ISSN 0269 0225 No.193 Autumn / Winter 2016 Diagnostic ...

www.diagnosticengineers.org Diagnostic Engineering: Autumn / Winter 2016

ISSN 0269-0225 No.193 Autumn / Winter 2016

THE JOURNAL OF THE SOCIETY OF DIAGNOSTIC ENGINEERS

Diagnostic Engineering

Resolve Through Knowledge


THE Two marks of assurance

For more information contact:

Bill Parker, Chief Executive Officer

Tel: 01924 821 000

e-mail: [email protected]

Accreditation Scheme

Benefits of Joining Your company will join a growing Partnership of independently audited goods

and service providers.

By successfully achieving Accredited status your company will be recognised as a provider of Excellence in Industry.

The AIP and / or the AEP logo can be used to promote your business throughout the full range of promotional material.

Free inclusion of your logo on the Institution web site, which is visited by a vast number of Diagnostic practitioners.

You will receive an authorised and embossed “Excellence in Industry” achievement certificate and commemorative award.

Your business partnership will be promoted throughout all of the Institutions activities.

The Society of Diagnostic Engineers supports and encourages the recognition of "Excellence in Industry". Its growing Membership of Accredited Partners are amongst the elite of Industry recognised providers of goods and services. With continuing education and development being a foundation stone of the Institution the groundbreaking developments of products and services by these partners and others are quickly communicated to our Membership through our journal and accessible web site.


Journals through the ages Front Cover

Accreditation Scheme Page 2

Chairman’s Message Page 3

Contact Details Page 4

Diary Dates

Minutes of meeting of the Page 5

Council 23rd November 2016

The Diagnosis of Steel Corrosion Page 6

and the Maintenance of Steelwork By Elliott Berry (Director) and

Jeffrey N. Casciani-Wood (President)

SDiagE Annual General Meeting Page 12 Royal Armouries, Leeds

Learning from the Past - Page 14

Director’s Article #1

Maps, Chaps, and Perhaps By Vice Chairman: Malcolm Hedley-Saw

Maintec 2017 Page 15

Learning from the Past - Page 16

Director’s Article #2

The Oldest Diagnostic Problem

in the World?

By Vice Chairman: Malcolm Hedley-Saw

On a lighter note …. Page 18

The Importance Of An Page 18

Occupation After Retirement

Accredited Partners Page 19

Industry News Page 19

Spot The Thinker Page 20

Chairman’s Message Contents

Chris Gilbert, MIOA, FIDiagE, Chairman

Welcome to the Autumn / Winter edition of your Journal, and the end of another year in trying and confusing economic and diplomatic conditions.

When you read on further, it will be obvious that the Society has turned around its financial status, from a large loss last year to a small profit this year. This is due in no small part to the efforts of our Chief Executive Office, Bill Parker, supported by Marilyn who continue to strive to make cutbacks and gain sponsorship so that we can continue operations. This enabled us to put on a well attended event at a prestigious venue for our 35th Anniversary. It was a pleasure to see members and guests enjoy the Royal Armouries in Leeds, even if it was interrupted by the warblings of a smoke detector which is apparently sensitive to grinding activities!

Nevertheless, with brief formal proceedings, an interactive audience, an engaging presentation on airborne and structureborne ultrasonic measuring instruments, and an excellent buffet, the whole day was seen as a resounding success.

Thanks to all who contributed to the day, all those who attended the event and of course the main event organiser - Bill & Marilyn again.

During the latest Council meetings, which again the abridged minutes can be viewed later on in the journal, there was an unexpected announcement that Steve Reed, ex-chairman, Technical Director and major contributor to the council proceedings and journal alike has decided to step down as Director and Council member. Steve has not only provided a lot of guidance to the Society over the years, but has been an inspiration and mentor for myself - Thank you Steve, your input will be sadly missed.

Following on from the meeting, a second resignation came in from Andy Garnor, who was also a Director and Treasurer of the Society for many years. Andy contributed to the journal with many snippets throughout the years, where we got to enjoy the funnier side of engineering, and humorous pictures and stories in abundance …. unfortunately, not all could be published!

So, this should be seen as an opportunity for any budding helpers to get more involved in the operations of the Society. We do not need the Director’s roles to be filled immediately, but we would like more input on the Council, particularly if younger Engineers / Diagnosticians and / or female members are interested in helping to drive our Society forward.

The roles can often open up new opportunities and experiences, ranging from visiting Innovative Companies to travelling overseas on behalf of the Society. If you are interested or want to know a bit more about the vacant positions, contact Bill who will be happy to have a chat.

All that remains to be said is I hope all our Employees, Directors and Members have a Happy & Healthy 2017.

Kind Regards,

Chris


Diagnostic Engineering Published by Council members & volunteers of the Institution of Diagnostic Engineers

Registered Office:

Collacott House 16 Thistlewood Road Outwood Wakefield West Yorkshire WF1 3HH

Tel: 44 (0) 1924 821 000

E-mail: [email protected]

Web: www.diagnosticengineers.org

President:

Eur.Ing Jeffrey Casciani-Wood, CEng, FRINA, HonMIIMS, FLLA, FIDiagE

Chairman:

Chris Gilbert MIOA, FIDiagE

Company Secretary / Treasurer:

Andy Garnor, FIDiagE (Elliott Berry, MIDiagE)

Vice Chairman:

Malcolm Hedley-Saw, MIDiagE, NDD(IndDes)

Council Members:

Steve Reed, MIDGTE, FIDiagE (Im. Past Chairman)

Elliott Berry, Dip.Mar.Sur., RMS., RMC., M.I.I.M.S., MIDiagE., A.M.C.M.S., AMRINA

Chief Executive Officer:

Bill Parker, FIDiagE

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

The views expressed by contributors are their own and are not necessarily those of the Council of Management of the Institution of Diagnostic Engineers. Whilst every care is taken to ensure that the contents of the Journal are accurate, we can accept no responsibility for these, or for the effects of errors or omission. We will of course investigate any complaints arsing from this publication.

