hazardous engineering solutions - feb 2013

7/29/2019 Hazardous Engineering Solutions - Feb 2013

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February 2013 | Issue 10

4-6

16-17

30-35

Industry Latest News

Health & Safety

The Hazex/Maintec Show Preview

Halifax Fan LtdReports TwoRecord Years

Page 12


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4-6

16-17

22-23

27

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INDUSTRY LATEST NEWS

HEALTH & SAFETY

DUST AND FUME EXTRACTION

ATEX EQUIPMENT

THE HAZEX/MAINTEC SHOW

PREVIEW

EXPLOSION PROOF PRODUCTS


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Stands 47 and 48 will feature a comprehensive

selection of ABB equipment utilising a variety of

measurement techniques, including laser, zirconia

and FT-IR spectrometry.

Products on the stands will include the LS25

laser gas analyser. Enabling in-situ monitoring in

stacks, pipes, process chambers and other similar

applications, the LS25 uses tuneable diode laser

absorption spectroscopy (TDLAS) to measure

concentrations of various gases including oxygen

and ammonia in gas streams. Offering a very fast

ABB to highlight emissions technology and know-how at AE 2013

ABB will be exhibiting its latest range of air and gas analysers at the Air Quality and

Emissions (AE) Show at the Telford International Centre (13-14th March 2013).

response time, the LS25 is especially suited to

applications with fast changing conditions such as

municipal waste incineration where the composition

of gases may be subject to rapid changes.

Other equipment on display will be ABBs new

Endura AZ10 zirconia oxygen and StackFlowMaster

instruments.

For more information, email

[email protected] or call

0870 600 6122 ref. AQE 2013.

HES August 2012HES December 2012HES February 2013

Based on customer requirements new cost

saving innovations and improvements have been

implemented into the manufacture of Rittals TS

8 enclosures.

The following updates will start to take effect

from December 2012 onwards. Tool free

adjustment of the mounting plate depth;

additional markings every 100mm in the vertical

sections for positioning of rails; TS 8 punched

pattern on the door frame for easier installation

of equipment; simple mounting plate earthing

from the front to negate the need to remove

the rear panel or mounting plate and a low

tack baying seal for easier re-adjustment where

neccesary.

All benefits have been introduced for quick and

easy assembly of Rittals TS 8 enclosure, which

can realise customer savings in both time and

costs.

Rittal Introduce New TS 8 Updates

For more information follow the link below:

http://www.rittal.co.uk/information/TS8UpdateFlyerFINAL.pdf

Eef Comment On Lofstedt Progress Report

This report signifies welcome progress on restoring

a proportionate and balanced approach to health

& safety legislation. However, government must

ensure that in the rush to clear the stock ofregulations government doesnt remove measures

that business finds helpful.

Furthermore, having made welcome progress at

home, the UK government must now lead efforts

at EU level to ensure the forthcoming review of

health & safety Directives ensures that we only

see regulation from Brussels where there is clear

evidence it is needed and, whose impact on

business has been thoroughly assessed.

Commenting on the report on the progress of the Lofstedt Report

recommendations on health & safety, Terry Woolmer, EEF head of Health &

Safety Policy, said:

Finnish utility Teollisuuden Voima

Oyj (TVO) said that, based on recent

progress reports from the Areva-

Siemens consortium constructing the

plant, it is preparing for the possibility

that the start of the regular electricity

production of Olkiluoto 3 nuclear power

plant unit may be postponed until 2016.

Last year it said that it would be delayed

beyond 2014.

Construction of Olkiluoto 3 started in May

2005, with completion originally scheduled

for 2009. However, the project has suffered

several setbacks. TVO announced in

December 2011 that it anticipated the 1600

MWe Areva-designed EPR reactor would

begin commercial operation in August

2014, some five years later than originally

planned.

In July 2012, the company declared that

the plant unit will not be ready for regular

electricity production in 2014. Noting

that Areva-Siemens are constructing the

plant under a fixed-price turnkey contract

and are therefore responsible for the time

schedule of the project, it requested the

supplier provide an updated schedule and

completion date.

TVOs senior vice president, Jouni

Silvennoinen, said in a statement: We have

not yet received an adequate schedule

update. He added, Additionally, the

instrumentation and control (I&C) design

has not proceeded as planned, and

therefore the plant completion may be

further delayed.

