engineering maintenance solutions feb 2012

February 2012

MAINTEC 2012 the premier event for plant & asset management Pages 29 - 37

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A culture of reliability

How CMMS software can improve your chance of successful Implementation

Maintec Show Preview.

Visit Us www.engineeringmaintenance.info

5 - 7

13 - 15

16 - 25

29 - 37

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44

48 - 50

Industry Latest News

Maintenance Best Practice

Product Spotlight – Including Dry Ice

Cleaning

Maintec Show Preview

Humidity Calibrators

Editors Choice

Buyers Guide 2012

Contacts

PublisherMichael Dominguez

Editorialeditors/contributing: Jon Barret,

Christer Idhammar, Alan France

AdvertisingPaul Clappison - Magazine

Paul Miles - Online Advertising

[email protected]

Websitewww.engineeringmaintenance.info

Phonetel: +44(0)1634 731646

Fax: +44(0)1634 631644

AddressMSL Group, Cobalt House, Centre

Court, Sir Thomas Longley Road,

Rochester, Kent, ME2 4BQ

5engineeringmaintenance.infoJan/Feb 2012

Latest News

These new Norbar products are safe, easy-to-use and extraordinarily accurate, to better than the International Standard. They offer high performance capabilities for dealing with a wide range of precision tasks requiring sensitive and safe screw connection. These include:• Electronic assembly• Automotive applications such as assembling

crash sensors, inertia reel fixtures, airbags and interior trim

• Fitting cutting tool inserts

All adjustable tools are supplied with traceable calibration certificates.

Further features and benefits:Easy torque adjustment without need of additional tools• All tools feature a lock to prevent the accidental

adjustment of the set torque• Tools ‘slip action’ occurs when required torque

level is reached, avoiding over-tightening • All screwdrivers supplied with ¼ inch hexagon

bit holder using a 4mm hexagon stem• For maximum versatility and particularly for

applications with limited access, the bit holder can be removed and replaced with widely available screwdriver blades.

Sterling-SIHI Demonstrates Energy Saving Potential at Tate & Lyle Sugars

Sterling-SIHI performed an energy audit at Tate & Lyle Sugars, London, which demonstrated the potential to save 90% of energy costs associated with the assessed pumping system.

Initially the auditing team visited the Silvertown refinery to assess the current system, gain an understanding of

the layout, gather historical data, and most importantly – identify the system and process requirements. During the subsequent audit and thorough process research, Sterling-SIHI were in a position to take measurements and carry out run tests, enabling the auditors to determine a number of “what if” scenarios and establish an accurate process demand. Tate & Lyle Sugars received a detailed report and presentation, illustrating the energy-saving potential that could be achieved.Impressively, Sterling-SIHI’s recommendations on one pump alone, would lead to an installation previously using 590MWh of electricity per year, to operate using only 40MWh. This would cut Tate & Lyle Sugars energy costs by £27,400 (the equivalent of 300 tons* of CO2 per year). Imagine the possibilities, should such advice be extended to the several hundred pumps currently operating at the plant.* based on 0.544kg of CO2 emitted / kWh as standard values, not necessarily actual sites values.

• Comfortable, durable handle, constructed from a strong base material covered with a soft overlay for comfort and slip resistance

Philip Brodey, Director of Norbar, comments: “The new screwdrivers are an invaluable addition to our TruTorque™ range. Accurate, robust and reliable, they expand the potential of applying torque measurement principles to the most precise and delicate applications.”

Norbar TruCheck™ Screwdriver TestersNorbar has introduced three new products specifically designed to calibrate torque screwdrivers, applicable to both its own products and those of other manufacturers. Accurate to +/- 1% of reading, Norbar TruCheck™ Screwdriver Testers allow operators to perform quick and simple calibration checks from easy-to-read LED displays without the need to call on third party calibration services, saving both time and expense.

NORBAR LAUNCHES TRUTORQUE™ SCREWDRIVERS

An important development in torque tools has taken place with the launch of an innovative range of Norbar TruTorque™ torque screwdrivers. The selection includes adjustable tools providing exceptional flexibility of use and also fixed torque versions, ‘P’ Types, that have been designed for the production environment and pre-set for specific workplace demands.

For further information about Norbar products and services, contact:Norbar Torque Tools Ltd, Beaumont Road, Banbury, Oxfordshire, UK OX16 1XJT+44 (0)1295 270333 [email protected]

ifm electronic at Drives & Controls 2012From 17th to 19th April this year ifm electronic will be joining almost 300 other world class companies at the NEC in supporting Drives & Controls, the UK’s leading event for Drives, Automation, Power Transmission & Motion Control.

For further information, contact Mel Lewis, ifm electronic Ltd., Efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD. Telephone: 020 8213-0000. Fax: 020 8213-2228. E-mail – [email protected] or visit our website www.ifm.com/uk

ifm electronic is well known as a market leader in sensing technologies, from inductive, magnetic and optical position sensors to flow, pressure and temperature process sensors, and ifm electronic has a growing reputation for up-to-the-minute condition-based maintenance systems, along with plant safety and efficiency. On the control side, ifm electronic also offers much from dedicated controllers, including a major AS-interface offering, to identification systems covering RFID and barcode solutions.At the Drives & Controls exhibition ifm electronic will be displaying the very latest from one of the most innovative companies in these fields of expertise, with experienced staff on hand to introduce, demonstrate and explain the latest products.

A show like this with free entry and leading manufacturers such as ifm electronic is an opportunity not to be missed.

ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products.

Sterling Fluid Systems (UK) LimitedAtlantic Street, Altrincham, Cheshire, England, WA14 5DH Telephone: +44 (0) 161 928 6371 Fax: +44 (0) 161 925 2129 e-mail: [email protected]


Latest News

Atlas Composites are industry leaders in the design and manufacture of carbon, glass, kevlar and aramid composite components and tooling for the Aerospace, Defence and Satellite Communications industry. Customer approvals include Airbus, Agusta Westland, BAE Systems, Bombardier Aerospace, Cooper Antennas, GKN Aerospace, Lockheed Martin, MBDA, Meggitt, Nordham and Thales.

Work towards the revised standard began in 2010 using a gap analysis database designed by strategic partner TPT Consultancy, to verify the effectiveness of the management system and practices.

The gap analysis identified the need for Atlas Composites to make the transition from its procedural-based quality management system, which satisfied the requirements of AS9100 Rev B, to the required new process-led approach.

The first stage was to determine Key Performance Indicators for all the required processes. This was followed by integrating a review process where performance was measured against planned targets and improvements made where targets were not being met.

SGS conducted the successful audit in July 2011 and issued the AS9100:2009 accreditation with no non-conformities identified.

As a result, Atlas Composites business objectives are now clearly defined, deployed and integrated into the company, supported by clearly defined KPIs. The business process interactions are defined using the process approach and process owners identified. The process performance is measured through the effective deployment of KPIs to support continual improvement.

Delivery performance over the past 12

Fentex Ltd have consolidated their spill trays and absorption materials providing a range of products to achieve compliance with the national Pollution Prevention Guidelines (PPG26). Spill trays can be supplied for use with single or multiple primary containers of 1, 5, 20 and 25 litres capacity together with drums up to 205 litres. These provide the necessary secondary containment facilities during the storage or decanting of liquids, ensuring that drips, leaks and accidental spills can be successfully contained. They help maintain a clean, safe work area environment while preventing pollution or contamination of land, surface waters and groundwater from the run-off of inks, oils, solvents and a wide range of potentially harmful or noxious fluids. Applications for spill control equipment are truly universal, but typical industry sectors that would benefit from the use of Fentex products include motor trade and transport, printing, plastic production and the food industry, together with any areas where hydraulically powered machinery or plant are in use.

In general workshop conditions, spill trays can be used to provide a contained cleaning/dispensing area and can also deal with machinery leaks or the storage of oil contaminated components during breakdowns/servicing of machinery. They help to reduce floor contamination leading to better, safer working conditions, while leaked fluids that would have been lost can be recovered for

recycling or reuse.Individuals, private businesses and both large or small companies and commercial organisations are required to meet the pollution recommendations covered by the PPG26 guidelines as relevant to Scotland, Northern Ireland, England and Wales. Current legislation and recommended good practice requires that provision should be made for a spill tray capacity being provided to accommodate 25% of the total fluid volume of any stored primary container(s).

The spill trays are manufactured from durable, lightweight rigid plastic, in a wide range of rectangular and square sizes and various depth configurations. They incorporate an all-around moulded lip, some featuring a pouring spout, which ensures extra rigidity and good lifting control for trays during moving when they are full with their spill contents. Trays can also be supplied with moulded ridges on the base to allow for airflow under stored containers. For more generous sizes, on trays providing the larger spill retention capacities, drop-in removable grids can be supplied providing a non-slip storage surface while allowing for easy access and cleaning of the spill tray itself.

