS (Workplace Hazardous Materials
Information System) or other work place regulations.
Global Heat Transfer provides a complete solution
for all thermal fluid related issues. It offers 24 hour
delivery of premium quality thermal fluids and
planned maintenance programmes as well as
expert sampling and analysis services. The latter
allow the end user to remain compliant with industry
regulations and meet their insurance requirements.
Thermal Fluid Specialist Puts Food-GradeOil On The Menu
For further information contact: Andrew
Burns or Caroline Law,
Global Heat Transfer Ltd., The Global Group
of Companies,
Cold Meece Estate, Cold Meece, Stone,
Staffordshire, ST15 0SP
Telephone: +44 (0) 1785 760555
Fax: +44 (0) 1785 760444
www: http://www.globalheattransfer.co.uke-mail: [email protected]
Twitter: https://twitter.com/G_HeatTransfer
HES August 2012HES December 2012HES February 2013
Thermal Oil
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HES August 2012HES December 2012HES February 2013
The Protg ZM is a zero maintenance solution,
meaning no battery charging and no sensor
calibration is necessary to operate the monitor.
The monitor has a high performance battery
which provides two years of operation. In typical
conditions, calibration will not be necessary during
the operational lifetime. Three single gas models are
available including Oxygen, Carbon Monoxide and
Hydrogen Sulphide.
The Protg ZM is small, lightweight, ergonomically
designed and meets IP67 requirements for ingress
protection. We designed this monitor with ease of
use and comfort in mind. The unique
Protg profile fits your hand nicely making the
monitor comfortable to hold. Its so lightweight
and small, you will forget youre wearing it while it
protects you, says Mel Gerst, Scott Safetys Global
Product Line Manager for Portable Gas Detection.
The monitor is very simple to use. Just turn it on for
the first time, and it does the rest. Using the default
settings from the factory there is no need to set up
or program the monitor.
The Protg ZM features plenty of customisable
settings to meet your specific needs. For example,
a Hibernate mode is available on the CO and H2S
models. The Hibernate mode puts the monitor
in a deep sleep for up to one year to extend
the operating life beyond two years. Users can
customise the alarm set points themselves or order
monitors with custom alarm set points programmed
by the factory. Users can also set up custom bump
and calibration reminders if they desire. The monitor
has the option to display continuous gas readings,
life remaining or both. The monitor has a three point
alarm (audible, visual, and tactile) and data logging
capabilities.
The Protg ZM monitor is supported by a portfolio
of accessories including a four-bay test station
and IR Connect programmer. The test station
supports bumping, calibrating, hibernating and
programming of up to four monitors simultaneously,
and is available in both portable and table-top
versions. The IR Connect allows programming and
hibernating of individual monitors.
Scott Safety Expands The Protg Portable Gas
Detection Portfolio With The Addition Of The
ZM Protg Single Gas Monitor
Scott Safety announces the introduction of
the Protg ZM Single Gas Monitor a zero
maintenance single gas monitor that is easy to
use and delivers high performance in a small,
ergonomically designed package.
Mr. Gerst explained, The Protg ZM Single Gas
Monitor adds to Scott Safetys 80-year legacy
of working with customers to bring innovative
solutions to market. Our customers asked us for an
easy to use single gas monitor that enabled them
to focus on the task at hand instead of maintaining
equipment. We are excited to expand the Protg
family of gas detection instruments with the
introduction of the Protg ZM.
Scott Safety is a premier manufacturer
of innovative respiratory and other
personal protective equipment
and safety devices and offers a
broad range of globally certified
gas detection solutions including
singlegas, multi-gas and fixed gas
detection systems.
www.scottsafety.com
Health & Safety
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Page Header
17 HES February 2013
Health & Safety
Are Your Safeguards As Safe As You Think?There are machines in the UK fitted with multiple guards which
are monitored in one circuit by series connected safety switches;
does this sound like one of your machines? Can any of theseguards be opened simultaneously? Then read on!
Historically the practise of series-wired safety switches has arisen because it
saved money on cabling and safety relays, and because dual channel wiring
of the switches met Category 3 of the withdrawn standard EN 954. Category
3 lives on in the replacement standard EN ISO 13849-1 which requires that for
Category 3 to apply at least 60% of faults have to be detected in a diagnosis
mechanism (DC = low).
The ability of a system to detect 60% of dangerous faults can be impacted by
a phenomenon known as fault masking which can dramatically reduce the
Diagnostic Coverage and consequently the Performance Level.
1 Three safety gates are connected in series to an evaluation device. Initially all
the safety gates are closed and the relays outputs are on, i.e. the machine can
be operated.
2 On the left-hand safety gate, a short circuit occurs in the line to the switch with
the N/C contact. At first the fault is not detected (because a demand has not yet
been placed upon the safety function) and the machine can continue operating
(because the guard is still closed).
3 The left-hand safety gate is then opened, an event which the left switch
signals to the relay. During feasibility comparison of the two switches the safety
relay discovers an inconsistency and switches to a fault condition, i.e. once the
safety gate is closed the machine cannot be restarted (but in this case the safety
gate is left open).
4 Now the right-hand safety gate is also opened. Via these signals the relay
once again detects a normal condition. The fault condition is reset, the safety
gates can once again be closed from left to right and the machine is ready to
start up again.
This example illustrates an undetected fault in the safety circuit, which has built
up as a result of the clearing of the fault by the simultaneous opening of two
gates. An additional, subsequent fault could cause the whole interlocked guard
system to fail to danger. In the current standard EN ISO 13849-1, the maximum
diagnostic coverage (DC) that the switch can achieve is restricted, depending on
the masking probability.
In practice, a single switch pair that is evaluated by a safety relay can achieve
If more than one guard can be opened with a frequency of greater than once an
hour, or there are more than 4 of them in series, the statistical chance of a fault
occurring and being masked is high with the result that Diagnostic Coverage is
reduced to less than 60%. According to EN ISO 13849-1 this is equivalent to no
DC, and uder these circumstances, the best achievable PL is PL
c, or Category 1 in old terms. If your original risk assessment required Category
3 your system is no longer compliant.