Finnish utility says Olkiluoto

3 nuclear plant faces further delays

Latest Industry News

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5 HES February 2013


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Coromill 316 Exchangeable-Head Milling System Is

Now Available With Internal Coolant

The CoroMill 316 exchangeable-head milling system is a truly versatile

system for milling operations. It can be applied for high feed face milling,

slot milling, helical interpolation, shoulder milling, profile milling and

chamfer milling of components in material groups from ISO P to ISO S.

For more information and a closer look at

the CoroMill 316, visit

www.sandvik.coromant.com/productnews

Mine Explosion Kills Eighteen In Northern Russia

From March 1st this high performance system is

available with internal coolant holes.

The machining of such materials as Heat Resistant

Super Alloys, Titanium and Stainless Steels often

requires the use of coolant for temperature control

and chip evacuation during cutting. Re-cutting of

chips and chip jamming often lead to poor surface

quality, damage to the cutting edge and toolbreakage.

By offering an internal coolant solution, with

precise positioning of coolant holes to optimize

the effect of the coolant jet, CoroMill 316 is able to

outperform existing solutions with external coolant,

guaranteeing superior chip evacuation and a secure

cutting process.

The CoroMill 316 system allows machine shops

to quickly, easily and accurately switch between

various operations such as cutter type, radius

variation, teeth frequency, geometry and grade.

CoroMill 316 end mills are even suitable for five

axis milling of flanks which often require taperedtools for stability at longer tool reach.

On February 11 the Russian Interior

Ministry said nine people had died

and eight more could be trapped

under rubble at the Vorkutinskaya

coal mine in the northern Komi region

after a gas explosion. Later in the

day, Interfax said the death toll had

increased to 18, with 10 brought to

the surface.

The blast, at a mine owned by a division of one

of Russias largest steel producers, Severstal,was caused by a build-up of methane gas, the

Ministry said in a statement.

A total of 259 miners were working underground

when the explosion took place and the majority

have made it back to the surface, according

to the Emergencies Ministry, with some

accompanied out by rescue workers.

Initial reports had said around two dozen miners

were working in the shaft where the explosion

took place.

The mine, in the northern city of Vorkuta, is part

of the coal mining division of the Russian steel-

making giant Severstal, whose mills it provides

with hard coking coal concentrate.

According to AFP it has been operational since

1973 and has an output of 1.8 million tonnes of

coal a year, with total coal reserves estimated at

40 million tonnes.

Methane gas explosions remain a frequent

occurence in the coal mining industry in Russia,

despite recent drives to improve safety.

In 2010, 68 people were killed in twin methane

blasts at Russias biggest underground coalmine, the Raspadskaya mine in the Kemerovo

region of Siberia.

CoroMill 316 exchangeable-

head milling system is now

available with internal coolant

The CoroMill 316 exchangeable-head milling

system is a truly versatile system for milling

operations. It can be applied for high feedface milling, slot milling, helical interpolation,

shoulder milling, profile milling and chamfer

milling of components in material groups

from ISO P to ISO S.

From March 1st this high performance

system is available with internal coolant

holes.

The machining of such materials as Heat

Resistant Super Alloys, Titanium and

Stainless Steels often requires the use of

coolant for temperature control and chip

evacuation during cutting. Re-cutting of

chips and chip jamming often lead to poor

surface quality, damage to the cutting edge

and tool breakage.

By offering an internal coolant solution,

with precise positioning of coolant holes

to optimize the effect of the coolant jet,

CoroMill 316 is able to outperform existing

solutions with external coolant, guaranteeing

superior chip evacuation and a secure

cutting process.

The CoroMill 316 system allows machine

shops to quickly, easily and accurately

switch between various operations such as

cutter type, radius variation, teeth frequency,

geometry and grade. CoroMill 316 end

mills are even suitable for five axis milling of

flanks which often require tapered tools for

stability at longer tool reach.