Mini spill trays from 35 to 76cm in

Further information is available

on request to:

Fentex Ltd, Units E1 – E3, Brook

Farm Business Park, Ellington,

Huntingdon, PE28 0AE

Telephone: 01480 890104

Fax: 01480 890105

e-mail: [email protected]

www.fentex.co.uk

length can be supplied, suitable for small bottles and containers, or as convenient machine drip

trays. Larger trays from 40 to

60cm in width and 56 to 120cm in

length provide fluid spill retention

capacities from 2 – 28 litres. These

are complemented by larger

capacity drip pans and extra deep

trays with spill retention capacities

up to 120 litres. Handy trays for

general maintenance operations

or use as drip trays underneath

mobile plant or other vehicles

include a 41 x 31cm size tray

together with an 85cm octagonal

tray which covers a large floor

area. Both general purpose and

specialised oil and fuel absorbent

material rolls can also be supplied

for use with spill trays for easier

handling of leaked fluids. Spill

trays providing storage for multiple

standard 20 litre containers can

also be supplied. These cover

combinations of 2, 6, 9 or 16

containers per tray, all supplied

with removable internal grids to

elevate the stored containers away

from any spilt liquid and for easy

cleaning.

ENSURE COMPLIANCE WITH PPG26

POLLUTION PREVENTION GUIDELINES

months stands at 100%, and Quality Performance 99.4%.

“Making the transition from Rev B to Rev C was a key objective,” says Shaun Moloney, Managing Director, Atlas

Composites Ltd. “Without this there was potential that business could be lost. Delivery and Quality was excellent, and the challenge was to measure how effective we were in achieving this.”

Atlas Composites Ltd Achieves AS9100:2009 Rev C Accreditation

The latest revision is now the established benchmark for any company in the composite engineering industry wishing to tender for new business in Aerospace and Defence. Compliance with it proves that a company’s Quality Management System relies on clearly defined business processes to measure its effectiveness in meeting customer requirements.

8 engineeringmaintenance.infoJan/Feb 2012

International Industry News

The new initiative (http://machinery-surveillance.eu) was launched at a conference in Brussels on 24th November 2011, hosted by the European Commission, at which Thorworld managing director John Meale chaired a discussion on Market Surveillance to Protect Innovation. The highly successful event was an unprecedented partnership between seven major European trade organisations, representing the construction, machine tools, weighing, agricultural machinery, plastics & rubber machinery industries, as well as Orgalime, the European Engineering Industries Association, and FEM the European Materials Handling Federation – www.fem-eur.com.

As John Meale explains, this is a vital issue designed to ensure a fair and level playing field for European manufacturers and peace of mind for customers.

“As consumers, we are all familiar with the concept of illegal goods that do not comply with regulations, and we are aware of the hard work done by the authorities to prevent such products from being sold.

“The aim of this conference was to address the question: why, if there is such robust market surveillance for consumer goods, is there not a corresponding level of protection for commercial equipment and machinery?

“Too often, market surveillance for materials handling equipment is reactive rather than preventative – which means that it is then too late for reputable suppliers who have been undercut by unscrupulous manufacturers, or for the workers who face injury or even death.

Thorworld Backs Calls For Increased Market Surveillance Of Materials Handling Machinery

Leading loading/unloading equipment specialist Thorworld Industries Ltd is supporting a European-wide initiative to raise awareness of the importance of market surveillance, to prevent non-compliant and potentially unsafe machinery entering the European market.

For more information about Thorworld’s market-leading equipment and to obtain a copy of their latest Product Range Catalogue contact Tel: 01246 260982, Fax 01246 260493, Email: [email protected] or visit Web: www.thorworld.co.uk

The combination of Brammer UK and Buck & Hickman brings together extensive capabilities and resources to create a complete one-stop shop for industrial MRO supply, operating from some 120 locations across the UK. The appointment will see Ian build on the significant growth and development that he has overseen at Brammer since his appointment as UK managing director in December 2003.

Ian commented: “The acquisition of Buck & Hickman is an excellent strategic fit with Brammer’s ambitious development plans in Europe and the UK, with the tools, maintenance and health & safety market offering significant growth opportunities. There are strong synergies across the two businesses and bringing their operations together will allow us to further enhance our customer offer.”

“Combining the knowledge and expertise within both businesses will create a unique resource able to offer unrivalled product knowledge, advice and technical support, backed by a depth of product range and supply capability which is second to none. It also underpins our own belief in being

local and close to our customers, with an expanded branch network enabling customers to benefit from our commitment to customer service right across the UK industrial landscape.”

Brammer plc acquired the business and assets of Buck & Hickman, a market leader in tools, maintenance and health & safety products, many of which are supplied under the well respected ‘Roebuck’ brand, from Travis Perkins plc in September 2011 for £27.6 million.

Senior appointment aligns strengths of Brammer and Buck & Hickman

Ian Ritchie, managing director of Brammer, the UK’s leading distributor of maintenance, repair and overhaul (MRO) products and services, has an expanded remit to lead the recently acquired industrial tools, maintenance and health & safety product distributor Buck & Hickman, following its acquisition by Brammer plc.

For further information on Brammer

visit www.brammer.co.uk and for more

details on Buck & Hickman visit www.

buckandhickman.com.

Professor Miklas Scholz has developed a quick assessment toolkit which has been used in Baden (Germany) as well as in Scotland and England. Using the toolkit he has assessed over 220 dams in the German region and found that although most are well maintained, there is very little publicly available information on their risk of failure and the impact this can have. With his system, people living in areas near dams would have access to a simple traffic light scale of risk based on a scientific and rigorous series of tests, which can be applied in under three hours. He’s now calling for Germany’s engineering associations to relax their strict rules on how assessments are carried out and how the results are communicated. “I have sent my research paper to several engineering journals in Germany and met a very unnecessarily and unhelpful traditional attitude.” he said. “My novel and timely toolkit has been proven in the United Kingdom to be easy to use. It can be carried out without costly detailed site visits to identify the most at-risk dams. “It seems that German engineers who are responsible for these dams are unwilling to change their methods or open them up to proper public scrutiny.”

More public access to German dam data, academic demands

A University of Salford

academic is calling for

more public access to the

state of dams in Germany

after his quick assessment

toolkit uncovered several

at a comparatively high

risk of failure.


Latest Product News

They feature a patented arrangement of structurally packed, permeable hollow fibres spirally wound on a support core. This creates an optimised design combining efficient air flow with high contact areas to maximise the drying performance within a compact unit size. These products are ideal for in-line installation to ensure the delivery of dry compressed air at the point of use. This ensures maximum effectiveness with virtually any dewpoint or degree of drying being achievable.As the humid compressed air passes through the Hi-DRI unit, water vapour diffuses through the walls of the hollow membrane fibres without loss of compressed air. At the dryer outlet, a small volume of the now dry air is expanded and released into the annular space between the membrane fibres and the outer aluminium shell. This air purge then sweeps away entrained water vapour to atmosphere as a humid air stream.The Hi-DRI air dryer makes it easier and less expensive to supply pneumatic equipment and instrumentation with clean, dry compressed air. This simple, proven technology helps eliminate condensation, oxidation and microbial growth, resulting in reliable and predictable performance of downstream air operated equipment. It also reduces component failures, improves equipment performance and operator satisfaction while showing savings on both warranty and production costs.These dryers are designed to provide the superior solution for existing compressed air systems, maintaining maximum process reliability while remaining virtually invisible to the process installation. They do not contain moving parts and there are no desiccants or refrigerant to replace. They are also compact and lightweight, do not incorporate valves, drains or electrical connectors and do not require adjustments.Filtration combined with compressed air drying contributes most to the performance and reliability of airline powered operations. Humidity in airline systems is a major factor of corrosion and tooling wear, which can lead to production breakdowns. However, humidity also creates conditions conducive to the growth of micro-organisms within an airline, which can result in contaminated condensate. This is obviously highly detrimental in food or pharmaceutical production processes as well as in dental, medical or laboratory applications. Almost any dewpoint can be achieved, even when accommodating high humidity ambient conditions as experienced outdoors, in open workshops or on seagoing vessels.These Hi-DRI membrane air dryers are suitable for a wide range of industrial plant installations including specialised commercial operations. The range of models available cover air flow rates from 17 to 1050 litres/min. Multiple dryer units can be used in parallel to achieve higher flows where required. Outlet dewpoints from +15° to -40°C can be achieved at 7 barg

pressure (12.5 barg max) and with 35°C inlet air temperatures. With in-line connection ports at each end, the dryers can be easily integrated into an existing airline. They are compact, lightweight and cost effective, while the polymeric hollow fibre membrane is maintenance-free and does not need replacing where adequate pre-filtration has been provided. A 0.01 micron coalescing filter element is recommended to prevent damaging particulates, oil aerosols and liquid water entering the Hi-DRI filter. The use of a Hi-line HF series filter with regular replacement of the cleaning element will ensure long-term continuous, trouble-free dryer operation.Where cost effective centralised refrigeration drying is required, a Hi-line CDA dryer connected directly to a compressor can

be combined with individual Hi-DRI units of varying outputs fitted at points of use.