Possible cures for fault masking
include:
1. changing the wiring of existing
series-connected switches to
individually wired switches (which may
be costly in terms of wiring and the
need for extra safety relays or extra
inputs on safety controllers)2. the zoning of guard monitoring
switches into distributed I/O systems
(such as Pilz Decentralised Periphery
PDP67 systems)
3. Replacement of volt-free contact based switches with RFID-coded, self-
monitoring switches (such as Pilz PSENcode switches, PSENslock solenoid
interlocks. PSENini inductive sensors or PSENsgate gate access devices) which
can be wired in series and maintain 99% Diagnostic Coverage individually, with
PL e integrity
E-stops in series?
It is worthy of note that series connection of Emergency stop devices is unlikely
to incur a loss of Diagnostic Coverage, because its unlikely that any two E-stops
will be actuated
simultaneously or as frequently as once an hour. Therefore it is reasonable to
wire such devices in series.
Conclusion:
Designers of safety guards and associated circuits on new machines, and those
responsible for existent machines in use should review whatever safety guard
circuits they have where safety switches are connected in series. There are
solutions, as outlined above.
For a more detailed version of this article, please visit the Machinery
Safety Alliance website - www.machinery-safety-alliance.co.uk.
Alternatively, please email [email protected], telephone 01536
460766 or visit www.pilz.co.uk.
a DC = 99%. In the current draft of EN ISO 14119 (which will soon replace
the current interlocking standard EN 1088), the maximum DC for a group of
interlinked switches is dependent upon the number of switches connected in
series and their frequency of operation. As you can see in the proposed table
below, masking restricts the maximum achievable DC and PL.
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19 HES February 2013
Billerica, MA, USA, 4 February 2013. PanaFlow
HT from GE Measurement & Control is the first
ultrasonic flow meter for liquids, which has been
engineered to meet Safety Integrity Level (SIL)
accreditation to allow its operation in a Safety
Instrumented System (SIF). This has involved
extensive third party testing and certification
of every component of the flow meter, from
transducers to meter body. As a result, the benefits
of ultrasonic flow meters can now be enjoyed in a
wide range of safety-critical applications throughout
the oil and gas sector, while greatly mitigating risks
to personnel, plant, process and the environment.
Third party SIL accreditation specifies the safety
integrity requirements needed by a product for it
to be o part of a Safety Instrumented System,
explains Thomas Michalowski, global product
manager at GE. Such a system will control a
safety-critical function. For example, a flow meter
can measure the flow into a vacuum distillation unit
and then act to activate a valve if the flow is too low,
acting as process monitor.
The new PanaFlow HT is the first ultrasonic flow
meter to meet SIL accreditation and is also ATEX
and ICEX certified for operation from -200C to
+600C, which greatly extends the application of
ultrasonic flow metering throughout the refineries
sector.
Ultrasonic flow meters already enjoy wide
application throughout the oil and gas industry,
providing reliable and accurate flow measurement.
They have no obstructions which might clog
or restrict material flow, they operate without a
pressure drop and have no moving parts so that
they feature minimum drift, requiring no periodic
calibration. Furthermore, ultrasonic flow meters can
measure flow in both directions while, with patented
Bundle Waveguide Technology (BWT) transducers,
the PanaFlow HT can operate at high and low
extremes of temperature.
To date, safety-critical flow metering in refineries
has been carried out typically by wedge meters
and orifice plates, with SIL-certified pressure
transmitters. The introduction of the PanaFlow
HT means that refinery operators can now enjoy
the comprehensive benefits of ultrasonic flow
metering in pipelines from 3 in to 16 in (80 to 400
mm) diameter as standard, with special meters
available up to 36 in (900 mm). Typical applications
include vacuum distillation units, delayed coker
units, visbreakers, crude distillation units and fluidic
catalytic cracking units.
About GE Oil & Gas
GE Oil & Gas is a world leader in advanced
technologies and services with 37,000 employees
in more than 100 countries supporting customers
across the industryfrom extraction to
transportation to end use. Making the environment,
health and safety, quality and integrity our highest
priorities is The Way We Work. Our technologies
and services include: surface and subsea drilling
and production, monitoring and diagnostics,
measurement and controls, large-scale LNG,
pipeline compression and inspection, well site
and industrial power generation, technologies
for the refining and petrochemical industries, and
modular CNG and LNG units for transportation
sectors. Through our customized service solutions,
training programs and technologies, GE Oil & Gas
partners with customers to maximize their efficiency,
productivity and equipment reliability; develop their
next generation workforce; and fully benefit from the
megatrends of natural gas, the growth of subsea
and hard-to-reach reserves and the revolution in
asset health management.
GEs PanaFlow HT is Worlds First SIL-RatedUltrasonic Flow Meter
Allows Users to Benefit from Ultrasonic Technology
in Safety-Critical Applications
GE Oil & Gas
Measurement & Control
T +44 1925 604095
M +44 7720557346
F +44 1925604096
Flow Meters
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Steatite supplies Rugged Mobile Computers and
high-temperature lithium battery packs into the Oil
& Gas sector, which when required to be used in
potentially explosive atmospheres, have to meet
certain testing standards including;
ATEX (ATmosphres EXplosibles) Directive
94/9/EC
UL1604 Certification
Dangerous Substances and Explosive
Atmospheres Regulations 2002 (DSEAR)
One such mobile computing solution is the Getac
V100-Ex 2, which is the only ATEX certified laptop
to come as standard with intrinsically an safe serial
port, providing a means of wired connection to
instrumentation and other field devices within Zone
2 hazardous areas. The V100 Ex 2 also includes
Bluetooth and WiFi and is also the only zone 2
hazardous area approved laptop to come with GPS
and intrinsically safe 3G option.
Steatite Batteries has a long history of specializing
in lithium battery packs for use in harsh and
hazardous environments. By working with the
world leading cell suppliers we are able to design
battery packs designed to meet with ATEX and
safety requirements. Our batteries are used in
downhole, subsea, environmental measurement
and monitoring devices.