The editor extends his cordial acknowledgement to owners of copyright. He endeavours to obtain permission whenever possible but sometimes illustrations or short excerpts may be published without formal consent (especially where material has been forwarded by members or obtained from the Internet).

Diary Dates

Diary Dates:

Contact Details


Minutes of the Council - 23rd

November 2016

Minutes of meeting of the Council of the Society of Diagnostic Engineers held at Acoustic Associates (Peterborough) on Wednesday 23

rd November 2016.

Present: Chris Gilbert, Bill Parker, Jeff Casciani-Wood, Steve Reed, Elliott Berry

Apologies: Andy Garnor, Malcolm Hedley-Saw (Assumed no contact received)

Minutes of the previous Meeting: Bill apologised that the minutes of the last meeting (05-07-16) had been lost. Chris agreed to use his notes to create some abridged minutes. Matters Arising: Item 4: The preparation of an action plan was still to be completed (Council/Chr is). Item 5: Bill had not claimed his expenses for the aborted trip to Oslo and Council agreed unanimously that he should. Executive Officers Report Bank Current balances 2015

Development Fund £78.71 (£78.65) Reserve £101.60 (£101.54) Diags £1919.47 (£3304.78) Renewals received for November = 15 No outstanding Bill’s Incorrect Amount = 7 AGM £442.00 Paid BACS Run 08-11-2016 = £1330.00 Insurance £224.59 Paid, BACS Fee Paid, Journal Print £275.00 Paid

Membership: Cur rent Membership 994 2 new awaiting documents BACS: Run for December projected income £800.00, BACS Membership fee £420.00 paid Savings Made: Mobile phone cancelled £35.00, Employee payment reduction (Salary & Tac & NI), ILEVE agreed to attend and con-

tribute £200, Attendance’s to be agreed at today’s meeting EFNMS: Attended meeting in Prague 20th to 23rd October, Flight £247.10 Accommodation £347.75 (Paid on my Credit Card), Membership fee approx. £1400 due April 2017, Euro maintenance 2020 application confirmed. WEB Site: Pages tidied up and Journal loaded 2015/16 Accounts: Council were fully aware of the er ror by the accountants with their fir st submission of the annual accounts. Bill

challenged this document and received an amended version. This version, with several gramma errors corrected, was accepted. Bill to arrange for final version to be completed and then acceptance to be confirmed by Council Email.

Matters Arising: Shall we be renewing the accountants contract was discussed. It was agreed that we would wait to see their bill be-

fore deciding. Diploma in Diagnostic Engineering Ltd has been dormant for quite several years. It was agreed this company should be struck off. Bill to arrange.

Journals 2016/17: Chris advised that obtaining suitable mater ial for the Journal is a major struggle and the latest issue (193) is incom-

plete due to lack of material. Jeff/Elliott agreed to provide an article for this issue which may be suitable for splitting into two parts. It was also agreed that Bill would provide Chris with the minutes of the AGM for inclusion in current issue.

EFNMS: Bill gave a summary of his impressions of the EFNMS general assembly meeting in Prague. Although restr icted cash flow did

not permit funds to be available to finance this visit Bill had considered attendance important and funded the trip himself. Council did not condone this action but were appreciative of Bill’s commitment. Council agreed to reimburse Bill when funds permitted. Member-ship, or not, of EFNMS will need to be fully discussed prior to making a bid for the 2020 Euro maintenance conference.

MAINTEC 2017: With this annual event being taken over by Western Business Exhibitions, Bill was unsure if a contra agreement

would be forthcoming so had waited before making any arrangements. Bill advised Council he has received a phone call the day previ-ous with a verbal offer of the same arrangements that were received from Easifairs. Council agreed that Diags should attend the 2017 event, subject to receiving a satisfactory agreement in writing.

HMCA (Mark Upton): Bill introduced Mark and explained he had been in discussion with Mark and other colleagues recently with

the view of developing an insurance based members benefit package. Mark’s presentation was detailed and Council expressed interest and asked Bill & Mark to continue in its development.

AOB: The meeting concluded with a final round of any other business. At this point, Steve advised Council of his wish to resign. H e

formally presented a resignation letter. Chris acknowledged, with regret, and thanked Steve for his many years of service. Council agreed that Steve’s commitment during time served should be recognised and agreed Steve be awarded a Honorary Fellowship. Bill was tasked with providing suitable certification.

The forthcoming change to UK pension regulations was discussed. Chris advised he had undergone compliance with the help of NEST

pensions and advised Bill to follow this route. Discussion took place regarding arranging a “Christmas Do”. Bill recommended the Royal Armoires Legends event but availability of

Council members and suitable dates were not compatible. It was agreed that Bill would look for a suitable date and location in January. It was agreed that the next meeting would take place at Collacott House on Wednesday the 18th of January.


The Diagnosis of Steel Corrosion and the Maintenance of Steelwork


By Elliott Berry (Director) and Jeffrey N. Casciani-Wood (President)

It is a common engineering experience that steel structures corrode and that such corrosion is, by nature, electro-chemical in

origin. A careful examination of the metal’s surface will show that the corrosion usually takes one of two general forms: -

1. General rusting of which there are consecutively worsening five types ranging in severity from wüstite to magnetite.

2. Pitting.

To understand both corrosion and cathodic protection, it is first necessary understand how corrosion is caused. For the defect to

occur, three things must be present: -

1. Two dissimilar metals.

2. An electrolyte (commonly water with any type of pollution, salt or salts dissolved in it).

3. A conducting path usually a metal between the dissimilar metals.

The two dissimilar metals may be totally different alloys – such as steel and aluminium alloy – but are more likely to be

microscopic or macroscopic metallurgical differences on the surface of a single piece of metal. In the latter case, we will

consider freely non-uniform corroding steel.