For more information and a closer look atthe CoroMill 316, visit

www.sandvik.coromant.com/productnews

Latest Industry News

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7 HES February 2013


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HES August 2012HES December 2012HES February 2013 8


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9 HES February 2013

Walsall Ltd had over one hundred years of UK

heritage dating back to the early days of Walsall

Conduits PLC, which once dominated the world

of electromechanical explosion protection. Today,

Pepperl+Fuchs UK manufacturing is located

in the companies new 60,000 sq ft facility in

Wednesbury, just off the M6 J10. A complete

range of mechanical explosion protection products

and customised solutions are manufactured in the

West Midlands for customers throughout the UK,

examples of our portfolio are highlighted below:

Enclosures & Terminal Junction Boxes

Pepperl+Fuchs mechanical explosion protection

products are based around high quality enclosures

in the increased safety, intrinsic safety and

flameproof protection classes. The range provides

several different options of enclosure dependant

upon the project application and specification

required, with a variety of sizes and materials

available including stainless and mild steel, as well

as glass reinforced polyester (GRP). All products are

manufactured to the same exacting levels of quality

which Pepperl+Fuchs has been associated with for

over 65 years.

Local Control

Using Pepperl+Fuchs manufactured enclosures, a

comprehensive range of multi function local control

stations and control panels are also available.

Standard and customised local control stations

in glass reinforced polyester and stainless steelenclosures are complemented by Exd IIC Local

Control Stations utilising cast iron enclosures.

Exd Customised Enclosure Solutions

Pepperl+Fuchs has a huge amount of knowledge

and experience in creating customised Exd

enclosure solutions to meet the specific project

requirements of our customers. These bespoke

solutions allow the hazardous area mounting of

a wide range of industrial products which do not

have Ex approval. Components such as PLCs,

intrinsic safety barriers, starters, and transformers

can be mounted in an Exd enclosure which then

allows them to be located in a zone 1 certified area.

The enclosures are typically manufactured in cast

iron, aluminium and stainless steel materials with a

wide range of sizes and orientations available.

Solutions can also be engineered to customer

specific requirements using combinations of the

product range. A typical example would be an ASM

type Exd enclosure containing industrial equipment

close coupled to an FXL type Exe enclosure via

a line bush. The Exe enclosure is used to house

control functions and terminals therefore allowing for

easier installation.

Certification

As a global supplier to a wide range of industries

and applications, all Pepperl+Fuchs products are

certified to a variety of international standards

including the latest ATEX and IECEX guidelines.

Our products are used in a variety of applications

from oil platforms to pharmaceutical plants

and everything else in between; therefore we

ensure certification allows usage in gas and

dust environments as well as a wide range oftemperature extremes.

The equipment product construction standards

make provision for different methods or types

of protection, two common methods plus a

combination of both are as follows:

Increased Safety (Exe)

Increased safety (Exe) protection is based on the

premise that an explosion will not occur if a spark

cannot occur. Increased safety protection can only

be used for equipment that does not include spark

or heat producing components in normal service

and where increased safety measures have been

implemented to further reduce these risks. An

Exe enclosure need only meet a rating of IP54 to

prevent water ingress leading to electrical fault and

sparking. A simple example would be a terminal

junction box.

Flameproof (Exd)

Many types of industrial equipment such as PLCs,

contactors and MCBs can be certified using the

flameproof concept. The external enclosure of

flameproof equipment is designed to withstand

an internal explosion. The enclosure joints permit

the products of combustion, and the resulting

expansion of gases, to be relieved through the joints

and not to permit that explosion to transmit through

to the external atmosphere. In many instances

a combination of both Flameproof and Increased

safety in the same solution, rather than an Exd

enclosure on its own, can provide reductions in

cost, space and weight.

Hazardous Area Certified Enclosures - A Solution

For Every Application

Pepperl+Fuchs the worlds leading manufacturer of intrinsicallysafe explosion protection and electronic sensors acquired UK based

Walsall Ltd to increase expertise and capacity in the manufacture of

mechanical explosion protection products for use in hazardous areas

and harsh environments.

Telephone: +44 (0)161 633 6431

Email: [email protected]

Group Website: www.pepperl-fuchs.co.uk

Hazardous Area Enclosures


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Detect Heat & Overheat Before There Is Fire Or Explosion

Detect Heat and Overheat (and Fire) and

report/alarm from 60 385C

in Engine-rooms, Wind generators, Power Plants,

Ovens, Generators, Dryers, Trains, Gas turbines,

Heating rooms, Factories, Inventories and many

more. Reliable 2- or 4-wire N/O or N/C switches,

FM approved, connect to your existing alarm

system or take the comprehensive LICO HDL

& Stand-Alone or intermitting Alarmpanel HDL

to secure life and your values by in advance

monitoring.