Following the acquisition of RZ Pressure in 2008,
Steatite has continued to grow and establish itself
as the premier European supplier of battery power
solutions for the energy market.
Steatite designs and builds battery packs to
perform in some of the worlds harshest and most
dangerous environments and is regarded by service
companies and equipment manufacturers as the
largest proven supplier of battery packs for the
EMEA region, offering safe and reliable solutions
with dependable design and assembly.
Steatite provides lithium cells and battery packs that
deliver dependable power on demand, extremely
high reliability and peak performance. Major oil
services companies and OEMs rely on Steatite to
recommend the right battery and portable power
solution.
Battery packs for Down Hole drilling,
Exploration and Critical Monitoring
Custom Engineered Battery Packs
High temperature lithium battery packs up to
200 C
Wide range of battery packs that are UN
approved for transportation
Worldwide channel partner for Electrochem
cells
Steatite offers a wide range of products to suit
a diverse range of portable and fixed industrial
applications. The latest products aimed at explosive
atmospheric environments will be showcased
at Ocean Business 2013 (9th-11th April,
Southampton) and Offshore Europe 2013 (3rd 6th
September , Aberdeen).
Rugged ATEX Computers and Battery Packs
Steatite, through its divisions Steatite Rugged
Systems & Steatite Batteries has a long history
of supplying equipment intended for use in
potentially explosive atmospheres.
Steatite Limited
Ravensbank Business Park, Acanthus
Road, Redditch, Worcestershire
B98 9EX
Email: [email protected]
Tel: +44(0)1527 512400
Fax: +44(0)1527 512419
Web: www.steatite.co.uk
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Volvo Construction Equipments (Volvo CEs)
revolutionary extractor for bituminous fumes is
one of three finalists in the machinery component
category of the bauma Innovation Awards. The
system, which is available as an option on Volvo
CEs C-Series ABG pavers, introduces a new way
of removing fumes from the operators working
environment. The innovative feature improves
the working conditions of the operator who sits
directly above the auger channel. By delivering83% efficiency, the system exceeds the National
Institute for Occupational Safety and Health (NIOSH)
guidelines which state that 80% of fumes should be
captured. Volvos results have been independently
certified by an environmental institute.
Behind the breakthrough
The pioneering system works by using a fume
intake, with a fan located directly behind it, on
both the left and right hand side of the auger
channel, explains Anders P. Larsson, executive
vice president of Volvo CEs Technology function.
The fan captures and transports the fumes via two
tubes to the top of the paver where they are then
released. This means that the air in the operators
working environment is significantly cleaner than
was previously the case.
Volvos design is located at the back of the machine
and features a very short distance between
the intake and the fan eliminating the need
for additional piping and funnelling in the auger
channel. This increases efficiency, prevents any
loss of power and ensures that there is no effect
on the operators visibility into the auger channel.Because extra power is not needed, smaller fans
are used. These can be installed horizontally instead
of vertically which offers a smaller, more compact
architecture. This also helps to maintain visibility into
the auger channel which is vital to ensure consistent
material flow and good quality, smooth paving.
Innovative and efficient
During the majority of operating conditions, Volvos
ABG pavers run on smart power which lowers
the engine rpm and considerably reduces fuel
consumption. The new fume extraction system
continues this environmentally friendly and fuel
efficient approach and works just as efficiently when
the machine is operated in smart power mode as
it does when the machine is working in max power
mode.
As well as increased efficiency and visibility, another
benefit of the Volvo design is reduced noise. The
difference in sound between the system being on
or off is insignificant just 0.3 decibels. This means
that there is no risk of the system distracting the
operator or causing fatigue.
Paving the way
Although there is currently no legislation insisting
pavers meet the NIOSH 80% guideline, the Volvo
system has been designed to meet demands from
customers and operators in certain markets. Due to
the modular design of the Volvo system, it can beretrofitted to machines already in the field.
We are thrilled to be a finalist in these prestigious
awards which honor forward-looking developments
and outstanding innovations, says Anders.
This nomination is a credit to our hard working
employees who are helping Volvo CE to deliver
world class innovations. Achievements like this
are only possible thanks to great teamwork. With
more than 180 years of innovation behind us, we
are proud of the companys pioneering spirit and
will continue the Volvo tradition of being innovative
leaders in the construction industry.
Fume Extraction System Shortlisted ForBauma Innovation Award
Volvo Construction Equipments extractor for
bituminous fumes has been shortlisted for a bauma
Innovation Award. The innovative design improves the
operator environment on the companys ABG pavers
by substantially reducing fumes without significantly
increasing fuel consumption, noise or affecting visibility
into the auger channel.
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The new HE 9 Basic Ex-Hand Lamp is well suited
for inspection, maintenance, control, and repair
work that needs to be carried out in potentially
explosive atmospheres, including industrial
chemicals, petrochemicals, and pharmaceutical
plants, as well as in other potentially explosive
atmospheres such as rescue services, sewerage,
and water treatment plants.
The HE 9 Basic hand lamp is the successor to our
existing HE 8 range of hand lamps, which have
been used in hazardous areas for many years, said
Klaus Weyer, product line Manager at COOPER
Crouse-Hinds GmbH. The HE 9 Basic replaces all
Portable Hand Lamp For Zone 1 And 2 Hazardous Areas
Cooper Crouse-Hindshas launched a new explosion protected
hand lamp certified for use in ATEX Zone 1 and Zone 2
hazardous areas.
three previous HE 8 hand lamps, but is technically
similar to the HE 8 EURO PLUS hand lamp. We are
currently planning to introduce an HE 9 Premium
version that incorporates LED technology and an
emergency lighting function.