If the above conditions exist, the following reaction takes place at the more active sites: (two iron ions plus four free electrons).

2Fe => 2Fe++ + 4e-

The free electrons travel through the metal path to the less active sites, where the following reaction takes place: (oxygen gas is

converted to oxygen ion - by combining with the four free electrons - which combines with water to form hydroxyl ions).

O2 + 4e- + 2H20 => 4OH-

Recombination of these ions at the active surface produce the following reaction, which yields the iron corrosion product: (iron

combining with oxygen and water to form ferrous hydroxide).

2Fe + O2 + 2H2O => 2Fe(OH)2

This reaction is more commonly described as 'current flow through the electrolyte from the anode (more active site) to the

cathode (less active site)’ which results in the observed defects of general rust or pitting. General rust may take one of five

progressively worsening forms starting with wüstite or, most commonly, geothite (a light brown powder) and, at its worst,

magnetite which is black and lustrous - all of which require the presence of oxygen and moisture in order to form.

Wüstite requires very arid conditions in which to form and is rarely found on ordinary engineering structures. It is not, strictly,

rust and, for the purposes of this paper, may be ignored.

Pitting is largely galvanic in origin.

All types of corrosion are caused by the passage of a small magnitude direct electric current the components of which follows

Ohm’s law.



When a piece of copper and a piece of mild steel are placed in a container full of a liquid (called the electrolyte) nothing happens. If, however, the two are connected together electrically, then both are called collectively electrodes and a current which can be measured by an ammeter then flows through the connection. To complete the circuit, a flow of negative ions takes place from the mild steel (called the anode) to the copper (called the cathode). That results in the mild steel becoming pitted. That process was discovered by Galvani in the 18th century and named after him. The pits are roughly circular in area, conical in section with a depth/diameter ratio of approximately unity. The principle of the process is illustrated in the Figure 2 above. Since the grains that make up steel are 75% ferrite and 25% various carbides and the latter are cathodic to the ferrite, which means that mild steel suffers surface pitting when placed in a suitable electrolyte due to such galvanic action. A similar process underlies ordinary rusting.

There are two actions that the diagnostic or maintenance engineer can undertake to minimise deterioration due to either rusting or pitting. The first is to cover the surface of the metal with a suitable paint or other coating properly applied and maintained. That will not be discussed in this paper. The second is to fix to the surface of the metal blocks of a suitable material called sacrificial anodes to corrode away instead of the main metal from which the structure is manufactured. That method is properly called cathodic protection and its design is frequently assumed to be something of a black art.

The first practical use of cathodic protection is generally credited to Sir Humphrey Davy in the 1820s. Davy’s advice was sought by the Royal Navy in investigating the corrosion of copper sheathing used for cladding the hulls of wooden naval vessels to protect them from the ravages of the ship worm. Davy found that he could preserve copper in sea water by the attachment of small quantities of iron or zinc whereupon the copper became, as Davy put it, “cathodically protected”. The method is as equally applicable to underground piping as it is to the hulls of ships and the maintenance engineer should understand its use.

How does cathodic protection stop corrosion?

Cathodic protection prevents corrosion by converting all the anodic (active) sites on the metal surface to cathodic (passive) sites by supplying electrical current (or free electrons) from an alternate source. Usually this takes the form of attached blocks of metal called anodes, which are more active than steel. This practice is also referred to as a sacrificial system, since the anodes sacrifice themselves to protect the structural steel from corrosion.

http://www.stoprust.com/sacrificial-anodes.htm




In the case of aluminium alloy anodes, the reaction at the aluminium surface is: (four aluminium ions plus twelve free electrons): -

4Al => 4AL+++ + 12 e-

and at the steel surface: (oxygen gas converted to oxygen ions which combine with water to form hydroxyl ions): -

3O2 + 12e- + 6H20 => 12OH-

As long as the current of free electrons arrives at the cathode (steel) faster than oxygen is arriving, no corrosion will occur. The electrical current that an anode discharges is controlled by Ohm's law as stated above.

Ohm’s Law

Georg Simon Ohm (16th March, 1789 – 6th July, 1854) did his work on resistance in the years 1825 and 1826, and published his results in 1827 as the book Die galvanische Kette, mathematisch bearbeitet (The galvanic circuit investigated mathematically). His work is summed up in the simple equation: -

V = IR volts (1)

where

V = electrical pressure in volts

I = current in amperes

R = resistance in ohms

The relationship is illustrated in Figure 2 which is sufficient for the present purposes. By covering the variable that it is required to know, the figure will reveal the arithmetic required. Ohm’s law is sometimes written E = IR, E standing for the voltage V as above. The voltage is the algebraic difference in potential between the anode and cathode and is measured in volts.

Initially, the current will be high because the difference in potential between the anode and cathode are high but, as the potential difference decreases due to the effect of the current flow onto the cathode, it gradually decreases due to polarization of the cathode. The circuit resistance includes both the path through the electrolyte and that through the metal and includes any cable in the circuit. The dominant factor here is the resistance of the anode to the electrolyte.

For most applications, the metal resistance is so small compared to that of the electrolyte that it can be ignored (although that is not true for long pipelines protected from both ends). In general, long, thin anodes have lower resistance than short, fat anodes and will discharge more current but not last as long. Therefore, a cathodic-protection system designer must recommend anodes that they have both the right shape and surface area to discharge enough current to protect the structure and enough weight (mass) to last the desired lifetime when discharging this current.

As a general rule of thumb: -

The weight of the anode determines how much current it can produce and, consequently, how many square metres area of the structure can be protected.

Galvanic corrosion - often misnamed electrolysis - is one common form of corrosion in marine environments. It occurs when two (or more) dissimilar metals are brought into electrical contact under water. When a galvanic couple forms, one of the metals in the couple becomes the anode and corrodes faster than it would all by itself, while the other becomes the cathode and corrodes slower than it would alone.