Further information is available from: Hi-line Industries Ltd,5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PGTelephone: 01283 533377Fax: 01283 533367 [email protected]

MEMBRANE DRYERS SET HIGHEST STANDARDSFOR COMPRESSED AIR SYSTEMSThe new range of Hi-DRI compressed air membrane dryers from Hi-line Industries have been re-engineered to be technologically superior products, achieving new standards for reliability, performance and energy efficiency.

The latest HI-DRI compressed air dryers from Hi-line Industries Ltd, offering dewpoints from +15°C to 40°C.

Ball valves, utilising a drilled-through ball rotating in a retaining socket, are widely used for process line control operations within industry. Typical areas of application for these valves include oil and gas, chemical processing, power generation together with pulp and paper industries among many others.Ball valves offer both flow throttling and full shut-off conditions, while applications can involve an extensive range of pressures, temperatures and even the use of chemically aggressive fluids. The importance of specifying the right sealing products for use within these valves becomes paramount, particularly where breakdowns or plant shutdowns caused through valve failure can be catastrophic.The specialist sealing company, Dichtomatik Ltd, are able to provide the Kalrez® range of perfluoroelastomer ‘O’ rings from the Dupont™ Performance Polymers range, which have been formulated to provide superior sealing qualities for even the most difficult applications.A recent problem application featured a trunnian mounted ball valve used in the gas cleaning/sweetening processes. This involved the removal of carbon dioxide and acidic gasses such as hydrogen sulphide from gas streams, including synthesis gas produced by the gasification of coal, coke and heavy hydrocarbon oils. Gas sweetening is commonly undertaken in refineries, petrochem plants and NG processing etc, where the process often utilises a glycol-based solvent for the acid gas removal.

The solvent chemistry, together with RGD (Rapid Gas Decompression), can attack the valve seals and ‘O’ rings typically located in the valve seat. This can lead to seal life reduction, premature valve leaks and higher costs for both plant operation and maintenance.A successful solution was achieved by the fitting of DuPont™ Kalrez® Spectrum 7090 seals. These perfluoroelastomer products offer an excellent combination of chemical compatibility, with both RGD and high temperature resistance for ‘O’ ring applications, particularly where handling glycol-based solvents. Valve leakages can be dramatically reduced, with a reduction in maintenance procedures resulting from the extension of MTBR (Mean Time Between Repairs).

SOLVING SEALING PROBLEMS FOR FLOW CONTROL PRODUCTS

Further information is available from:Dichtomatik Ltd, Donington HouseRiverside Road, Pride Park, DerbyDE24 8HXTel: 01332 524401Fax: 01332 [email protected]

1111Jan/Feb 2012

engineeringmaintenance.info

13

Maintenance Best Practise

Reliability is a term that has become more commonly used in

the industry. Many organizations are using reliability to describe

their predictive maintenance department. To me reliability has

always encompassed the measurement of manufacturing

efficiency and includes Operations, Maintenance, Engineering

and Spare Part Stores as the major players. Together these

departments shall deliver Manufacturing Reliability and we know

that better reliability results in:

• Improved safety.

• Faster manufacturing throughput.

• Lower manufacturing cost.

• Lower energy consumption.

There are many ways to measure manufacturing reliability. The

least complicated is to divide Quality Tons Manufactured by

Capacity Quality Tons. However it is beneficial to break up this

equation in three elements: % Quality Tons x % Time Efficiency

x % Speed performance. If each of these is 95% the total

manufacturing reliability is 85.7%. By measuring these three

elements it will be easier to pinpoint where the biggest losses

are. It is not uncommon for mills to only measure the time

element of this formula often expressed as % availability or “%

time we have sheet on reel” for a paper machine. To me this is

wrong because you might have a high availability but you might

have to scrap all products made or you are not running at full

speed.

I see the equipment reliability component of manufacturing

reliability as the revenue side of what the maintenance

organization does and the process reliability component as

the results of what the operations organization does. The

maintenance organization is supported by efficient and cost

effective stores and engineering is responsible for cost effective

design including maintainability and reliability considerations.

The roles of these departments must be clearly defined and

their joint goal should be manufacturing reliability. They are in a

relationship of equal partners and never in an internal customer

relationship between each other. (See article in October 2011

PPI issue).

Organizational silos.One of the biggest obstacles to overcome is that organizations

are set up in silos with different goals.

For the engineering organization it is not necessarily so that

lowest Life Cycle Cost (LCC) over more than fifteen years

of ownership is most important. Costs as a result of poor

maintainability and reliability design might consequently be

much higher than necessary over the years equipment is owned

and operated. In most organizations the project manager is

A Culture Of ReliabilityChrister Idhammar is a world

renowned and award winning

Reliability and Maintenance

Consultant and Guru. He is the

Founder and CEO of IDCON,

INC in Raleigh NC, USA; A

reliability and maintenance

training and consulting company

to the Pulp and Paper Industry

worldwide since 1972.

www.idcon.com

13Jan/Feb 2012


driven and awarded if projects come in on time and under

budget not by lower LCC. Key operations and maintenance

people are often not included in the early specification phase of

a project and many good ideas are lost. It is not uncommon that

basic documentation such as detailed bills of materials is left

out. This will lead to difficulty to optimize stores and much extra

work to document these bills of materials later.

The operations organization is rewarded by tons manufactured.

The maintenance organization is measured primarily by cost as

set in the maintenance budget and stores are often challenged

to reduce inventory value. It is not necessarily so that these

measurements are wrong but if applied in organizational silos

they lead to sub optimization and total results will suffer.

To improve this situation mills need to rethink their departments

roles and goals and bring them together in a partnership

work system with one goal expressed as manufacturing

competitiveness e.g. Quality Tons/Cost (instead of Cost/Ton) to

articulate the focus on manufacturing reliability. All other goals

and performance indicators shall drive actions to support this

goal.

Increased reliability will drive down costs.

Cost to achieve improved reliability is important. Most of the

cost consists of implementation of better maintenance and

operations practices and training of your employees to do better

with what they already have. After a short period of increased

costs reliability will improve and manufacturing costs including

maintenance costs will continuously go down over many years.

An established fact is that improved reliability is a major driver to

improve safety and costs.

To simplify there are three ways to reduce maintenance costs:

• Cut the cost.

• Prevent Maintenance.

• Execute remaining maintenance more efficiently.

Cut the cost

To just cut the cost instead of improving what drives cost is the

wrong thing to do.

If maintenance costs are cut by layoffs of people and no

improvements in systems, processes and practices are done it

will within one to two years lead to more overtime, more use of

contractors more total maintenance hours, lower reliability and

higher costs. Some valid maintenance work can be deferred

with the risk associated with that but sooner or later the work

must be done.

To just cut the cost is a short term action with expensive long

term results. My observations are that this is not as common as

it used to be but it is still far from uncommon.

Over the years this will repeatedly happen in mills where a well

defined, documented, communicated and executed reliability

and maintenance strategy is absent. 60% of mills have had

more than three mill managers, production managers and

maintenance managers in the last ten years per response to a

survey on www.idcon.com .

If you do not have a reliability and maintenance strategy to

execute there is a risk that each new manager will implement a

new program. This will very often confuse the organization and

ongoing improvements will discontinue.

Prevent Maintenance.To prevent maintenance work from occurring is the right thing

to do.

“To me reliability has always encompassed

the measurement of manufacturing

efficiency and includes Operations,

Maintenance, Engineering and Spare Part

Stores as the major players.”


Jan/Feb 2012engineeringmaintenance.info14

15

Whatever name you give your maintenance program it will

always be important to execute the fundamental elements

of maintenance better and better. To prevent maintenance

or maintenance prevention includes the following must do

essential elements.

• Right equipment. Procurement of new equipment should

be based on lowest Life Cycle Cost and include reliability

and maintainability design.

• Lubrication. It is still one of the most important things to

do well by trained people.

• Alignment must be done to a precision level with

considerations to operating temperature, pipe strain,

number of shims etc.

• Filtration of hydraulic fluids, lubrication oils, seal water for

mechanical seals must be done to specified levels.

• Balancing must be done to precision level.

• Operating Practices are essential to prevent maintenance.

Operators must understand how to operate equipment and

the impact wrong operating practices have. E.g. how to

start a pump, what happens to an electric motor if it is dirty

or is frequently started. Redundant equipment should be

shifted to operate same amount of hours etc.

• Fixed Time Maintenance is very seldom justified and often

leads to over maintaining. Only if it is justified based on

failure developing times and distribution of failures in time it

can be cost effective to do.

Execute remaining maintenance more efficiently.Maintenance Prevention will increase reliability and reduce

maintenance work. All work cannot be prevented so remaining

work should be done more efficiently by skilled people in the

following process:

1. Identify work early through good inspections of

equipment and disciplined priorities.

2. Plan work.

3. Schedule work.

4. Execute work according to schedule.

5. Record work done.

6. Use recorded information to trigger a Root Cause

Problem elimination action.