The HE 9 Basic hand lamp is certified to the
European ATEX Directive 94/9/EC for use in
explosive gas atmospheres in Zones 1 and 2, in
accordance with the latest IECEx standards. The
lamp uses environmentally friendly, rechargeable,
high-tech Lithium-ion batteries (3.75V / 4.8 Ah),
which provide up to five hours battery life. These
lightweight, high energy density batteries make
handling easier, but also eliminate memory effects,
which ensures a reliable power supply to the lamp.
A protective circuit and electronics guarantee
protection against deep discharge and overcharging
of the Li-lo batteries. The HE 9 can be recharged by
using a separate, compact, plug-in charger unit.
Visit www.crouse-hinds.com.
For information on Eaton visit:
www.Eaton.com.
The solenoid operators are designed for use on
the 327 range of direct operated solenoid valves
and are available in epoxy coated aluminium or
stainless steel. The solenoids are certified to ATEX,
Category 1G/2D and Equipment Protection Level
(EPL) Ga/Db. Both operators are IECEx approved
and certified to IEC 61508 Functional Safety (SIL 3
capable).
The polarity insensitive solenoid operators have a
power consumption of only 0.5W at 24V DC and
feature a newly developed electronic booster coil
and stainless steel core for optimum performance.
Available with either an epoxy coated aluminium or
Intrinsically Safe (Ex I) Direct Acting Solenoid ValvesFor Use In Harsh Environments
ASCO Numatics has introduced two intrinsically safe
solenoid valves with Ex ia IIC T6 certification.
316L stainless steel enclosure rated to IP66 and
IP67. The operator can be rotated 360 and locked
into position to select the best position for cable
entry. Electrical connection is via a cable gland
(M20x1.5) or cable connection 1/2 NPT and easy
access screw terminals.
The 327 series solenoid valves feature a brass,
stainless steel or aluminium (NAMUR) body. These
valves have a large flow rate (Kv 0.45 m/h), operate
from 0 to 10 bar and require no minimum operating
pressure.
The solenoid valves are suitable for use in ambient
temperatures from -40C to 60C, and are rated
to ll 1/2G Ex ia IIC T6 Ga / II 2D Ex tb lllC T85C
IP66/67 Db, Certification: ATEX and IECEx EN
60079-0, EN 60079-11, 60079-31, EN 61241-0
and EN 61241-11.
For more information please visit:
Web: www.asconumatics.eu
Hazardous Area Equipment
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Burkert Supplies Atex Devices For Fuelmatic System
Burkert Fluid Control Systems is providing a
complete package of Atex-rated valves, flow
sensors, level switches, positioner systems and
conductivity and flowmeters for Green Fuels
Fuelmatic system.
Designed to produce up to 20,000 litres per day
of high-quality biodiesel, the fully automated
Fuelmatic is skid mounted to facilitate shipping and
installation.
UK-based Green Fuels designs and manufactures
a range of low-cost processing equipment that
produces biodiesel for small-scale, domestic usage,
right up to commercial production levels.
The advanced technology integrated into Green
Fuels systems enables customers to produce their
own high-quality biodiesel inexpensively and safely
for use as a sustainable road transport fuel.
The Fuelmatic system is suitable for the medium-
scale commercial production of biodiesel.
Designed to produce up to 20,000 litres a day, the
Fuelmatic offers key advantages in that, as a skid-
mounted unit, it can be transported to the source
of the feedstock material from which biodiesel is
produced.
This is said to compare favourably with larger
fixed biodiesel plants, where feedstock has to be
transported to a central location - a process that is
costly and, in view of the emissions from the many
trucks required to transport the feedstock, non-
ecological.
In its redesign of the Fuelmatic, Green Fuels
stipulated working with a single source for the
supply of all valves, sensors, flowmeters and
positioners.
However, all the products had to be Atex-approved
EeX lA devices, powered via safety barriers.
In addition to finding a company with the required
products, Green Fuels also required the supplier to
provide technical support to assist in the integration
of the Atex equipment into the redesigned
Fuelmatic.
Burkert offers a range of Atex products and
can provide consultancy, system design and
manufacture and installations and testing.
The fully automated Fuelmatic is controlled by a
PLC that interfaces with Burkerts 8640 pneumatic
valve islands.
These units are built to specific requirements and
save space by providing for the actuation of up to
24 valves on compact modular backplanes.
The Type 8640 provides users with a combination of
pilot-valve input/output (I/O) modules and fieldbus
communications for the control of process valves.
On the redesigned Fuelmatic, the 8640 system
provides the actuation of Burkert pneumatic angle
seat, globe and diaphragm valves, all with Type
1062 electric feedback switches, and the Type
2712 modulating globe valve with an Atex electro-
pneumatic positioner.
Completing the package are Atex-approved flow
and displacement sensors, a vibrating level switch,
positive displacement flowmeters and a conductivity
transmitter.
We offer global experience you can
rely on. Brkert is an adaptable
organisation with flexible processes.
We are continually committed to
achieving success, both for our
customers and ourselves. Consistent
and continuous investment in
research & development and in
staff training enables us to offer
our customers the very best in
technology and services. For any
request or goal you might have for
your fluid process control, Brkert
can be relied upon; working together
with you, well find the best solution,
both from a technical and an
economical point of view.
As Brkert has grown, sales
activities abroad have expanded,
supported by an increasing number
of subsidiaries in key industrialised
countries. Our global presence
enables us to focus on the most
topical problems in specific markets,
whilst offering our customers the
most efficient solutions in their
country.
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The 94/9/EC compliant range options include
temperature class to T4 (135C) and both non-
conductive and conductive dusts.
The ATEX classification 2G/Zone 1 geared motors
available from the UK assembly service suit IEC
frame ATEX rated motors in both standard and IE2
high efficiency classes, for frame sizes 80 through
180. Geared units include a broad selection of
foot and B14 or B5 face mount versions with a
wide choice of motor mounting positions. With
torque output from 32 to 3200 Nm, options include
synthetic and food grade oils, Viton seals and
backstops. Motor options include a wide choice of
voltages, thermistors,
IP66 sealing,
encoders and
auxiliary fans.