Either (or both) metal in the couple may or may not corrode by itself (themselves) in seawater. When contact with a dissimilar metal is made, however, the self corrosion rates will change: corrosion of the anode will accelerate; corrosion of the cathode will decelerate or even stop.




The choice of material depends upon the position of the metals concerned in what is known as the galvanic series. For information, the galvanic series is given in the table below. It is a list of metals and alloys ranked in order of their tendency to corrode in marine environments.

Metals at the top of the scale are called noble and those at the bottom base. The galvanic series can be used to predict which metal will become the anode and how rapidly it will corrode. If any two metals from the list are coupled together, the one closer to the anodic (or active) end of the series, the upper end in this case, will be the anode and thus will corrode faster, while the one toward the cathodic (or noble) end will corrode slower. For example, suppose an aluminium alloy with a voltage range of -0.7 to -0.9 V (an average of -0.8 V) as shown on the series, is coupled to a 300 series stainless steel with an average voltage of -0.07 V.

The galvanic series predicts that aluminium alloy will be the anode, and that the voltage difference between the two alloys will be about 0.73 V (obtained by algebraically adding the two average voltages). It is that voltage difference that drives the current flow to cause and accelerate corrosion of the anodic metal.

The two major factors affecting the severity of galvanic corrosion are: -

the voltage difference between the two metals on the galvanic series (see Table 1 below).

the size of the exposed area of cathodic metal relative to that of the anodic metal.

Corrosion of the anodic metal is both more rapid and more damaging as the voltage difference increases and as the cathode area increases relative to the anode area. The approximate voltage difference for any two metals can be taken directly from the table. It is worth noting that marine slime films composed primarily of microscopic bacteria and diatoms can change the potentials of many of the alloys near the noble end of the galvanic series as indicated.

The potentials of these alloys become more positive in the presence of slime films thus increasing the voltage difference when these metals are placed in contact with more anodic alloys. This has been found to increase the corrosion rate of copper, steel and aluminium anodes by a factor of 2 to 5 but to have no effect on the corrosion rate of zinc anodes. A slime film may also change which metal in the couple becomes the anode.

In a marine situation, when the two metals in a galvanic couple are close together on the series, such as manganese bronze and silicon bronze, their voltage ranges overlap and either one can be the anode, depending on the exact exposure conditions. In this case, more detailed information would be needed to predict the behaviour of the couple. The effect of the second factor above, the cathode to anode area ratio (RC/A) is illustrated by the example of a rivet in a plate. In the first situation the rivet is of aluminium alloy and is comparatively small and the plate of stainless steel and the RC/A ratio is large. In the second the situation is reversed: the stainless steel rivet is small and the RC/A ratio is also small.



In both, the aluminium alloy is the anode and stainless steel is the cathode. Corrosion of the aluminium alloy rivet in the first arrangement would be severe. However, corrosion of the large aluminium plate in the second arrangement would be much less even though the potential difference is the same in each case. The cathodic member of the couple is one of those alloys identified as being influenced by slime films and, if there is a reason not to paint, periodic cleaning of the bare metal surface can minimize the effect of the slime and reduce the corrosion rate of the anode. Periodic cleaning is not recommended for reducing galvanic corrosion of other alloys because removal of corrosion product films from those metals usually increases corrosion rates.

Whenever the vessel is slipped, the existing anodes should be wire brushed back to bright metal and then coated with soft soap before painting the hull. Any paint accidentally applied to the anodes will then wash off with the soft soap when the vessel is placed in the water. If it is necessary at some time for the vessel to change from a salt to a fresh water environment or vice versa then it should be borne in mind that this will have a deleterious effect on the anodes fitted. Magnesium or aluminium anodes (which are suitable for fresh water) have a much higher driving potential than anodes manufactured from zinc. If a vessel fitted with magnesium or aluminium anodes passes into salt water for anything longer than about seven days, the anodes will waste away very quickly.

Vessels, which are, fitted with magnesium or aluminium alloy anodes moving into a salt water environment for longer than a week, should therefore be fitted with a replacement zinc anodic system. Conversely vessels fitted with zinc anodes (suitable for use in salt water) will find over a period exceeding about seven days that the metal will be coated with an impervious off-white crust of zinc salt which will very effectively prevent it working even when returned to salt water.

After any trip into a fresh water environment a vessel fitted with zinc anodes should have these thoroughly scaled clean back to bright metal. If proceeding into fresh water for longer than about seven days a vessel should be fitted with replacement magnesium or aluminium anodes.

Over Protection

The issue of under protection is, of course, well understood. Put simply, too little protection results in corrosion while too much results in inter alia loss of paint coats and eventually corrosion. Thus, the maintenance engineer should also be aware that it is possible to put too many anodes on a given structure, a danger which is called over-protection. That occurs when the sacrificial anodes generate a current higher than necessary to

protect the more noble metallic fittings. Common issues on metal structures given over protection include: -

Paint stripping – This is the hydrogen blistering of paint and occurs because of the destruction of the adhesion between the coating and underlying metal to which it has been applied. The defect can be often seen near where sacrificial anodes are attached to steel structures. The process often results in local blistering of the paint coat near the anodes and is often referred to as cathodic disbondment. It is sometimes mistaken as osmotic blistering.

Biological Growth – Excessive cathodic protection accelerates the formation of calcareous deposits on a structure.

Alkali Attack – This can also arise as a result of excessive cathodic protection systems and can lead to the formation of alkaline conditions on metal when there is insufficient flow of water to return the water to its natural pH, resulting in accelerated corrosion.

Photograph 1: Galvanic pitting on the side of a tank in fresh water.



This can be accentuated as the paint blisters to create an even more alkaline condition and further lead to rapid deterioration of the submerged or buried metal.

Embrittlement and Metal Blistering - Studies have also shown that the metal-hydrogen interaction which is effected by the entry of hydrogen into the interstices within the metal’s crystal structure by the over protection potentials may significantly influence the strength behaviour of mild steel by the influence of the hydrogen on the rate of increase of lattice dislocation multiplication i.e. the metal tends to become brittle. Ductility may be retained if the potential does not exceed -900 mV. In wrought iron, the hydrogen tends to collect inside the metal causing metal blistering near the anodes.