LICO Mecatronic S.R.L. Str.Bucinului

Nr.2B / 19 RO-540526 Targu-Mures

Romania

Tel. +40 365 807 497

Fax: +40 365 434 999


LICO Hungaria Kft Raba u. 4

H-2030 Erd, Hungary

Tel + 36 23 520 113

Fax + 36 23 520 115

email: [email protected]

LICO Electronics GmbH Klederinger Str. 31

A-2320 Kledering Austria

Tel + 43 1 706 43 00

Fax + 43 1 706 41 31

email: [email protected]

Learn more by visiting:

www.prevent-a-fire.eu

or www.fenwal-direct.eu

A World First At MAINTEC

It takes a proven method of inspection and not

only extends its scope of application into explosive

environments but also adds in RFID technology so

that findings can be tagged to a location and trends

easily documented.

The world launch platform for this development is

the CorDEX Instruments stand at the MAINTEC

CorDEX Instruments, the UK manufacturer

of instrumentation and equipment for

hazardous environments, is introducing a

new intrinsically safe product at MAINTEC

2013 that is a well suited for anyone involved

in predictive maintenance.

show. The company will also be showcasing several

other products in its popular range of handheld

inspection and NDT devices for operation in

hazardous areas.

Visitors are invited to test drive CorDEX

Instruments other ATEX certified products including

the ToughPIX series of digital cameras, the

LaserMETER 3000XP laser distance meter and the

UT5000 intrinsically safe ultrasonic thickness gauge.

The companys IW Series Intelligent IR Windows

with locking mechanism and multiple identification

system will also feature.

Tel: +44 (0)1642 454373


http://www.cordexinstruments.com/

Latest Product News

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Halifax Fan Ltd, based in Brighouse enjoyed sales

growth of 30% in 2000/11 and followed that up with

a record 43% growth over the last twelve months.

Established in 1965 to serve the local textile

industries, Halifax Fan designs and manufactures

a wide range of industrial fans and has grown

to be a global player with offices and factories

in China, Hong- Kong, Thailand and Sydney

Australia. Managing Director Malcolm Staff, Fan

technology hasnt changed much over many years

but their application is essential in a great many

industries. We saw the opportunity to strengthen

our position simply by making our products more

reliable and more efficient, reducing their total cost

of ownership. It was also clear that the main growth

Halifax Fan Ltd Reports Two Record Years.

While the global economy is still struggling

and major UK high street chains are failing,one Yorkshire based traditional engineering

company reports two bumper years.

market was the Far East, particularly China, where

power stations and petrochemical plants were

being built widely and that to enter that market,

we needed a local base. In 2006 we opened a

modest manufacturing facility in Shenzhen, just over

the border from Hong-Kong and this has grown

to span three factory units totalling some 4,000

m2. Crucially, from the outset, we focussed on

embedding our UK quality practices in the Chinese

plant and invested in staff training to ensure that

product quality and reliability is constant regardless

of which plant our products are built in.

The petrochemical and oil industries particularly

demand fans built to the highest safety standards

and Halifax has developed a particular expertise in

this sector, even to the extent of in-house testing

and certification to these standards. This has

resulted in repeat orders such as the two year

contract to supply 50 hazardous area fans per

month to a US oil sector company and a single

order for Halifaxs biggest ever fan worth almost

$1m.

All of this has required a continuous investment

in computer based design and manufacturing

technology, moving software and communications

to the cloud and extensive personnel training and

most significantly, apprenticeships and graduate

sponsorships to overcome the UK shortage of

skilled engineers. Plans are in place for further

growth globally so this one UK company that has

got on its bike and found success where other

less bold companies have struggled to weather the

recession.

For more information on halifax fans,

please contact:

t:+44 1484 475 123

W: www.halifax-fan.com

e: [email protected]

Industrial Fans

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Thermal oil specialist Global Heat

Transfer is calling for the food and

pharmaceutical industries to ensure they

use compliant food-grade (FG) thermal

fluids in heat transfer applications.

The company believes that, although the use of FG

fluids is a regulatory requirement imposed by several

bodies including the FDA and NSF, it is one that

many manufacturers are entirely unaware of.

If there is any possibility that an oil or lubricant could

come into contact with food products, a certified

FG fluid must be used to safeguard consumer

health. Failure to use FG oil in a food application

can result in the loss of the manufacturers top tier

accreditation if the EFSIS (the European Food Safety

Inspection Service, part of SAI Global Insurance

Ltd.) learn that an inappropriate product is being

used.