NORD
SK 200E
decentralized
frequency
inverters are also suitable
in ATEX classification 3D/Zone 22 in IP55 & IP66
enclosures, available with output ratings up to 22
kW.
NORD DRIVESYSTEMS UK Geared Motor
Same Day Assembly Service Expanded For
ATEX Gas And Dust Up To 18.5 kWNORD DRIVESYSTEMS has expanded its
fast assembly service for ATEX geared motors
to include Gas Zone 1 & 2 and Dust Zone 21 &
22 for nominal motor power ratings up to 18.5
kW. Consolidating NORD as one of the leading
ATEX drive suppliers in the UK, the geared
motors are available with a wide selection of
options for standard delivery within 3-days or, for
very urgent requirements, a same day assembly
and despatch service.
NORD also supplies a complete programme
of geared motors for more demanding ATEX
Category 2D and 3G/Zone 2 applications that are
available with quick turnaround from its German
manufacturing facilities. Covering EX d & de
pressurised encapsulation, EX e increased safety
and EX n non sparking motors, a wide range of
options are available including pressure resistant
encapsulated motors, motor brakes, special
voltages, reinforced gear unit bearings, and many
more. Users interested in the complete NORD
ATEX range can download or request the G1001
catalogue for gas atmospheres or the G1022
catalogue for dust atmospheres from www.nord.
com or email [email protected].
In addition to the fast turnaround service
for Category 2 ATEX geared motors, NORD
DRIVESYSTEMS also offers a rapid assembly
service across its full range of NORDBLOC.1 and
UNICASE geared motors from its Abingdon facility
including helical bevel and helical worm designs
spanning output torque from 90 Nm to 3200 Nm.
For technical information, please contact
Andrew Stephenson at:
NORD GEAR LTD. (U.K.)
11 Barton Lane
Abingdon Science Park, Abingdon
OX14 3NB Oxfordshire
United Kingdom
Tel: +44 (0)1235-534404
Web: http://www.nord.com
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With this in mind, South Korean company Samsung
Heavy Industries (SHI) is developing a 7MW offshore
wind turbine that promises to be the most powerful
of its kind when its demonstrated towards the end
of 2012. The firm plans to test the new generation
of wind turbines at Fife Energy Park off the east
coast of Scotland before taking orders to build them
at its European facility in Methil, Scotland.
In order to help SHI achieve its goal, David Brown, a
company that is perhaps best known for having its
initials on the back of several Aston Martin models,
will be delivering an innovative new gear system that
will be able to generate three to five per cent more
energy than existing gearboxes.
This increase in energy output could be key
to energy companies that are deciding which
gearbox to go with in an age when government is
desperately trying to bring down offshore winds
cost of energy from 150 per megawatt hour to
100 per megawatt hour by 2020.
Ian Farquhar, managing director of wind energy at
David Brown, said: Weve probably got in David
Brown the most comprehensive gear-making
capability in the world.
Farquhar explained that David Brown works in an
environment where in the design and production of
a gearbox, the cost or consequence of failure, in
relation to a wind turbine, is extremely high.
But how exactly did David Brown end up in the
wind-energy market? Scottish entrepreneur, Jim
McCull, bought the 152-year-old Huddersfield-
based gears company back from the US after it had
a 10-year-spell at Textron. The 368m sale went
through in November 2008 and the company is
now targeting new and developing markets.
David Brown began assessing the performance of
the existing gearboxes in wind turbines and found
some alarming statistics.
Offshore wind turbines are designed to survive for
more than 25 years. But we found that there was
a very high rate of interventions related to gearbox
issues between six and 10 years, said Farquhar.
Our estimates tell us that the market for gearbox
repair was $150m last year. By 2020 that will grow
to $2bn Farquhar went on to establish a business
unit of David Brown that specifically looked at post-
warranty inspection work, which helped the firm to
identify a lot of common gearbox failure issues.
We saw that because of the very variable and
poorly understood loads that the winds drive into
these gearboxes, there are a lot of misalignment
effects in the forces going through the gearboxes
and therefore a lot of bearing failures and gear tooth
failures, he explained.
The costs of repetitive gearbox failures are enough
to plunge wind-energy companies into spiralling
financial difficulties. One manufacturer quoted to
me the cost of an insurance claim for one written-off
gearbox can be up to $500,000, said Farquhar.
Our estimates tell us that the global market for
gearbox repair was maybe $150m last year. We
believe that by 2020 that market will have grown
beyond $2bn.
David Brown spotted the gap in the market for
more reliable gearboxes and launched a service and
repair business to mend broken gearboxes. This
enabled it to gain additional valuable experience on
the trends and failure modes of existing equipment,
which it used to provide a series of upgrades to
existing turbines, for companies such as Vesta,
one of the worlds oldest and largest wind-turbine
companies.
But as you may have guessed by now, in addition
to repairing gearboxes it is also manufacturing
customised gearboxes for new customers, such
as Samsung Heavy Industries. Having seen all
of these different design models, common failure
Manufacturer Gears Up For Record-Breaking Turbine
Offshore wind turbines have been getting bigger and better
since the first wind farm was installed in Denmark in 1991.
Nowadays, the general rule is the bigger the wind turbine the
more energy it can produce, reports Sam Shead.
Wind Turbines
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modes, and having an understanding for some of
the challenges that exist offshore, we can design a
specific application for a customer, said Farquhar.
Were very much like the Saville Row of gearboxes
in that we will design something specific to the
customer.
Building a gearbox for the worlds most powerful
wind turbines Farquhar explained that one of the
key criteria for wind turbine gearboxes is that they
are as light as possible.
Heavy gearboxes require stronger tower structures
and present greater transportation and erection
issues. Approximately 20 per cent of the mass of
a wind turbine is associated with the gearbox, the
largest single contributor after the blades.
The compact, low-weight gearbox that has been
designed for SHI will still weigh between 50-90
tonnes but Farquhar claimed it is 10 to 15 per cent
lighter than any competitor product on the market.