What is the secret?The secret is that there is no secret. The above concepts are

very well known and documented in hundred of books the last

fifty years. So why is it so difficult to do something so simple

well? One of the reasons for this is that companies often make

it much more complicated than it is. New names on well known

concepts confuse people. They think it is another new program

that will only last until we get the next manager so why make

too much effort to buy in? We need to realize that to improve

maintenance is 90% about people and 10% about technology

and as engineers we often like to deal with technology more

than with motivating people. Most maintenance people like

gadgets while they might not like to change to working in a

disciplined system. A reactive system rewards action and extra

income through overtime.

The big challenge is to change the way maintenance work is

viewed by top management. Maintenance is often controlled

way too much based on cost instead of the results delivered

through efficient maintenance work. As mentioned above,

the results of maintenance work include equipment reliability

followed by better safety and lower costs. Maintenance

managers are often not aggressive enough. As a maintenance

manager you need to know how good your organization is

compared to how good it can become. Then you need - a well

documented plan showing how you are going to close that gap,

what benefits you will deliver and how much it will cost. Then

you need to sell that plan to top management and then to the

people in your organization that will help you deliver the plan

over the next three to five years.

Remember that almost all improvement initiatives have to

be executed by your front line organization; if they are not

supported to execute nothing will be delivered. As the picture

above describes the front line organization in a bigger mill

includes planners, supervisors, coordinators, operators and

maintenance crafts people.


15Jan/Feb 2012



Non Destructive Testing

Condition Monitoring

The TD Pocket-Scan coupled with Technology Design’s Corrosion Mapping Kit is the ideal solution for recording material loss data without the need for bulky and costly mechanical scanners. Data is collected manually with a standard normal ultrasonic probe and positional information is recorded by the

Condition MonitoringThe TD Pocket-Scan coupled with Technology Design’s

Corrosion Mapping Kit is the ideal solution for recording

material loss data without the need for bulky and costly

mechanical scanners.

For more information on all our

products, please contact Jackie Berry:

E: [email protected]

W: www.agr.com/fo

video tracking system.The TD-scan Ultrasonic Software provides integrated tools for both setup and analysis of data. The data is viewed as a true depth C-scan with associated side views that can be interrogated using a range of powerful software tools including an easy to use report generator. The TD Corrosion Mapping Kit is easy to use and is the answer to your ongoing condition monitoring challenges.

17

The compact, battery-powered logger features burn-out response, and has a built-in temperature channel allowing the particular process and the ambient air temperature to be monitored simultaneously. It incorporates a connection that supports both standard and miniature thermocouple plugs. Data is downloaded to a PC via a USB connection and viewed with easy to use Tinytag Explorer software. From £99 + VAT.

New Tinytag Thermocouple Data LoggerGemini Data Loggers’ Tinytag Ultra 2 Thermocouple

data logger provides fast response, versatile and

cost-effective temperature monitoring. It supports

the most popular thermocouples types – K, J, T and

N – providing monitoring from -270°C to 1370°C,

depending on the type being used.

Gemini Data Loggers (UK) LtdScientific HouseTerminus RoadChichesterPO19 8UJ

+44 (0)1243 [email protected]

17Jan/Feb 2012



Non Slip Flooring

Cranes

Efficient Lifting and Handling from 125 Kilos to 200 Tonnes

Street Crane Company overhead travelling cranes for industry are available in configurations for safe lifting and handling up to 200 tonnes. In the mainstream one to 50 tonne category they offer the advanced ZX modular hoist.

For lighter lifts, LX chain hoists meet handling meet needs from 125 Kilos up to five tonnes safe working load. These may be used for static lifting or attached to crane beams for easy product transfers.Light crane systems are designed for local handling and productivity, freeing the main factory overhead crane for heavier lifts and down shop transfers.

More information Andrew Pimblett, Tel. 01298 812456 Fax. 01298 814 945Street Crane Company, Chapel-en-le-Frith, High Peak, SK23 0PH, UKE-Mail: [email protected] Web: www.streetcrane.co.uk

With our first of a kind heated version called the Arctic Pad, this innovative all season solution gives year round protection for colder climate operations.

Safety, Warmth & Comfort it all starts with the feet!

Take the next step towards improving safety.

PROVIDING SOLUTIONS FOR THE LEADING CAUSE OF ALL ACCIDENTS AND INJURIES – SLIPS, TRIPS & FALLS.

At AMS we believe that one slip or fall injury is one too

many, so whatever the application or environment, our every

expanding line of solutions called the Advanced Mat System

ensures that you have the right mat for the right application.

www.advancedmatsystems.com

19

Dry Ice Cleaning

Used by many leading names in the dry ice

sector- Air Liquide, Messer, Linde, BOC,

Praxair, Coljet, Yara, etc -the combination

of high quality insulation and robust plastic

construction with steel fittings ensures

that the containers have a very long life.

The ease of movement on casters or feet

makes the containers very easy to handle

so that the dry ice pellets for blast cleaning

can be taken direct to the point of use and

still at exactly the right temperature.

Olivo contain dry iceOlivo portable insulated containers

have been manufactured for over

fifty years.

Contact: www.olivo.fr

19Jan/Feb 2012



Dry Ice Cleaning

As well offering ranges of

traditional industrial cleaning

machines such as parts washers,

vacuum cleaners and stationary

high-pressure cleaners, Kärcher

has developed highly innovative

blast cleaning products to improve

safety, reduce costs, and offer

new levels of blast cleaning

standards.

Kärcher ‘s range of Ice Blasters

offer a portable, non-aggressive,

but thorough method of cleaning

surfaces, tools, moulds and

machines without causing

damage to the substrate or the

environment. The machines

can be used in indoor and

outdoor areas and do not require

Safe, mess-free cleaning with Kärcher Ice Blasters

As one of the world’s largest manufacturers of cleaning equipment, Kärcher has the products and knowledge to provide the best cleaning solutions for a wide variety of industrial environments.

chemicals.

The process is

particularly suited

to environments

where machine

cleaning and

maintenance is

essential, and

can significantly

reduce downtimes

and costs.

The system uses

dry ice pellets kept at -79ºC,

injected into a jet of compressed

air, accelerated to speeds in

excess of 150 m/s and then fired

at the surface to be cleaned. The

abrupt cooling of the surface

causes a thermal shock and

produces fine cracks in the top

layer. The dry ice pellets

penetrate these cracks

and sublimate instantly

(turn into a gas without

becoming a liquid) lifting

the contaminant from

the surface, and return

to the atmosphere as

CO2 gas leaving only the

contaminant behind. As

cleaning with dry ice

is performed without

chemicals or detergents,

and leaves no

wastewater, it is

environmentally

friendly and can

be used in areas

To find out more about how ice

blasting can make a difference to

your business, and to find your

nearest specialist, call 01295 752

142, email [email protected]

or visit www.karcher.co.uk

where cleaning with water is

prohibited or inconvenient. Unlike

sand blasting, ice blasting keeps

surface abrasion to a minimum,

and there is only the contaminant

to collect after cleaning has been

completed.

This superb technology is available

from Kärcher’s officially appointed

Ice Blaster specialists, all of whom

can offer expert advice on your ice

blasting requirements.


Dry Ice Cleaning

Dry Ice Cleaning

Jan/Feb 201222 engineeringmaintenance.info

Flow Meters

Flow Meters

To learn more about the M series Mass Flow Meter, and all of Alicat’s flow control products, visit:www.alicatscientific.com, or call +1 520 290-6060.

Alicat Mass Flow MetersTucson, Arizona – For industrial analytical lab use, Alicat

Scientific, Inc. offers the ATEX-rated M series Mass Flow

Meter. The M series mass flow meter is a good choice for

analytical applications including process measurement,

calibration of HPLC and analyzers, and in pilot reactors.

The M series mass flow meters quickly and accurately measure pressure, temperature and volumetric flow in addition to mass flow. Alicat’s patented laminar flow differential pressure technology delivers highly accurate results with a much faster response time than that of competing technologies. Devices come pre-calibrated (NIST traceable) for Acetylene, Hydrogen, Ethylene, and Propane, as well as 16 other gasses and 10 gas mixes. For use in a wide range of applications, an ATEX approved -X option is available.Operating simply as a stand-alone device, the integrated digital display of the M series Mass Flow Meter enables users to change the configuration of the meter without the need for computers, complicated software or scripts. For more complex operation, the M series also interfaces with most process control software without requiring any additional equipment or controllers, a simple to install and cost effective solution.


Leak Protection

Corrosion Monitoring

The engineers at the plant were looking for a long term repair solution for a caustic tank suffering leaks on the welded seams where the caustic acid was leaking from the painted mild steel tank. The tank was situated within a stainless steel secondary containment area and was made up of four half round sections which were welded together. The tank contained around 8000 liters of 28% caustic soda.

The tank was fully drained prior to the application and the front of the secondary containment area was removed to aid access. A scaffold was erected to gain access to the higher parts of the tank.

Application service provider Belzona Technosol won the contract to refurbish the tank. The entire area was pressure washed to ensure full adhesion of the Belzona products. An 80mm wide repair area was then masked off along the length of the welded seam and prepared

using a Monti® MBX Bristle Blaster, a hand-held surface preparation tool suitable for use on a variety of substrates including metals, rubbers and plastics.