Non toxic, clear in appearance and odourless, FG

oil is extremely important in the food processing

industry as it is a regulatory requirement and a

sound financial investment. FG oil is designed not

to contaminate food so, should a minor spillage

occur, there would be no need for products to be

recalled. Furthermore, Globaltherm FG performs

better than none FG products in FG applications

as it maintains carbon in suspension rather than

depositing it and therefore helps to reduce carbon

build up.

Global Heat Transfers FG oil is a high efficiency

heat transfer fluid specifically developed for non-

pressurised, indirectly heated, liquid phase heat

transfer systems that require

bulk temperatures up to

326C (620F), as are used

in food processing plants,

pharmaceutical operations

and other FG applications.

Globaltherm FG thermal

fluid from Global Heat

Transfer is fully H1 certified

by the US Food and Drug

Administration (FDA). It also

holds NSF (National Science

Foundation) International

HT1 approval.

Made from a mixture of pure heat transfer

hydrocracked base oils, Globaltherm FG thermal

fluid has excellent thermal oxidation stability

allowing operation at high temperatures for

extended periods, which can be extended when the

oil is maintained and monitored properly. It is non-

hazardous, non-toxic and odourless, which means

it requires no special handling and is not considered

a controlled substance under United States OSHA

(Occupational Safety and Health Administration),

Canadian WHMIS (Workplace Hazardous Materials

Information System) or other work place regulations.

Global Heat Transfer provides a complete solution

for all thermal fluid related issues. It offers 24 hour

delivery of premium quality thermal fluids and

planned maintenance programmes as well as

expert sampling and analysis services. The latter

allow the end user to remain compliant with industry

regulations and meet their insurance requirements.

Thermal Fluid Specialist Puts Food-GradeOil On The Menu

For further information contact: Andrew

Burns or Caroline Law,

Global Heat Transfer Ltd., The Global Group

of Companies,

Cold Meece Estate, Cold Meece, Stone,

Staffordshire, ST15 0SP

Telephone: +44 (0) 1785 760555

Fax: +44 (0) 1785 760444

www: http://www.globalheattransfer.co.uke-mail: [email protected]

Twitter: https://twitter.com/G_HeatTransfer


Thermal Oil

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The Protg ZM is a zero maintenance solution,

meaning no battery charging and no sensor

calibration is necessary to operate the monitor.

The monitor has a high performance battery

which provides two years of operation. In typical

conditions, calibration will not be necessary during

the operational lifetime. Three single gas models are

available including Oxygen, Carbon Monoxide and

Hydrogen Sulphide.

The Protg ZM is small, lightweight, ergonomically

designed and meets IP67 requirements for ingress

protection. We designed this monitor with ease of

use and comfort in mind. The unique

Protg profile fits your hand nicely making the

monitor comfortable to hold. Its so lightweight

and small, you will forget youre wearing it while it

protects you, says Mel Gerst, Scott Safetys Global

Product Line Manager for Portable Gas Detection.

The monitor is very simple to use. Just turn it on for

the first time, and it does the rest. Using the default

settings from the factory there is no need to set up

or program the monitor.

The Protg ZM features plenty of customisable

settings to meet your specific needs. For example,

a Hibernate mode is available on the CO and H2S

models. The Hibernate mode puts the monitor

in a deep sleep for up to one year to extend

the operating life beyond two years. Users can

customise the alarm set points themselves or order

monitors with custom alarm set points programmed

by the factory. Users can also set up custom bump

and calibration reminders if they desire. The monitor

has the option to display continuous gas readings,

life remaining or both. The monitor has a three point

alarm (audible, visual, and tactile) and data logging

capabilities.

The Protg ZM monitor is supported by a portfolio

of accessories including a four-bay test station

and IR Connect programmer. The test station

supports bumping, calibrating, hibernating and

programming of up to four monitors simultaneously,

and is available in both portable and table-top

versions. The IR Connect allows programming and

hibernating of individual monitors.

Scott Safety Expands The Protg Portable Gas

Detection Portfolio With The Addition Of The

ZM Protg Single Gas Monitor

Scott Safety announces the introduction of

the Protg ZM Single Gas Monitor a zero

maintenance single gas monitor that is easy to

use and delivers high performance in a small,

ergonomically designed package.