The gearbox is a multi-stage epicyclic (planetary)
unit, which means it has several outer gears
revolving about a central or sun gear. The planet
gears will be mounted onto a movable arm or
carrier and provide a link to the outer annulus
gear, which will have a diameter of approximately
3m. David Brown claims the system will offer a
combination of high power density, efficiency and
structural integrity.
Our motivation is not purely about maximising the
selling price. Were taking a whole-life cost view
The gearbox will initially cost somewhere between
500,000 and 900,000 but the company hopes to
reduce this over time.
Farquhar said: Our motivation is not necessarily
purely about maximising the initial selling price.
Were taking a whole-life cost view. The way in
which were working with our customers means
we are all motivated to try and make continuous
improvements.
Samsung has elected and signed a memorandum
with Methil and Fife Council to potentially set up a
100m assembly facility in Scotland for 500 people.
David Brown has an agreement with Samsung
that it will set up an assembly facility in the same
location if Samsung goes ahead with this plan.
On a more immediate note, David Brown is planning
to expand its Yorkshire facilities in order to meet the
demands of the new partnership with SHI.
Two new buildings that are being built in Mirfield
will include a gearbox research and innovation
centre, as well as a gear-manufacturing centre of
excellence.
Farquhar said this one project could increase the
current size of the company by three to four times.
David Brown is seeking to draw on its gear history
to solve a relatively contemporary issue. The
company is looking to make a significant difference
to the wind energy market and its new gearboxes
could help to reduce the price of wind energy,
making this renewable source a far more attractive
option.
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Brand new for this year is the complimentary
Business Strategy Conference. Theres tremendous
value to be had from listening to the experience of
peers especially if they are some of the biggest
brands in the UK today. Based on this idea, the
Business Strategy Conference will feature experts
from many of the UKs brightest companies. From
a special theatre on the show floor, names such
as Britvic, Pepsico , Alcon, Experian and Scottish
& Southern Energy will explore how they are
addressing the maintenance issues of the day.
For those looking for practical sessions, there will
also be The Maintenance Exchange featuring a
rich programme of 38 learnShops. Delivered by
some of the shows most innovative exhibitors,
these will provide visitors with unique insights into
the very latest innovations, products and services
to be found within the maintenance and asset
management arena.
These free learning opportunities will run alongside
an exhibition packed full of exhibitors, many of
whom, like CorDEX Instruments, are using the show
to globally launch new products.
James Walker, Decksafe Solutions, AW Chesterton,
Metool, SAACKE Combustion, Intertek, Keytracker,
REBO BV, MOLYDAL Lubricants, Lubricus Grutzner
and Ernst Schad are just some of the many names,
from both the UK and overseas, making their
MAINTEC debut. They will join MAINTEC veterans
such as Schaeffler (UK), Flowcrete UK, R.Stahl,
ERIKS, Idhammar Systems, SPM Instruments,
PRUFTECHNIK and Prevost UK.
Indeed there is so much to see and do that the
Institution of Diagnostic Engineers (IDE) has decided
to host a spring gathering during MAINTEC. This
will also be attended by members of the Institution
of Local Exhaust & Ventilation Engineers, another
show supporter. IDE Chief Executive, Bill Parker,
says: Wed urge all our members to put the dates
in their diary.
So lets take a closer look at whats on offer at
MAINTEC 2013.
The Business Strategy Conference
The Business Strategy Conference is being run
throughout the three-day show and features a
phenomenal line-up of world-class experts and
major end-user brands. Each day addresses a
different strategic theme. On day one the focus ison Making the Business Case for Maintenance.
Mark Haarman, CEO, Mainnovation will kick off
proceedings by exploring the economic drivers of
a maintenance organisation. For those struggling
to measure maintenances economic contribution,
he will have suggestions and lessons from real life
experiences. Delegates will learn why steering
on value leads to continuous improvement and
what can be learned from leading maintenance
organisations around the world.
In a session moderated by Bill Parker, CEO,
Institution of Diagnostic Engineers, and drawing
on case studies, John Davenport, Operations
Director, Alcon and Paul Dennis, Technical
Facilities Manager, Experian will explore successful
maintenance strategies, how to choose the right
one for your business and the merits of total
productive maintenance versus a reliability-centred
maintenance approach.
There is much debate within the profession about
MAINTEC 2013 PACKED WITHLAUNCHES & LEARNING
MAINTEC, the leading exhibition for the UKs maintenance,
plant and asset management community returns to the NEC on
5-7 March 2013 packed with more learning opportunities and
product innovations than ever before.
Hazex/Maintec Show Preview
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which is better control maintenance or a reactive
maintenance operation. Mark Thompson, Head of
Wastewater Assets, Southern Water will explore the
merits of each. Drawing on his own experience he
will look at how you decide which one is the right
strategy for your company. He will then explore the
idea of whether there is a third way that involves a
mix of asset management systems and reactive self
monitoring devices.
The theme for day two is Innovation in Action
with Steve Statham, Manager, Manufacturing
Technology Centre starting the day by exploring
the latest effective methodologies and high-
impact technologies. As innovations go, social
media has been transformational for many areas
of business; Steve will outline its implications for
maintenance professionals, specifically social
medias role in providing feedback and alerts for
building maintenance. He will also give examples
of where innovation in asset management is helping
to overcome those thorny maintenance issues of
legacy systems & obsolescence.
Condition-based monitoring is a hot issue. Is
an evolutionary or revolutionary approach to
implementation best? Which assets and equipment
should be included and what about all the data
you are likely to gather? Any attendees struggling
with these and other questions will get the chance
to learn firsthand from
Dr Sethuraman Muthuraman,
Condition Monitoring
Engineer, Scottish &
Southern Energy.
He will even have
some suggestions
for those daunted
by condition-based
monitoring, outlining
the occasions
when reactive
or preventative
measures may suffice.
Many wonder whether formal
standards really add value to an organisation.
This day will be your chance to find out as in his
talk Daniel Pairon, Global Head KPMG Asset
Management will outline the core standards in
asset management and how PAS 55 / ISO 5500x
certification might actually empower your company.