The product selected for the repair of the leaking areas was Belzona 1111 (Supermetal) a multi-purpose, machinable, repair and rebuild system. The two-component paste grade product is based on a ceramic steel reinforced polymer system which when cured is durable and chemical resistant. The product is ideally suited to applications on tanks, pipes, casings, keyways, bearing housings, shafts, hydraulic rams, engine blocks and flange faces.

The first layer of Belzona 1111 (Supermetal) was applied incorporating Belzona 9341 (Reinforcing Tape) to the repair area. Once cured, a second coat of the reinforced product was applied. After removing the masking tape the product

was left to cure. This application will provide a long term, corrosion protection solution for this caustic tank.

Belzona Repairs Leaking Caustic TankIn September 2011, Belzona refurbished a leaking caustic tank for a global soft drink manufacturer at their bottling plant in London.

Belzona Polymerics LimitedClaro Road, Harrogate, HG1 4DS England

Telephone: +44 1423 567641Facsimile: +44 1423 505967

[email protected]

http://www.belzona.com


Online Condition Monitoring


An integrated plant-wide machine

condition and performance monitoring

strategy is essential to achieving this.

Since its inception in 1991, Brüel & Kjær

Vibro’s Compass platform has been the

industry leading integrated monitoring

solution. Successfully utilized in refineries,

offshore and onshore oil & gas production

facilities, LNG, olefin, polyolefin and

chemical plants, the system has delivered

considerable uptime, efficiency and cost

benefits to customers the world over.

Combined with our global sales and

technical support network, Compass can

deliver uptime to your plant!

Brüel & Kjær Vibro has delivered plant-wide condition monitoring

systems to the O&G and petrochemical industry for over 20 years

The oil & gas and petrochemical industries face

the most demanding challenges in fulfilling today’s

machine management and reliability requirements.

Brüel & Kjær Vibro is part of Spectris

plc, the leading supplier of productivity

enhancing instrumentation and controls.

Contact: Brüel & Kjær Vibro, e-mail:

[email protected], www.bkvibro.com






Brüel & Kjær Vibro provides a comprehensive integrated monitoring solution to the hydro industry

As the Operation & Maintenance

requirements become more demanding,

the importance of effectively monitoring

these machines becomes imperative.

Hydroelectric power plays an increasingly important

role in the worldwide energy market.

Over the past 20 years, Brüel & Kjær

Vibro has built a global customer base by

monitoring all types of turbines ranging

from 1MW to 1GW. Our dedicated hydro

monitoring systems are tailored to the

varying demands of the hydro industry

and include unique specialized functions

including the multiple machine state

monitoring function - ideal for pumped

storage applications. In addition to

comprehensive vibration monitoring, Brüel

& Kjær Vibro also provides integrated air

gap, magnetic flux, process, performance

and cavitation monitoring. Combined with

our global sales and technical support

network, we can provide a solution to

your Hydro application!




EtaPROTM Detects Machinery Problems Sooner Rather Than Later

Productivity increases because plant staff

can be proactive with maintenance that is

focused on avoiding future failures rather

than reacting to them.

GP Strategies’ EtaPRO technology suite is the power

generation industry’s leading real-time Performance

and Condition Monitoring System. Our first principles-

based thermodynamic modeling software, VirtualPlant™,

calculates “targeted” performance, validates data,

and simulates “What-If” scenarios for combined cycle,

Rankine cycle, and nuclear power plants.

To provide early warning and reduce unplanned

maintenance, GP Strategies integrated advanced pattern

recognition (APR) technology into Version 10 of EtaPRO.

EtaPRO APR models are used to detect anomalies in

plant or equipment conditions by continuously comparing

current values to detailed empirical models of “normal”

data.

To learn more about EtaPRO please contact:GP Strategies CorporationEnergy Services GroupTel: +1 (716) 799.1065Fax: +1 (716) 799.1081Email: [email protected]: www.etapro.com






Wind turbines are subject to widely variable operating conditions, which together with the compact construction, non-rigid foundations, complex gearbox

Brüel & Kjær Vibro provides a unique dedicated monitoring system and service concept for the wind turbine industry

Condition monitoring requirements in the wind industry

are like no other, thereby requiring an entirely different

monitoring approach to traditional rotating machines.

and slow rotating speed complicate the analysis and diagnostic process. To deal with these challenges, Brüel & Kjær Vibro has developed a unique monitoring

concept that combines its dedicated wind turbine condition monitoring system with a unique service program; the surveillance centre. The GL certified surveillance centre uses ISO18436 certified specialists and the unique alarm management concept integral to the monitoring system to evaluate all alarms and provide actionable information to the client’s service organisation. This versatile combination reduces unplanned maintenance, enables just-in-time service, maximises uptime and reduces maintenance costs. Your wind turbines/turbine park can benefit from this dedicated monitoring concept.

Compressed Air

That is why Atlas Copco and its

distributors conduct energy audits as

the definitive approach to identifying

trends, establishing how well

operators’ systems are performing,

and recommending energy-efficient

solutions where needed.

Applying simple non-intrusive air

audit data logging techniques over

a fixed period of time will establish a

true indication of a system’s air usage

and cost and, ultimately, will help to

identify any wastage factors such as

leakage and pressure drops.

Whether the purpose of an air

audit is part of an on-going service

contract, a means to monitor

the progress of an established

installation or to determine the level

of efficiency of an existing system

for its potential replacement, the

fundamental question that the

Atlas Copco distributor asks of the

customer is ‘Do you know how

much compressed air you use and

how much it costs to produce?” For

the answer, the starting point is to

measure the power requirement for

the compressor installation, a simple

initial procedure that may be followed

by a full system audit where deemed

necessary.

Atlas Copco authorised distributors

have successfully applied these

monitoring techniques to a

considerable number of diverse

applications throughout industry,

and as a result of implementing

these energy-efficient measures, it

is not uncommon for operating cost

savings of as much as 40% to be

realised. For example, the Wales-

based distributor Control Gear helped

a bridgeworks and water engineering

products manufacturer in South

Wales to make savings of £8,000

per annum following an energy audit.

With the aid of iiTraks and supporting

software a potential saving of

£12,000 was also realised by another

of the distributor’s customers who

manufacture vibration dampening

products in Wiltshire. In the North

West, Precision Pneumatics helped

a theme park to cut its annual

power consumption by 50% and

also achieved a 35% annual energy

savings for a newspaper publisher

in the area. In South Yorkshire, the

Compressed Air Division of the

Search Group of Companies was

also able to achieve £35,000 in

energy savings for a large engineering

plant and a further £15,000 per

annum for a health care products

manufacturer.

That is why it is standard practice

within the distributor network to

conduct these investigations as

part of its professional energy

management expertise. Every

distributor in the nationwide network

has the technical capacity and

dedication to help compressed air

users maximise energy savings

and to improve the reliability and

productivity of their compressed air

systems.

Using the latest iiTrak data loggers,

which basically supersede the

Distributors Lead The Way To Energy Efficient Compressed Air Systems

Most compressed air users would agree that to

get the best return from their capital investment,

the monitoring, measuring and management of

compressor installations is essential if optimum

control, improved productivity and energy efficiency

is to be achieved.



Compressed Air

conventional measurement box

monitoring procedure, Atlas Copco-

trained engineers can help operators

to establish a true indication of a

system’s air usage and cost without

any interruption of the air supply or

production process. The end result

is an accurate indication of a plant’s

compressed air demand and, most

importantly, of any potential wastage.

The compact, unobtrusive, battery-

powered iiTrak loggers incorporate

the latest data capture technology

to log compressor load status via

current sensing. They are designed

as stand alone units, with one

logger allocated to each machine

in a multiple installation, or one unit

dedicated to each compressor

characteristic to be measured. Easily

installed at the point of use, they

are connected by a single cable for

one leg of incoming power. All data

is captured by the unit’s flash card

memory for subsequent computer

download and scrutiny.

The true amount of energy drawn

by each compressor (both on load

and off load) is measured. The mains

voltage and power factor correction

is also recorded which gives the

true kilowattage consumed by

each compressor. The candidate

compressors are logged for a

minimum period of one week after

which the data is downloaded to

a computer. In some instances,

the user’s production process

programme and relevant air demand

variations may require an extended

measurement period to be necessary

but the battery power for the iiTrak

units is adequate for approximately

three weeks of operation before

replacement is necessary. The unique

Atlas Copco software programme

for the iiTrak enables simulated

compressor comparisons to be made

against the actual system.

It is usual for Atlas Copco’s iiTrak

energy monitoring to take place

prior to a full, in-depth investigation

to obtain a comprehensive

understanding of the air usage

by scrutinising every stage from

compressed air production to its

point of use.

The audit procedure employs

sophisticated equipment items such

as a mass flow measurement meter,

relative pressure sensor/transmitters,

ultrasonic leak detection apparatus

and power meter monitoring.