Mr. Gerst explained, The Protg ZM Single Gas

Monitor adds to Scott Safetys 80-year legacy

of working with customers to bring innovative

solutions to market. Our customers asked us for an

easy to use single gas monitor that enabled them

to focus on the task at hand instead of maintaining

equipment. We are excited to expand the Protg

family of gas detection instruments with the

introduction of the Protg ZM.

Scott Safety is a premier manufacturer

of innovative respiratory and other

personal protective equipment

and safety devices and offers a

broad range of globally certified

gas detection solutions including

singlegas, multi-gas and fixed gas

detection systems.

www.scottsafety.com

Health & Safety

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Page Header

17 HES February 2013

Health & Safety

Are Your Safeguards As Safe As You Think?There are machines in the UK fitted with multiple guards which

are monitored in one circuit by series connected safety switches;

does this sound like one of your machines? Can any of theseguards be opened simultaneously? Then read on!

Historically the practise of series-wired safety switches has arisen because it

saved money on cabling and safety relays, and because dual channel wiring

of the switches met Category 3 of the withdrawn standard EN 954. Category

3 lives on in the replacement standard EN ISO 13849-1 which requires that for

Category 3 to apply at least 60% of faults have to be detected in a diagnosis

mechanism (DC = low).

The ability of a system to detect 60% of dangerous faults can be impacted by

a phenomenon known as fault masking which can dramatically reduce the

Diagnostic Coverage and consequently the Performance Level.

1 Three safety gates are connected in series to an evaluation device. Initially all

the safety gates are closed and the relays outputs are on, i.e. the machine can

be operated.

2 On the left-hand safety gate, a short circuit occurs in the line to the switch with

the N/C contact. At first the fault is not detected (because a demand has not yet

been placed upon the safety function) and the machine can continue operating

(because the guard is still closed).

3 The left-hand safety gate is then opened, an event which the left switch

signals to the relay. During feasibility comparison of the two switches the safety

relay discovers an inconsistency and switches to a fault condition, i.e. once the

safety gate is closed the machine cannot be restarted (but in this case the safety

gate is left open).

4 Now the right-hand safety gate is also opened. Via these signals the relay

once again detects a normal condition. The fault condition is reset, the safety

gates can once again be closed from left to right and the machine is ready to

start up again.

This example illustrates an undetected fault in the safety circuit, which has built

up as a result of the clearing of the fault by the simultaneous opening of two

gates. An additional, subsequent fault could cause the whole interlocked guard

system to fail to danger. In the current standard EN ISO 13849-1, the maximum

diagnostic coverage (DC) that the switch can achieve is restricted, depending on

the masking probability.

In practice, a single switch pair that is evaluated by a safety relay can achieve

If more than one guard can be opened with a frequency of greater than once an

hour, or there are more than 4 of them in series, the statistical chance of a fault

occurring and being masked is high with the result that Diagnostic Coverage is

reduced to less than 60%. According to EN ISO 13849-1 this is equivalent to no

DC, and uder these circumstances, the best achievable PL is PL

c, or Category 1 in old terms. If your original risk assessment required Category

3 your system is no longer compliant.

Possible cures for fault masking

include:

1. changing the wiring of existing

series-connected switches to

individually wired switches (which may

be costly in terms of wiring and the

need for extra safety relays or extra

inputs on safety controllers)2. the zoning of guard monitoring

switches into distributed I/O systems

(such as Pilz Decentralised Periphery

PDP67 systems)

3. Replacement of volt-free contact based switches with RFID-coded, self-

monitoring switches (such as Pilz PSENcode switches, PSENslock solenoid

interlocks. PSENini inductive sensors or PSENsgate gate access devices) which

can be wired in series and maintain 99% Diagnostic Coverage individually, with

PL e integrity

E-stops in series?

It is worthy of note that series connection of Emergency stop devices is unlikely

to incur a loss of Diagnostic Coverage, because its unlikely that any two E-stops

will be actuated

simultaneously or as frequently as once an hour. Therefore it is reasonable to

wire such devices in series.

Conclusion:

Designers of safety guards and associated circuits on new machines, and those

responsible for existent machines in use should review whatever safety guard

circuits they have where safety switches are connected in series. There are

solutions, as outlined above.

For a more detailed version of this article, please visit the Machinery

Safety Alliance website - www.machinery-safety-alliance.co.uk.