A panel discussion featuring David Smallbone,
Head Asset Management, AMCL closes day two.
In a lively session the cost of asset failure versus the
cost of condition monitoring will be debated.
People, processes and legacy sit at the heart of
good maintenance management and day three
focuses on these elements. Keynote speaker,
Wayne Curry, Engineering Team Leader, Britvic will
outline how the company manages the impact of
new processes and KPI reports on maintenance
staff. In a highly practical talk he will also cover
the usability and access issues you face when
rolling out new devices and equipment to a
mobile work-force. This people focused day
closes with Ian Rigby, Engineering Manager,
Pepsico, who will look forwardto 2017. Ian will predict what
shape, dynamics and focus the
maintenance team will have
by then.
The Maintenance
Exchange
Complementing the
Conference will be
The Maintenance
Exchange, featuring
38 free-to-attend
learnShops, designed to help plant
and asset managers, engineers and maintenance
professionals save money, improve efficiencies and
enhance asset care.
For instance John Roberts, Managing Director at
Idhammar Systems, will give an insight into the
OEE concept and how it is linked to return on
investment. The concept is based on the availability
of the plant for production and the performance
of the plant. This is determined by the rate that
units are produced and the quality of the saleable
product. When these elements are considered
together, and the current and desired efficiencies
analysed, strategies to reduce energy usage can
emerge.
Managers of Energy from Waste (EfW) plants will
be interested in the talk by Robin Buller, Director of
Business Development at KRR ProStream. Using
smart technology to maintain these specialist
systems can result in more efficient outputs,
explains Robin Buller. He will be focusing on three
cleaning technologies, in particular, for boilers, bag
house filters and heat exchangers. KRR ProStream
specialises in power generation facilities and this
talk will give delegates the opportunity to discuss
specific efficiency issues with industry experts.
Condition based maintenance offers many
economic benefits, as Stan Jackson, Managing
Director from SPM Instrument UK will explain. The
concept focuses on using staff more effectively on
routine inspections to determine possible corrective
maintenance. This is said to increase reliability and
ensure maintenance work is planned.
Similarly, Roy Davis, Senior Consultant at MCP,
will speak about how Operator Asset Care
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is implemented to complement maintenance
excellence and the benefits to a business when
asset care is carried out. He explains: The
increased awareness and machinery-based
knowledge of production operators will ensure that
any machinery failures or malfunctions are detected
at an early stage, so that planned actions can be
implemented.
For those who have a health and safety agenda,
Sira Test and Certification Ltd will hold a seminar
on the worlds first international scheme for
the certification of personnel associated with
equipment, installations and servicing used by Ex
industries, known as IECEx.
Any uncertainty of hazards associated with static
electricity will be clarified by Mike OBrien, Product
Manager from Newson Gale. Sometimes thought
to be witchcraft due to its invisible nature, static
electricity can spark an explosion in combustibleatmospheres, explains Mike OBrien. The highly
dangerous charge can be built up by the movement
of powder and liquids in a plant. Using a video to
illustrate the dangers, he will be discussing practical
measures on how to manage static electricity.
Attendees who work with fragile substances will not
want to miss the talk by David Furley, Distribution
Manager at CorDEX instruments. He will explain
how to control the deployment of standard
thermography equipment. Visitors will also be able
to hear about web-based predictive maintenance
systems, from Dr John Atkinson, Technical Director
from C-Cubed.
Andy Parkinson, Business Development Manager
from James Walker will speak about improving
efficiency and costs by reducing maintenance
downtime, while Ian Pledger, IAM Product Specialist
from Schaeffler will discuss the implementation of
an efficient asset management system using plant
condition monitoring. Dr Trevor Holroyd, Technical
Director at Parker Kitti Wake Holroyd, will speak
about the application of acoustic emission to detect
ineffective lubrication in operating machinery.
Marketing Manager at Ernst Schad, Ram
Greenshpon will explain how to keep your good old
gearbox in service at a fair cost, whilst Reliability
Maintenance Solutions will be speak about
improving reliability by correcting the big four:
balancing, shaft/belt alignment, looseness and
resonance. Flowcrete will hold a seminar about how
to get more from your floor.
Packed Show Floor of Innovating
Exhibitors
Exhibitors sit at the heart of MAINTEC and this
year is no exception. Many are using the
show to launch new products or showcase
their very latest work. For instance BEKO
Technologies will be outlining how it has
helped one of the largest car manufacturing
plants in the UK replace its old dryers and
thus reduce running costs significantly and
improve air quality. The initial project was to
replace just two dryers but projected energy
savings provided a sound case to change all four
existing dryers.
Thermal Energy International will show how a FLU-
ACE Condensing Heat Recovery System which it
implemented for Premier Foods saved the company
110,000 per year, which is approximately 7.5
million kWh of annual gas savings.
First time exhibitor, SAACKE Combustion, recently
helped Harveys Brewery improve the operation of
its boiler plant. SAACKE recommended fitting a
burner with a superior turndown, thus allowing the
boiler to match the sites steam demand massively
improving efficiency.
Those in the food or drink sector should also check
out CRC Industries UKs new StopLight Food
Safety Programme. Developed specifically for
MRO chemicals, its a leap forward in the control of
chemical product movements.
Among the vibration monitoring products from
Hansford Sensors making their UK show debut
will be the new HS-109 Triaxial accelerometer. This
allows three axes to be monitored simultaneously,
plus a new version of the companys spot facing
tool, which has been re-engineered to extend its
operating life even further.
Maintaining reliable RH measurements
in harsh or corrosive environments
is notoriously difficult as the
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conditions themselves degrade the sensors andequipment, often in short time-periods. Michell
Instruments will be showing how its DT722 RH and
temperature transmitter provide a solution to this
problem.
Ocip Energy will outline how a recent project to
install new LED fittings at Fletcher Moorlands site
is on target to save the company 70% of its lighting
costs.