Anode Calculations.

The surface area of the hull and anode determines the amount of protection given. The voltages of all metals will vary depending on the salinity of the electrolyte and the total weight of anodic material determines the useful life of the protection system. It is common to use the standard formula for sea water immersion: -

Total weight of anodic material required to give this amperage is calculated from

WA = A x Y x 8760 (2)

C

Where

WA = Weight of required anodic material in kg

Y = Required life in years in Y

8760 = Number of hours in one standard year in h

C = Capacity of Anodic Material in ah/kg

= 780 for zinc, = 2700 for aluminium, = 2000 for magnesium

The area to be protected is simply calculated from its overall dimensions.

Required current amperage is calculated from

A = SA x CD/1000 in Amps (3)

where

SA = Surface area in m²

CD =Current Density 10 – 30 generally about 20 mA/m²

It is generally recognised that it is good practice to place the anode(s) at a point where it or they can 'see' the item it is or they are protecting. The anodes are generally reckoned to have a working range of about 5 metres (15 feet) and should be so spaced to include that idea.

Photograph 2: An anode corroding and gas-sing off as a result of over protection

Photograph 3: Corrosion of the inside of a steel tank due to over protection


SDiagE Annual General Meeting - Royal Armouries, Leeds

The 19th Annual General Meeting of the Society of Diagnostic Engineers

took place at the Royal Armouries, Leeds on the 5th of October 2016.

What follows is a concise record of the minutes.

Bill Parker opened the meeting with a welcome to the 11 Members attending and advised he had received 27 apologies.

The minutes of the last AGM were accepted with no matters arising.

Bill then handed over to Chris Gilbert for his Chairman’s report—see facing page

for the full report)

Returning to the formal structure of the meeting Elliott Berry presented the

Directors report and financial statement. On completion questions were taken and

the accounts were accepted by all members present.

The Profit & Loss Account as well as Balance Sheet are shown below:

Following our executive officers report Bill advised that due to a current review of our accountants no formal resolution 1 was being

tabled. In previous years Resolution 2 involved the members of Council of Management who were due for re-election and still willing

to continue in this role. This year no member of Council was due re-election so no resolution was presented.

With a beautiful hot & cold buffet lunch served the preceding

were unexpectedly interrupted. A tannoy announcement “Will

the blacksmith please report to reception” our event manager

quickly clarified this was a code to evacuate the building. Our

members and guests were escorted from the building.

Following a short delay the “All Clear” was announced and we

returned to conclude lunch.

Without any complaint arising our Members & guests

previously chosen hot buffet items were quickly removed and

replaced with fresh hot produce.

The meeting was concluded with a “seasonal” Chairman’s closing statement.

Following the interrupted buffet lunch and closing statement a demonstration of Ultrasonic

leak detection, mechanical analysis and electrical inspection equipment entertained all

participants.

Our thanks go to Chris Hallum www.uesystems.com

http://www.uesystems.com/


SDiagE Annual General Meeting - Royal Armouries, Leeds

Chairman’s Report: Chris Gilbert MIOA, FIDiagE

With my fifth year as Chairman, of the now more commonly referred to Society of Diagnostic Engineers, we finally

appeared to have turned the corner of draining our financial reserves. This has been due to our CEO’s diligence and the

Director’s willingness to make changes in order to make ends meet in an extremely small and difficult members

market.

Operating the Society on the required charitable breakeven basis still remains a challenge, and we would like to

encourage all members to get more involved in the promotion of the Society, and go on a recruitment drive – this is as

simple as suggesting that a colleague contacts us to see how membership could benefit their knowledge base, their credibility and their

contacts within the fields of Diagnostic Engineering and Maintenance industries. It is still worth mentioning that any funds raised over and

above our meagre operating costs are (and have to be by law) invested into the membership. The more we have, the more we can invest in

training, events, meetings and educational needs of the membership and wider community, for example young engineers or sponsored

placements etc.

Your Institution has again been involved in European discussions aimed at leading the way in Maintenance related issues, and is considering

the option of hosting a major event in the UK on behalf of the European Federation of National Maintenance Societies – keep an eye out for

announcements. We are also continuing with face to face meetings and discussions with likeminded organisations, to not only boost our

membership, but to make available the wealth of experience and knowledge contained within our own ranks.

Our journal continues to be one of the main interfaces with members, and has contained such diverse subjects as our own Steve Reed’s

(Technical Director) 3D Printing Demonstration, Microbial Attack on Iron and Steel by Director Elliott Berry (Director of SDiagE), a forensic

story associated with the damaged sea wall at Dover and the history published by Costain & Network Rail, with even a glimpse into

Mechanical Diagnosis through Ultrasound Imaging by Gary Rees of UE Systems.

I would once again like to thank the Directors for their ongoing efforts in supporting the Society, for supplying articles for the Journal and

would also like to single out the work of our prestigious President (Jeffery Cascani-Wood) and Technical Director (Steve Reed), both of whom

provide a wealth of knowledge and information regularly reproduced in the journal.

Finally, and the biggest thanks of all goes to Bill Parker, our intrepid CEO, who not only arranges and facilitates all the meetings, but tries to round up the Director’s and guide them on their way. We should not forget the help and “guidance” from his wife Marilyn and the help of Bill’s son Liam throughout the year – it’s a true team effort.

At the end of the formal proceedings, a few thanks and trophies were handed out for events going on throughout the year. Shown on the left is the Stuart Reed Memorial Trophy awarded to Neal Gilbert for apparently winning the annual fishing match.

Both before and after the AGM, the halls of The Royal Armouries were open to all visitors. All attendees expressed their appreciation of the location and the wonderful exhibits contained in this gem of a museum.