These instruments pinpoint

inefficiencies such as inadequacies

in the production and utilisation of

the compressed air supply, poor

pipework design and pressure drop

sites. It will also reveal where systems

are operating at too high a pressure

and where energy is being wasted

because of piping network leaks.

With this data available, the next

stage in the distributor’s investigation

is to look at the operator’s present

and future requirements in depth,

to submit a full report of the

application findings, and to make

recommendations on actions

and equipment solutions based

on precise audit data and close

knowledge of how the application

operates. As a result, customers can

be provided with the most energy-

efficient systems tailored to suit their

precise needs. The recommendations

may well include energy-efficient VSD

compressors that match compressor

output to process demand thereby

generating energy savings of up to

35%.

29

Maintec Preview

More than 1,700 chief maintenance officers, engineering

and plant managers – many from UK blue chips like

Astra Zeneca, BAE Systems, NHS Trust, Royal Mail and

Walkers Crisps – attended the 2011 show to get their

hands on the latest kit and talk to the developers making

advances in condition monitoring, asset management

and hazard detection.

The 2012 show will once again play host to all the

major players within the sector such as Fluke (UK) Ltd,

Idhammer Systems Ltd, and Panasonic UK Ltd, as well

smaller growing companies such as 2011 debutants

Business Development Strategic Maintenance Ltd.

Colin Wilson, Consultant Director at the company,

commented: “At MAINTEC 2011 we had 59

conversations of note over the three days with several

potential companies interested in using or reselling this

product. This was our first MAINTEC exhibition, having

last year come as visitors to assess its suitability as an

exhibition for a small, growing company like ours. We’re

certainly glad we came as exhibitors.”

easyFairs UK, Managing Director Matt Benyon, added:

“Maintec is the perfect platform for both large and small

companies to showcase their latest maintenance and

engineering offerings to key decision makers within the

industry, as well as visitors wanting to witness first hand

the very best in maintenance technology.”

Exhibitors and visitors will get all the benefits of the

easyFairs approach to trade shows, including convenient

and cost-effective all-inclusive stand packages and free

learnShops™ that focus on practical knowledge sharing

and cover the latest trends, issues and technology

developments.

Exciting additions have also been added to easyFairs

MAINTEC 2012. In particular, a new hazardous goods

event called ‘HAZEX’ will be taking place, to reflect the

growing responsibilities of maintenance professionals,

and the growing concerns and tighter legislation over

plants’ health and safety.

The show also has the support of key sector

organisations, including the British Compressed Air

Society, the British Institute of Non-Destructive Testing,

the Institution of Diagnostic Engineers, Institute of Asset

Management, the Facilities Management Association,

United Kingdom Thermography Association and The

Institute of Engineering and Technology.

MAINTEC 2012 TO SHOWCASE THE VERY LATEST IN MAINTENANCE TECHNOLOGY

Now in its 37th year, easyFairs MAINTEC –

the only UK show dedicated to the industrial

maintenance and asset management sectors

– returns to Birmingham’s NEC next February

(28 February – 1 March 2012) to showcase

the very latest technologies in the sector.

To find out more information about the

show visit:

www.easyFairs.com/MAINTECUK

and for stand bookings and exhibiting

enquiries contact Jerry Dawson on:

+44 (0)20 8843 8823

or e-mail: [email protected].

29Jan/Feb 2012



Maintec Preview

Maintec Preview


Maintec Preview

Nearly eight in 10 maintenance and engineering managers interviewed by easyFairs ahead of the 28 February – 1 March NEC exhibition say they expect their budget to remain the same or increase over the coming year. Additionally, over a third (36 per cent) said that improving plant productivity is the main driver behind their maintenance spend. This is welcome news given that 55 per cent of respondents are planning to tackle the economic slump through added investment in predictive maintenance technologies that will extend plant longevity, improve efficiency and avoid catastrophic, costly plant failures. However, easyFairs found opinion divided when it came to views on the board’s attitude to maintenance; 8 per cent said they saw it as expensive, while 8 per cent believed their bosses considered it as good value for money. Nearly two fifths said their respective boards saw maintenance as an invaluable part of the business, but one fifth said directors saw it merely as a “necessary evil”. easyFairs UK & Ireland Managing Director Matt Benyon said: “Businesses are still finding it tough, but many realise that cutting back on maintenance budgets is false economy. There’s a wealth of advanced, affordable technology on

show at MAINTEC 2012 that can deliver significant efficiency savings and help protect machinery and equipment.” Now in its 37th year, easyFairs MAINTEC 2012 is the UK’s leading exhibition dedicated to showcasing the latest asset management solutions, and offers maintenance managers an opportunity

to source the predictive maintenance technologies to help them tackle the tough economic climate. Matt added: “There’s a lot going on at this year’s show. We’ve launched a new hazard prevention area called HAZEX, plus have put a real emphasise on predictive maintenance technologies, which will come as pleasing news to those who took part in the survey.” Indeed, and in addition to utilising predictive maintenance systems, the research showed that training (45 per cent), energy management (42 per cent), and inventory/spare parts management (39 per cent) were other popular ways respondents planned to boost profits. Additionally, more companies are responding to the recession by focusing on contracting and outsourcing: of those surveyed over half (55 per cent) do not outsource maintenance and asset management at the moment, but contracting and outsourcing was ranked top priority for them over the coming months. Other key findings included that 70 per cent said the board uses productivity to measure plant performance, followed by downtime (61 per cent) and running costs (42 per cent). And encouragingly, 41 per cent said that the current climate had not forced them to postpone planned investment in major new equipment.MAINTEC 2012 takes place from Tuesday 28 February to Thursday 1 March 2012 at the NEC, Birmingham.

Maintenance Key To Improving Plant ProductivityMaintenance budgets are set to remain buoyant

and focus on improving plant productivity, even in

these times of austerity, research from MAINTEC

2012 show organiser easyFairs has revealed.

For more information or to register for the show please visit www.easyFairs.

com/MAINTECUK, and for stand bookings and exhibiting enquiries contact

Jerry Dawson on +44 (0)20 8843 8823 or email [email protected].


Maintec Preview

Instead of utilising a valve mechanism

to close off steam, the highly efficient

GEM steam traps use the patented

venturi orifice design to effectively drain

condensate from the steam system and

maximise energy and water conservation.

As the GEM steam traps have no moving

parts to wedge open or fail they provide a

permanent solution to steam trapping and

condensate return problems. GEM steam

traps also improve product processing

by enhancing the quality of steam and

reducing equipment repairs, downtime

and replacement costs. Available in a

wide range of sizes for a cross section

of applications, and with optional filter

where applicable, the GEM steam traps

provide companies with a fast payback in

increased equipment reliability, water and

energy savings of up to 30%.

TEI’s flue gas condensing heat recovery

economisers can reduce the energy

consumption of an industrial boiler by up

to 18% by capturing the waste heat in the

flue stream and converting it to hot water.

Thermal Energy International Inc. is an

innovative technology company providing

custom energy and emission reduction

solutions. The company’s award winning

energy recovery, conservation and

bio-energy solutions provide significant

financial and environmental benefits to

customers.

Thermal Energy International produces a range of GEM venturi orifice steam traps to suit a range of applications.

Thermal Energy International Raises The Bar On

Thermal Efficiency On Stand C8 At Maintec 2012Thermal Energy International Inc. (TEI) will be exhibiting its range of awarding winning energy efficiency products on stand C8 at the NEC Birmingham from 28th February to the 1st March. TEI’s products include its GEM venturi orifice steam traps and its flue gas condensing heat recovery economisers .

About Thermal Energy International Inc.Thermal Energy International Inc.

is an innovative clean technology

company providing a variety of

award winning energy efficiency,

emission reduction, water

efficiency and bio-energy products

and solutions to the industrial,

commercial and institutional

markets worldwide. Thermal

Energy’s products include; GEM®

- Steam traps and condensate

return systems, FLU-ACE® - Direct

contact condensing heat recovery,

and Dry RexTM - Low temperature

biomass drying systems.

Thermal Energy International

Inc. is also a fully accredited

professional engineering firm,

and offers advanced process and

applications engineering services.

FLU-ACE®, GEM®, DRY-REX®,

THERMALONOX®, and THERMAL

AUD® are trademarks of Thermal

Energy International Inc.

For more information, visit:

www.thermalenergy.com &

www.gemtrap.com.