There will be a unique demonstration of Schaeffler
FAG WiPro s condition monitoring system for wind
turbines. Via a live remote link to a wind farm
based in Scotland, visitors will be able to see in
real time how the main rotor bearings, gearbox
and generators on five wind turbines are being
monitored 24/7.
Fluke UK will show its Fluke CNX Wireless
System. This is the first set of test tools that
wirelessly connects multiple measurement modules
and sends simultaneous readings to a master
device up to 20 metres away, allowing users to
troubleshoot problems quickly and efficiently.
Steam system and flow control specialists
Valveforce has created pneumatic control valves to
handle a wide range of fluids such as thermal oil,
steam, water, nitrogen and natural gases.
Dust extraction specialists, Dustcontrol UK, will
showcase their latest centralised dust vacuum
system - the DC 11 Module. By reducing noise
to 65 dB(A), the DC 11 Module is easier to fit in a
building where noise is a challenge.
MAINTEC will be the first opportunity to see
Idhammar Systems new Maintenance Management
System V11. This offers a number of new
benefits including minimized downtime, improved
maintenance planning, audit compliance and
greater control over budgets and stock.
T-Cards Direct is launching the latest upgrade to
its new T-Cards Online at the show while Xetec
will show its FlexMaint computerised maintenance
management software.
James Walker has successfully tested Supagraf
Premier, a premium fugitive emissions valve
packing, to ISO 15848-1 2006 Class A at 690bar.
It will be showing visitors how this is the lowest
rating of leakage definable under ISO 15848-1 and
demonstrates a step change in performance for
braided graphite fugitive emissions packing.
Recently launched, Agility 4.1 from SoftSols is
the latest version of its Agility Computerised
Maintenance Management System and builds
on the introduction of dashboards and key
performance indicators in earlier releases.
Hayley Groups brand new SmartVendTM eliminates
the need for RFID tags, barcodes and the
requirement to manually account for inventory. This
automates data-collection and provides the user
with real-time intelligence on inventory use.
For those focused on people development MCP
Consulting and Training will show how an Operator
Asset Care programme equips the very people
operating production equipment to improve its
reliability and performance. MGTS will explain its
unique approach to technical training designed for
both mature and new entrant employees across a
wide range of engineering disciplines.
HAZEX
Successfully launched last year, the HAZEX area
brings the UKs top hazard prevention experts and
innovations under one roof. For instance in a world
first, CorDEX Instruments, the UK manufacturer
of instrumentation and equipment for hazardous
environments, is introducing its new TC 7000
intrinsically safe thermal imaging camera at HAZEX.
Newson Gale is showcasing its Bond-Rite
static earthing clamps plus its Earth-Rite series of
hazardous area static grounding systems. Also
in this area R.STAHL is introducing IS1+ a key
innovation for the companys already leading
explosion-protected remote I/O system IS1.
DENIOS is running a live and explosive free
lecture. Running for all three days this experimental
lecture uses graphic demonstrations to explore the
limitations of flammable materials in the workplace.
And the Winner is
The winners of the first ever MAINTEC
Maintenance Professional Awards will also
be announced live from the show floor.
There are two categories: Maintenance
Professional of the Year and, in support
of newer entrants to the industry,
Maintenance Apprentice of the Year.
MAINTEC is free to attend and pre-
registration is advised to avoid queues on
the day. Register visit www.easyfairs.com/
maintecuk.
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Besides explosion-proof and maintenance-free LED
signal towers of the EDLM and EDWM series, which
achieve ATEX guideline 94/9 EC and are suitable
for zone 1 and 2, Patlite also offers visual, audible
and hybrid products which are suitable for zone 2
and 22.
Safely encased
The innovative, explosion-proof signal towers
EDLM (3 coloured LED modules) and EDWM (5
coloured LED modules) come with a high-strength
main body made of aluminium alloy. Thanks to
their pressure- and flame-proof housing they reach
protection IP66. They have been designed for use in
potentially explosive atmospheres in environments
such as (petro-) chemical industries, handling with
combustible dusts, production of gas and even in
food industries.
The terminal block of the EDLM and EDWM models
is found at the back and provides easy access to
the signal tower. The signal towers are suited for
flush mount, wall mount and horizontal mount.
The EDLM type comes with patented prism facet
LED modules in the colours red, yellow and green.
The EDWM type is available with 5 LED modules in
red, yellow, green, blue and transparent.
The Japanese Tokuyama group is planning to
install a fair quantity of EDWM signal towers at its
polycrystalline silicon production plant in Malaysia.
Besides providing safety for our co-workers and
machines, the explosion-proof LED signal towers
model EDWM-502 helps us to improve quality
control and productivity, explains a company
spokesman from Tokuyama. The company
values the signal towers because they are highly
dependable, maintenance-free and offer a long
lasting serving life.
Energy-efficient LED lights
The series AR-070 and AR-078 are signal towers
with up to five LED modules and a diameter of 40
or 60 mm. The signal lights are resistant against
gas or dust explosions and are approved for zone
2 and 22. The energy-efficient LED modules with a
PATLITE patented prism cut provide full and brilliant
illumination.
Vertical and horizontal cut lenses in combination
with a double-reflection system enhance the
diffusion of the LED illumination. The LED modules
available in the colours transparent, yellow, red,
blue and green - as well as the main body are made
of strong synthetic materials. They withstand even
high pressure and heat as well as damage caused
by acid or bases.
The signal towers reach IP65 protection. That allows
installation even in damp or dusty environments.
The AR-078 and AR-070 series signal towers can
be either flush or wall mounted and are available
with one to five LED modules. They can also be
ordered with a flashing/non-flashing function and /
or two super-loud alarm sounds with an 85dB (at
1 m) output. The type with alarm sound reaches
protection IP54.
Large product spectrum
Explosion-proof products that are suitable for Zone
2 and 22 also include the hybrid type LKEHFE/
EXN and LKEHFV/EXN, the signal horns EWH24/
EXN and PVW04JF/EXN as well as the LED working
lights of the CLA series and the bar lights CLF2024/
EXN and CLT3024/EXN.
All explosion-pro