A few snapshots of the “serious” nature of Diagnostic Engineers, and invited guests are shown below, and gives an insight into the goings on at such a seemingly boring event!

Thanks to all who attended - a good day was had by all. Retired Director Roy Pettitt as

you’ve never seen him before

The attendees assemble outside during the evacuation One of the groups enjoying the exhibits, and camera!


Learning from the Past - Director’s Article #1

By Vice Chairman: Malcolm Hedley-Saw MIDiagE

Maps, Chaps, and Perhaps

Some years ago I ventured into print in the Journal, on puzzling details of the structural failure of the

Titanic, and her supposedly improved sister ship the Britannic, which sunk in short order after hitting a mine

in the Eastern Mediterranean during WW1: goaded into it by some of the fatuous inaccuracies peddled on

TV around that time. What caught my eye were the long horizontal failures, like they came un-zipped

horizontally, as the rivets failed. What caught my attention was my coincident struggle to fit into the back of a small hatchback

a large sheet of resilient plastic, entailing rolling it up into a coil, held against it’s will with a rope. What impressed me, simple

soul that I am, was the extreme flexibility along its axis compared with the curve of the other axis: obvious really.

I bow to the superior knowledge of our revered chairman Jeffery who disagreed, but who failed to rise to my suggestion that he

go into print refuting my theory.

Prompting these thoughts of yesteryear was a book I picked up recently by Chapman Pincher, in his time acknowledged as the

best investigative journalist specialising in security matters (A heaven sent name, with only one other career option). It said it

was a novel: a political novel, totally convincing, about the loss of a Polaris submarine. It turned out to be the most

fascinating and enigmatic book I have read, not least because while its published and copyright date was 1970, it dealt in as

exact detail as I recall, matters ten years in the future! The context was East – West machinations leading up to the final,

successful Strategic Arms Limitation Talks, finally signed by Reagan and Gorbachov in Reykjavik in 1986!

Pincher’s cynical but wholly realistic view of the machinations of top politicians left me confused as to what did or did not

really happen. Was it presented as a novel to avoid the tentacles of the Official Secrets Act? Although published forty six

years ago, it is still apposite today, with all the ‘do we don’t we?’ over the next generation of Trident, in the game of cat and

mouse that continues every day, under the waves. Not to mention Putin’s renewed attitudes of aggression.

But to return to matters speculative and diagnostic: I am one of those anoraks who questions technical details. In this case, the

implosion of a submarine below its collapse depth. Surely, it would not as described, leave components scattered about the sea

floor, as did the Titanic and other wrecks surveyed at great depths. Pressure hull collapse comes back to having similarities to

the damage to the Titanic and Britannic, bearing in mind that the pressure hull consists of a long tube tapering to hemispherical

ends. Would such a skilfully constructed vessel survive until it collapsed in a longitudinal catastrophic manner, or would a

potentially weak area like the torpedo tube covers of a hunter killer, fail first? The end for the crew would be mercifully swift

due to instant pressurising of the interior. Bereft of any remaining buoyancy it would plunge on, downwards, but I doubt

whether anything would fall off.

Returning to my hobbyhorse, having checked in my Machinery’s handbook and BS 308 Workshop Handbook, diagrams

showing how correct pitching of rivets make the joints stronger than the plates themselves, analogous to the design of the

frames to cargo doors on aircraft, which are made to be stronger than the uninterrupted shape of the fuselage.

This is all good stuff, but I suspect nobody considered the effect of

overwhelming force, because – there is no answer.

Like for example, designers don’t consider attempting to design a crash

resistant fuselage. In a passing irony, if no one had seen the iceberg, and it had

collided fair and square head on, The Titanic might have survived, although

injuries from broken bones would have been considerable. An admittedly

smaller vessel collided head on and survived to make harbour.

Am I right, Jeffery? Answers: not on a postcard, but in other contributions

please.

As a scientist said at the end of Pincher’s book, when pushed for a simplistic

answer by the PM, to a complicated question: ‘if geography is about maps, and

history is about chaps, science is about perhaps.’

The penthouse Conspirators. Chapman Pincher. Published by Michael Joseph

1970.

No Isbn, but with a number: 7181 0703 9

https://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwi3tPrq-oDRAhUGwBQKHXKsAf8QjRwIBw&url=https%3A%2F%2Fbuckinghambooks.com%2Fbook%2Fthe-penthouse-conspirators%2F&psig=AFQjCNGIj2SJM9FJslKsbNjZQYiiL4pA-A&ust=148226


Maintec 2017

Prioritise your visit to Maintec 2017

Whether your business covers multiple sites or is focussed in a particular region of the U.K., no venue can compete with Birmingham's NEC for accessibility. Situated at the heart of our transport networks no venue is better connected, which is why the NEC is the obvious choice when we bring the MRO community together in March. New for 2017 We know just how valuable your time is and are therefore committed to the continuous improvement of the educational content we provide. Our range of conference and seminar topics is designed to inspire you to be heard and affect real workplace enhance-ment. Delivered by engaging and thought provoking individual speakers as well as carefully created expert panels, we provide the chance to exceed your CPD requirements without any delegate fees - entry is free to qualifying professionals who register online in advance. Maintec is strategically co-located with 3 complementary exhibitions, all organised by the same team: The Health & Safety Event; The Fire Safety Event; Facilities Management With access to over 400 exhibitors and no fewer than 8 focused educational theatres, these events combine to provide your Maintenance, FM,

Safety, and Security teams with direct access to a compelling, entertaining and valuable visiting experience.

Tuesday 21st March

Wednesday 22nd March

Thursday 23rd March


Learning from the Past - Director’s Article #2

By Vice Chairman: Malcolm Hedley-Saw MIDiagE

The Oldest Diagnostic Problem in the World?

Pitch-forked forty years ago into making potters wheels due to an urgent need for solvency, I remained

ignorant of their history, until asked by a museum to make a working replica of a Roman potters wheel.