Maintec Preview

E24

D14

F10

D1

D3

D12

C2

B2

E3

C8 C7

C3F7

B15

D5

D8

D21

C15

A14

B14

F9

F5

C10

C20

A11

F21

A7

A12

B7

F11 B8

E13

C9

B5

E19

A2

A6 B9

C17

A25

E11

A19

F18

E15

B4

B6

E8

F20

A21

F14

F25

F16

B10

F22

A3

D7

B11

C14D11

E21

A17C13

F4

C21

A4

E1

A2a

C18

F2

F15

B25

A5

B1

F1

B14a

B21

A15

D22

E9

C16

B3

B13

D23E23

B22C19

B18

E7

A22

A18

B26

B17

C17a

B12

A26

D17

A1a

F12

D6

C5

C23

A1b

B19

A1

D13

D19

B16

B19a

E25

D20

F8

D18

F6

Maintec 2012 Floor Plan

Exhibitor list on pages 34 & 35

Maintec Preview

Adash 3TP Ltd A25AESPUMP Ltd B14aAlpine Components B10Ambersil (CRC UK Ltd) B4Antech Hydraulics (NTZ Filtration) A12AV Technology Ltd C20BCAS F4Bel-Ray Company Inc. E8BELGRAVIUM A1bBINDT - The British Institute of NDT F12C-Cubed Ltd/Jenton Group B5Castle Group Ltd D22Censol Ltd A4CEPSTRA (UK) LTD A15Clean Air Group D13Cobalt Conveyors E25Control Freq GSM C19CorDEX Instruments F5

Crimson Industrial Vision Ltd A2Des-Case Corporation D12DP Doors & Shutters Ltd C16Dust Control Systems Ltd F9

Dustcontrol UK Ltd E15

EA Technology E21Easylaser / Damalini AB A19ERIKS STOREROOM SERVICES B9

ERIKS UK Ltd A6

Facilities Management Association E23Flexilube Ltd B6FLIR Systems E3Flowcrete UK Ltd A14Fluke (UK) Ltd F7Flux Pumps International (UK) B18Gardner Denver Ltd F1Gemini Data Loggers (UK) Ltd B16Hansford Sensors Ltd C7High Voltage Partial Discharge C21Hire Torque Ltd C3Holroyd Instruments Ltd F22Icetech UK B1

Idhammar Systems Ltd C15IFM Electronic Limited B2IGS UK LTD A1Infor C10Inpro-Seal C17Institute of Infrared Thermography A2aIPEC Ltd B13IPS International Ltd B11Jacob UK Ltd D7Jena Rotary Technology F16John L Lord & Son Ltd (Specialist Flooring) D6Jungheinrich (UK) C5Jungheinrich (UK) C23KRR Prostream C13Kuwait Petroleum International B7Lighthouse (UK) Ltd A17Llumarlite Ltd B3LOBO Systems Ltd F25Losomat UK B12MACS EU Ltd E9Maintenance Connection UK LTD E13Mattei Compressors F6MEPCA B17

Metrum Information Storage Ltd A7Michell Instruments Ltd D21Micropoly Europe Ltd B25MIDLAND GROUP TRAINING SERVICE E19MONITION LTD - Fixturlaser UK A3

Exhibitor List | Maintec 2012



Maintec Preview

Maintec Preview

MSL Group A26OCIP Energy Ltd D23OPTRIS GmbH E1Pickerings Lifts F15Plate & Locate F18PMI Software Ltd E11Prevost UK Ltd F2Probe Technical Recruitment F21Process Industry Informer B26PRUFTECHNIK Ltd D1

Quartzelec Ltd D17

R. STAHL D18Radir Ltd C2RMS Ltd F20Ro-Dor Ltd D5

RRC Training A18S.E.M.CO D19

SAFELIFT ONSHORE A1a

SCHAD AUTOMATION E7Schaeffler UK Ltd D3

Shire Systems Ltd D11

Sira Test & Certification D20

Siveco UK Ltd C9SMARTAG LTD C14

Softsols Group D8SPM Instrument UK Ltd A21

SRI

B19aSRO Solutions LtdC18Technical Training SolutionsA11Tempus MTAS LtdB15

Teseo UK F14Testo Limited B8THE INSTITUTE of ASSET Management F8

Thermal Energy International C8

TotalMobile A22TR Floor Systems B21Valveforce B14Walrus Pumps UK Ltd B22WD40 Company B19Western Business Publishing C17aWymark Ltd F11XETEC A5

More Maintec Preview On Page 36...


Maintec Preview

Maintec Preview

New to the show this year will be

the VISIO PRIME Inspector – a 6mm

dia. Video Endoscope with 4-way

articulation specifically designed for

industrial inspections or machinery, pipes

and tubes, and other hard to access

equipment. The VISIO PRIME Inspector

will deliver high quality images, allowing

minimal dismantling to inspect the area

of interest. Weighing in at less than 1kg,

this highly portable, battery powered unit

has the ability to go anywhere and makes

an ideal inspection tool when you need to

get to those hard to access areas.

With a complete range of Video

Endoscopes, the Crimson Industrial

Vision is able demonstrate systems to

suit every application, from a simple video

inspection camera to the premium fully

articulating, long range endoscope for

detailed inspection. Also on show will be

a range of FLIR Systems Thermal Imaging

cameras, including the latest i7 and

E-Series. As a special offer at Maintec,

if you buy a FLIR E or T series camera

after visiting us on Stand A2 at the show,

we will include an Extech BR250 Video

Borescope free of charge.

New Video Endoscope for Maintec 2012

Inspection camera Specialist Crimson Industrial Vision will be

bringing its range of Thermal Imaging cameras and Remote

Visual Inspection products to MAINTEC 2012.

There will be 30 learnShops

(seminars) running over the three

days, with speakers from major

brands such as Britvic, Siemens, and

Schaeffler, all revealing their secrets

to help those visiting succeed in

2012.

“In today’s challenging economic

climate, it is even more important

to introduce an effective condition

monitoring (CM) regime that enables

engineers to keep their machinery

running efficiently,” says Ian Pledger,

Field Service Engineer for Schaeffler

UK, and who will be the first speaker

to start the learnShops programme.

Ian continues: “We talk to many

industry professionals who are

considering CM for their facility but

who are not sure at first how best

to go about it, or feel that CM may

be too complicated or costly. With

actual case study examples, we can

demonstrate that it is possible to

start off slowly with a few techniques

and then develop them over time to

suit their plant equipment and their

maintenance budgets.”

EXPERTS TO REVEAL WINNING MAINTENANCE

TECHNIQUES AT MAINTEC 2012

easyFairs has attracted a wealth of maintenance specialists,

all willing to share their winning techniques and vast

experience with visitors of the MAINTEC 2012 show, taking

place from Tuesday 28 February to Thursday 1 March 2012

at the NEC, Birmingham.


Maintec Preview

Maintec Preview


Health & Safety

This has never been clearer as more and more innovative Draeger ideas are becoming viable commercial offerings and state-of-the-art equipment for the very best in personal protection. As part of this total solution offering, Draeger has opened a number of dedicated Safety Centres across the UK. Located in Aberdeen, Blyth, Gatwick and Plymouth, additional Centres are also currently being discussed

In charge of this initiative is Brian Hesler, ex Fire Chief at Northumberland Fire and Rescue Service, who brings first hand experience of the need for effective training and first class equipment. Developed to meet business demands and serve its customers better, these Centres are intended to bring Draeger closer to its customers. Combining sales and service from experienced personnel, they also offer a wide range of training courses and access to the complete range of Draeger gas detection and respiratory protection products on a short or long term rental basis.

Draeger’s Aberdeen Safety Centre, for example, has been proven to offer a very successful formula. Opened 18 months ago, it has just been granted approval to double the size of its facility to offer more training and other services alongside additional storage. As well as assisting and supporting fire and rescue services, this facility also supports general industry and, of course, Aberdeen’s core oil and gas industry which operates in both upstream and downstream market areas. Offshore safety inductions, for instance,

have been carried out for up to 35 people a day prior to rig shutdowns.

Located just 20 minutes from the harbour, the Centre is run by Kenny Durward who has extensive experience in rental, service and maintenance as well as the marine, oil and gas industries. In addition to service, maintenance, face fit testing and a range of training courses, including OPITO approved H2S awareness training, this Bridge of Don site is also finding that the rental side of the business is extremely buoyant. Whether planned or in an emergency, plant and rig shutdowns require the use of different personal protective equipment over differing time frames. Offering fully maintained and certificated equipment for rental over short, medium and long term periods, Draeger ensures that essential equipment is available immediately. On-site training can also be provided at the time of rental if required.

In the north of England, the Blyth Safety Centre combines a centralised administrative base with repair workshops, services, lecture areas and confined space training facilities. Welcoming customers from all over the UK, it echoes Aberdeen’s commitment to meeting customer needs with more choice and more experience in training, service and the sale or rental of equipment.

Other specialist personnel, each bringing their own particular knowledge and experience to dedicated areas of the business, as well as these new facilities, have joined Brian’s team. Peter Silk,

formerly a technical advisor to Firebuy and Assistant Divisional Officer with the London Fire Brigade (LFB), manages the new Southern Safety Centre at Gatwick. Now operational, Gatwick ,in addition to the range of services offered by Aberdeen , also offers test facilities for chemical protection suits as well as calibration and repair of thermal imaging cameras, and test and certification of compressed air cylinders.

Peter will also be responsible for the running of another new Safety Centre in Plymouth, looking after the needs of Cornwall, Devon, Somerset and the south west. Modelled on Aberdeen and covering all areas of industry, the Plymouth Centre offers the full range of services and, like each of the other facilities, can accommodate Draeger’s mobile confined space trailer and mobile display vehicle.