‘Thank you. Where’s the data?’ ‘ There is none.’ The bad news, and the good news.

Despite the thousands of tons of Roman pottery lurking in the vaults of Europe’s museums, there is no

complete record of a wheel!

Conclusions 1. They must gave been made entirely of wood, which has rotted away. 2. Whatever result I

came up with, ‘experts’ couldn’t challenge me. For, like the one eyed man in the kingdom of the blind, I

was king. In the world of Potters wheels – I was king.

The only data they could come up with was some sketches of iron shafts, believed

to have been shafts for potters wheels, from far away Austria and, that the wheels

rotated anti – clockwise. You can tell by the throwing rings found, especially

inside. Good: that told me that the wheel consisted of a flywheel of some sort that

was kicked around by the right foot ( most people are right footed as well as right

handed). In other parts of the world wheels rotate clockwise (e.g. pulled around

by hand or stick), giving rise to a situation not unlike which side of the road you

drive (but not as dangerous!)

This sea of ignorance prompted more research than was strictly necessary,

becoming more interesting the deeper I delved. And caused me to define the

basic requirements for throwing. All that is required is a disc (called the wheel

head) firmly fixed to a shaft having a bearing at either end. These bearings need to have little lateral movement. Thus the shorter

the shaft, the more accurate the bearings have to be. What isn’t required is surprising: the wheel head doesn’t have to be flat (or

even round), or the shaft straight. Not that you can tell the public this.

By an extraordinary coincidence my partner had in her possession a five volume set of elegantly leather bound books dating

back to the eighteen fifties detailing an archaeological dig of a Roman settlement in which the only recorded Roman wheel was

discovered. Of no interest to the gentlemen treasure hunter author, the only data he’d recorded was the wheel head was fourteen

inches in diameter, and made from Kimmeridge shale, a sort of compressed, machine-able coal found in Dorset ( and in parts of

the east Coast of Scotland).

By the time the Romans arrived woodworking technology included most of the tools that would have been familiar, to the 19 th c

carpenter plus one with which we are more familiar today: the pole lathe (If you go to country fairs).

I also knew that the Romans, or more likely the native Brits, used half and half joints, and pegged them together with oak dowels

up to about ¾ inch size, or 20 mm. Oak would have been the preferred material, as it was cultivated into straight grown timbers

for house building and engineering jobs. Thus, armed with a kids’ ruler calibrated in Roman inches, I designed a simple frame,

including a rudimentary seat. Throughout history, potters made enough money to have an assistant turn the wheel (until William

Morris and co, in the 19th c, gentrified it, sometime after Wedgwood’s’ mechanised it) So, in my design, the potter had an

assistant sitting facing. It was pure speculation.

Now we come to the flywheel. Probably made of an assemblage of square

section oak stakes laid closely side by side, over another layer, at right

angles, trimmed in to a flat cylindrical form, held together by oak pegs.

Quite a lot of work: I cheated. Working closely with the co-operative owner

of a timber yard who supplied green oak, owner of an enormous band-saw,

he sawed out a one piece disc about nine hundred mm. diameter, and a

hundred thick. ( 35 ½ X 4 ins)

All oak was worked green up to recent times (except for ship building), in no

small way accounting for the grotesque distortions in timber framed

buildings.

The parts were finished in the traditional way, using a coopers’ adze.

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiJxJmB_IDRAhXCuBQKHWBFDvcQjRwIBw&url=http%3A%2F%2Fpottedhistory.blogspot.com%2F2010_04_01_archive.html&psig=AFQjCNEkPhWHQtcossP4cAHi7hoDhvnEmg&ust=14822613480179

https://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwig3-zL_IDRAhWMWRQKHU8WCfcQjRwIBw&url=https%3A%2F%2Fwww.pinterest.com%2Fdarkjewelsvault%2Fportable-kick-wheel%2F&psig=AFQjCNEkPhWHQtcossP4cAHi7hoDhvnEmg&ust=1482

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwjSqISX_YDRAhUEbxQKHUbEB_4QjRwIBw&url=http%3A%2F%2Fwww.larsdatter.com%2Fpotters.htm&psig=AFQjCNEkPhWHQtcossP4cAHi7hoDhvnEmg&ust=1482261348017988


Learning from the Past - Director’s Article #2 - continued

It is better to be born lucky than rich – so it is said, personally, having no experience of the latter. I had been asked, not long

before, to make two identical momentum wheels for a potter and his wife. We are talking about simple devices you kick up to

speed and use the momentum of the flywheel to do the work.

The ubiquitous crank was never used in antiquity. It didn’t become popular until rotating

beam engines were a common sight, spawning many other inventions, including treadle

potters’ wheels, and the bicycle.

I went for a heavy flywheel taking a guess that commercial minded Roman potters (pottery

in the Roman world equated in importance to say, the automobile industry today), would

choose a flywheel heavy enough to last one cycle for the largest pot they made. Exploiting

the happy coincidence that, unlike a car, you start at max speed and go slower and slower.

Where my luck came in, of the two identical wheels, one worked perfectly, while the other threw lop sided pots. My method of

making a flywheel is two chipboard discs (about 840 mm - 33ins diameter), sandwiching twenty bricks, arranged radially

(removing 2 at a time, achieves a lighter flywheel without upsetting the balance).

With the main bearing located under the wheel, with a 25 mm steel shaft passing through. The first one I made had a loose

fitting hole through the top disc. Amazingly, this was the one running perfectly. A minute’s reflection in his garden shed, and

twenty minutes’ work enlarging the tighter one, solved a problem that has plagued potters for at least two thousand years. When

considering how to join a massive flywheel weighing say 90 kilos (200 lbs), it is natural to fit it securely, equals rigidly, to the

shaft. What nobody understood was that it s all but impossible to fix the shaft at precisely ninety degrees to the lateral centre of

gravity of a large, not very regular (but statically balanced) rotating mass. I had accidentally solved a problem I was unaware of,

stumbling upon the ready made solution. You simply allow the mass a little up and down but not radial movement, separating

the means of driving it. The iron shafts were probably an attempt to solve the problem by brute force. It all made sense.