Representing a significant capital investment and employing around 50 people so far, these Safety Centres are at the forefront of a new era in Draeger customer service. Additional Centres are currently being discussed, as is the potential to work with partners in joint facilities. Also under development is an innovative E-learning platform which is set to take online training to a completely new level.

Brian concludes “We are still growing, still recruiting and still looking at ways to become even closer to our customers. The development of these Safety Centres was the result of in-depth customer discussions and listening to industry feedback. We are fully committed to meeting our customers’ needs and, in so doing, believe that we can help to ensure the utmost safety for those customers. A total solution offering is the key to our success and, we believe, the key to a safer future.”

Draeger Safety Centres – Now Across The UKOne of Draeger’s greatest successes is being able to offer

its’ customers “a total solution” rather than just “a product”.

For further information contact

Customer Service, Draeger Safety

UK Limited, Ullswater Close, Blyth

Riverside Business Park, Blyth,

Northumberland, NE24 4RG.

Tel: 01670 561200,

fax: 01670 356266,

www.draeger.com.


Humidity Calibrators

The temperature compensated

control probe provides higher

accuracy over the range of

measurement. Newly designed

electronics is incorporated within

the heat/cool circuitry and a more

efficient peltier mechanism, has been

incorporated for faster response and

temperature stability. The number of

ports in the chamber door has been

increased to accept 5 probes with

diameters of 10mm, 12mm, 15mm

The M2000SP-XR Humidity GeneratorOne System…Three Functions

High Accuracy Calibration of Instruments Over Full

Operational Range The field proven M2000SP-XR with new

solid state electronics for high accuracy and performance

over the full operating range of humidity and temperature.

and 18mm. NVLAP Accredited

calibration of control probe. System

tested for performance at ICH

guideline parameters to meet

accuracy and long term stability

requirements. Typical response time

is 3 minutes for 70%RH step change.

Production and Volume Calibrations

at Ambient Temperature

The chamber size of the M2000SP

standard system is 2 liters. For

calibrations of multiple data loggers

or sensors the chamber

capacity must be

increased. The

M2000SP-XR, using

the 12 port external

chamber, provides the

increased calibration

capabilities through the use

of a chamber with

internal dimensions

of 250mm x 200mm

x 100mm (h x w x

d). Nine (9) horizontal

ports have sufficient

separation

to prevent

interference and

to maximize

number of

transmitters for

insertion within the

chamber. Three (3) top ports are

for instruments with long probes

(250mm) or reference standards

to verify internal readings. Clear

chamber door for visual observation

of instruments with digital displays.

Calibration of Chart Recorders

with Embedded Sensors Using

Programmed Procedures

For fast, accurate calibration of

battery operated chart recorders

having the RH/T sensors embedded

within the recorder housing. The

internal blower of the M2000SP has

been modified for a more efficient air

flow, both within the internal chamber

and the external chambers. The

large external chamber has internal

dimensions of 300mm x 250mm x

150mm (h x w x d). Accurate RH

calibrations over the range of 10-

90%RH, at ambient temperature,

can be done more quickly than when

using larger chambers. A typical 3

point RH calibration can be done in

less than 1 hour after temperature

has stabilization. The internal

chamber conditions are verified using

a reference instrument calibrated

by an NVLAP Accredited laboratory

according to ISO/IEC guidelines and

17025 procedures. Through the

use of pre-programmed calibration

procedures , the required calibration

cycle can be done automatically.

Kaymont Consolidated Industries

Tel: (631) 951-9100

Fax: (631) 951-9109

180 Oser Avenue, Suite 200,

Hauppauge, NY 11788

[email protected]


Level Measurement

Hardness Test Solution

SiloPatrol® level sensor can improve silo inventory control and plant safety

Monitor Technologies’ SiloPatrol® smart weight and cable-based level sensors are effectively utilized to improve inventory control of powders and bulk solids stored in vessels.

The sensors measure the material inventory level

automatically and on-demand without the need for plant

personnel to climb silos, which helps to increase plant

safety. SiloPatrol can also be interfaced with optional

operator interfaces.

The SiloPatrol® uses time-proven weight and cable

techniques and includes Hall Effect sensor technology,

state-of-the-art sealed bi-directional optical sensing, a

split-compartment enclosure design, isolated outputs and

other valuable features to produce a rugged, reliable and

accurate measuring system designed for the harshest

and most dynamic conditions.

For more information:

Please visit www.monitortech.com, e-mail monitor@

monitortech.com or call 1-630-365-9403 for more details.


Induction Heat Treatment

Infrared Thermometers

Our standard infrared thermometer started back in the 1970s with the System 1, some of which are still in operation today. System 4 our latest range of infrared thermometers has evolved to be suitable for a wide range of applications, ranging from steel and glass to cement and road stone. We are now able to meet the majority of special customer requests for temperature ranges to meet their exact application requirements. Please visit our website:www.landinst.com for further details.

Land Instruments International - Over 60 years of providing temperature measurement solutions

Land Instruments InternationalEmail us on [email protected]

Call us on +44 (0) 1246 417691Visit us at www.landinst.com

LAND has been at the forefront

of infrared (non-contact)

temperature measurement for

over 40 years.


Editors Choice

How CMMS Software Can Improve Your Chance Of Successful Implementation

80% of CMMS Implementations fail

80% of CMMS Implementations

fail is a term that can be found in

many articles. Those failures can be

described in many ways, e.g. where

the budget overruns, where only 20%

the software is eventually utilised

(then sometimes regarded as a great

success), or where the changing of

the original to the planned business

process simply failed. The reasons for

the latter can be attributed to difficult

selection processes, incomplete

requirement identification and/or a

lack of implementation management.

Rigid CMMS software

Rigid CMMS software with a lack

of possible customisation can be a

significant reason. Another factor

is that the software does not have

sufficient features, or in fact the

opposite where it

has far too many features and is

simply too difficult to operate. Failure

to operate in a manner that suits

the “way we do things”, means you

have not achieved workforce and

management commitment, and all

efforts are on trying to use the new

system in the same manner as the

old, the result being shelfware and

not software. But what if the software

could operate in both old and new

manners? Is that possible?

Possible solutions

Possible solutions can be found in

CMMS software that offers modules

as your system grows, therefore

allowing continuous improvement.

Many suggest that configuration or

customisation of the system is the

only way forward, but this can prove

to be expensive, but not anymore.

The new solution

The new solution is in modern

software creation technology. The first

step is to consider software that has

all the possible features you would

ever want but has 80-90% of them

turned off

or invisible. The second and more

important requirement is that menus,

screens, dialog boxes and wizards

are flexible. Flexible means they can

be configured, and even for different

users, but take care, don’t abuse this

capability. This allows a step-by-step

process in moving from an existing

duplicate system to a new improved

system. Indeed in many cases it can

be the opposite, i.e. a need to reduce

the number of fields on the screen

or better still screens in the process.

In either case that’s continuous

improvement, introducing a new field

on the screen, month by month.

And the argument of web versus a

network system is over. Do both with

the one system.

Contact Xetec on:

By Phone:Manchester, M22 5XB: +44 161 408 7777Bray, Co Wicklow: +353 1 442 9997 By E-mail:[email protected] or [email protected]


Heat Exchangers

Spare Management Software

• Hygienic, Double Tube-Sheet Exchanger for the Pharmaceutical Industry.

• Shell and Tube to all TEMA Classes and Types.

• Electric heaters certified for use in Explosive Atmospheres, Ex d IIA T3, other gas groups and temperature class are available.

• Condensers. • Re-boilers and Evaporators.• Atmospheric Vaporisers

(Longitudinal Fins).

Logichem Process EngineeringLogichem Process Engineering (LPE) offers a wide range

of Heat Exchangers – manufactured and supplied in

various materials and designed with the most advanced

process, thermal and mechanical software. All of LPE’s Heat

Exchangers comply with the TEMA and ASME codes.

For more information,

contact:

Mr Ignatius Herbst

(Managing Director)

Email:

[email protected]

Or visit us at:

www.logichemprocess.com

LPE’s Heat Exchanger range includes:

An Explosive Proof Syngas Ex d Heater.

PARTS-PUBLISHER is a customisable standard

software that enables equipment manufacturers

and operators to assemble, distribute and

automatically update parts and service information.

The application delivers all parts and service

data – such as parts catalogues, maintenance

manuals, technical specs and sales collateral – pre-

filtered according to serial number, product line or

configuration/trim package. PARTS-PUBLISHER

catalogues employ an intuitive user interface

that provides a synchronised view of assembly

drawings or 3D models and associated parts lists,

including detailed information such as pricing, part

Solutions for Parts and Service InformationUse PARTS-PUBLISHER to automate

parts catalogue creation, improve parts

identification, streamline parts ordering

and reduce mis-orders

For more information please visit:

www.docware.com

Demo catalogues and videos online!

description, service bulletins etc. Built using industry

standards, the product integrates seamless with key

business applications such as ERP, PLM or CAD.

Buyers Guide


49

Buyers Guide

Ad

vert

ise

Her

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49Jan/Feb 2012


Buyers Guide


engineering maintenance solutions feb 2012

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