As the maths of dynamic balance weren’t resolved until the nineteen twenties, in furthering the illusion of authenticity, I had a

problem. My solution was four wedges at the junction between the wheel head shaft and the flywheel, enabling very delicate

angular adjustment – by trial and error. I have no idea whether it was ever done, because it demonstrated an understanding of the

problem. This struck me as the least incredible option.

My offering turned out to be very successful, not least because of advice on the bearings from a very old millwright. Embedded

in the end of the shaft was a dowel of fruitwood, having a rounded end, located in a complementary hole in the member

underneath. I tried lubricating with beeswax. The stiction effect was – awesome, I added Bacon fat ( The Romans loved pork).

Great improvement. Finally, a drop or two of olive oil. Hey presto! An all wood plain bearing that I estimate was over ninety

percent efficient as a modern ball bearing.

However, as I delved deeper, I came to a rather perverse conclusion. For areas where the water table was lower than three feet,

say a metre deep, it was customary to dig a hole fitted with a central wooden pile to support the flywheel, and bury a stout beam

across the hole near the surface to hold the wheel head securely.

The one thing they wouldn’t allow me was to excavate a large hole – in the museum’s floor!

To sum up: for a lifetime’s work, I have achieved zilch that will outlive me – except solving the longest

undiagnosed problem – in the World!

Anything older, I would be pleased to hear about.

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwilsJCp_4DRAhXOERQKHWCMCvwQjRwIBw&url=http%3A%2F%2Fm.ebay.com%2Fitm%3FitemId%3D111510503880&bvm=bv.142059868,d.ZGg&psig=AFQjCNGHWSaWRLT3tckzXjhC4KLb4YOj7w&ust=148

http://www.google.co.uk/url?sa=i&rct=j&q=&esrc=s&source=images&cd=&cad=rja&uact=8&ved=0ahUKEwiXio3m_4DRAhVBWRQKHTDHD_0QjRwIBw&url=http%3A%2F%2Fgetting2themythofit.blogspot.com%2F2012%2F06%2Ffather-time-is-mythical-character-that.html&bvm=bv.142059868,d.Z


On a lighter note …..

This engine is as supplied so I am not able to take credit for either the design or construction. A stirling engine having eight Hot Expansion Cylinders and eight Cold Contraction Cylinders this linear motion cleverly converted to rotary motion to drive the propellor shaft. Open frame construction allows visual inspection of this feature and all other aspects of this clever design are clearly visible.

Starting with the fuel supply a small plastic container of liquid butane feeds the eight branch manifold from where individual gas nozzles direct the ignited gas flame to the ends of the eight hot cylinders expansion occurs of the air within the cylinders creating linear motion of the connecting rod. Air transfer occurs via the copper pipes and contraction occurs in the cold cylinders due to the difference in temperature. This design uses the mass of surrounding aluminium as a heat sink when running the temperature of the cold cylinders are further cooled by the driven propeller.

Truly an amazing little "toy" fascinating to watch running and all credit to the designers. It came with two spare burner nozzles which create a good mix for that complete combustion devoid of a red or yellow flame.

The only thing for me to do now is to create a fully working instrument panel comprising propeller speed and attach thermocouples on all sixteen cylinders to display temperatures and cycle differential temperatures. The other little add ons maybe an auxiliary drive for a small generator powering up a few leds and piezo electric ignition. Jobs for winter evenings so watch this space.

The Importance Of An Occupation After Retirement

As we get older we sometimes begin to doubt our ability to "Make a difference" in the world. It is at these times that our hopes are boosted by the remarkable achievements of other "Seniors" who have found the courage to take on challenges that would make many of us wither.

Harold Schlumberg is such a person:

THIS IS QUOTED FROM HAROLD:

"I've often been asked, 'What do you do now that you're retired?'

Well...I'm fortunate to have an engineering background and one of the things I enjoy most is converting beer, wine and whiskey into urine. It's rewarding, uplifting, satisfying and fulfilling. I do it every day and I really enjoy it."

Harold Is An Inspiration To Us All.


SDiagE Partners

Acoustic Associates Peterborough 111 Spalding Road Deeping St. James Peterborough PE6 8SD Tel: +44 (0)1733 89 63 46 www.aapb.co.uk

Artesis St John's Innovation Centre Cowley Road, Cambridge, CB4 0WS www.artesis.com

Thermascan Ltd

21 Brunel Road Barkers Lane Industrial Estate Bedford MK41 9TQ

Castle Group

Salter Road Scarborough Business Park Scarborough North Yorkshire YO11 3UZ Tel: +44 (0) 1723 584 250 www.castlegroup.co.uk

MFH Engineering (Holdings) Ltd Charlotte House 500 Charlotte Road Sheffield England S2 4ER Tel: (0114) 279 9999 www.mfhgroup.co.uk

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We got a mention in the following:-


Spot the Thinker

Bill Parker, Chief Executive Officer, Tel: 01924 821 000 or e-mail: [email protected]

This issues spot the thinker is a far out photo

of an astronaut working on the space

station. With Major Tim Peake

featuring so much this year

with his momentous visit to the

International Space Station, I

thought we’d pay our

humble tribute to space

exploration!

So, can you spot the two

thinkers strategically

hidden.

As usual, a plea on behalf of your journal team, if you have a suitable photo for the thinker to hide in, preferably directly or

tenuously linked to Diagnostic or Maintenance Engineering, then send it in and you may get it published. Don’t forget to

reference the source if its not yours, then we can reprint it without any legal issues.

ISSN 0269 0225 No.193 Autumn / Winter 2016 Diagnostic ...

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Transcript of ISSN 0269 0225 No.193 Autumn / Winter 2016 Diagnostic ...