Alternatively, please email [email protected], telephone 01536

460766 or visit www.pilz.co.uk.

a DC = 99%. In the current draft of EN ISO 14119 (which will soon replace

the current interlocking standard EN 1088), the maximum DC for a group of

interlinked switches is dependent upon the number of switches connected in

series and their frequency of operation. As you can see in the proposed table

below, masking restricts the maximum achievable DC and PL.


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Billerica, MA, USA, 4 February 2013. PanaFlow

HT from GE Measurement & Control is the first

ultrasonic flow meter for liquids, which has been

engineered to meet Safety Integrity Level (SIL)

accreditation to allow its operation in a Safety

Instrumented System (SIF). This has involved

extensive third party testing and certification

of every component of the flow meter, from

transducers to meter body. As a result, the benefits

of ultrasonic flow meters can now be enjoyed in a

wide range of safety-critical applications throughout

the oil and gas sector, while greatly mitigating risks

to personnel, plant, process and the environment.

Third party SIL accreditation specifies the safety

integrity requirements needed by a product for it

to be o part of a Safety Instrumented System,

explains Thomas Michalowski, global product

manager at GE. Such a system will control a

safety-critical function. For example, a flow meter

can measure the flow into a vacuum distillation unit

and then act to activate a valve if the flow is too low,

acting as process monitor.

The new PanaFlow HT is the first ultrasonic flow

meter to meet SIL accreditation and is also ATEX

and ICEX certified for operation from -200C to

+600C, which greatly extends the application of

ultrasonic flow metering throughout the refineries

sector.

Ultrasonic flow meters already enjoy wide

application throughout the oil and gas industry,

providing reliable and accurate flow measurement.

They have no obstructions which might clog

or restrict material flow, they operate without a

pressure drop and have no moving parts so that

they feature minimum drift, requiring no periodic

calibration. Furthermore, ultrasonic flow meters can

measure flow in both directions while, with patented

Bundle Waveguide Technology (BWT) transducers,

the PanaFlow HT can operate at high and low

extremes of temperature.

To date, safety-critical flow metering in refineries

has been carried out typically by wedge meters

and orifice plates, with SIL-certified pressure

transmitters. The introduction of the PanaFlow

HT means that refinery operators can now enjoy

the comprehensive benefits of ultrasonic flow

metering in pipelines from 3 in to 16 in (80 to 400

mm) diameter as standard, with special meters

available up to 36 in (900 mm). Typical applications

include vacuum distillation units, delayed coker

units, visbreakers, crude distillation units and fluidic

catalytic cracking units.

About GE Oil & Gas

GE Oil & Gas is a world leader in advanced

technologies and services with 37,000 employees

in more than 100 countries supporting customers

across the industryfrom extraction to

transportation to end use. Making the environment,

health and safety, quality and integrity our highest

priorities is The Way We Work. Our technologies

and services include: surface and subsea drilling

and production, monitoring and diagnostics,

measurement and controls, large-scale LNG,

pipeline compression and inspection, well site

and industrial power generation, technologies

for the refining and petrochemical industries, and

modular CNG and LNG units for transportation

sectors. Through our customized service solutions,

training programs and technologies, GE Oil & Gas

partners with customers to maximize their efficiency,

productivity and equipment reliability; develop their

next generation workforce; and fully benefit from the

megatrends of natural gas, the growth of subsea

and hard-to-reach reserves and the revolution in

asset health management.

GEs PanaFlow HT is Worlds First SIL-RatedUltrasonic Flow Meter

Allows Users to Benefit from Ultrasonic Technology

in Safety-Critical Applications

GE Oil & Gas

Measurement & Control

T +44 1925 604095

M +44 7720557346

F +44 1925604096

Flow Meters


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Steatite supplies Rugged Mobile Computers and

high-temperature lithium battery packs into the Oil

& Gas sector, which when required to be used in

potentially explosive atmospheres, have to meet

certain testing standards including;

ATEX (ATmosphres EXplosibles) Directive

94/9/EC

UL1604 Certification

Dangerous Substances and Explosive

Atmospheres Regulations 2002 (DSEAR)

One such mobile computing solution is the Getac

V100-Ex 2, which is the only ATEX certified laptop

to come as standard with intrinsically an safe serial

port, providing a means of wired connection to

instrumentation and other field devices within Zone

2 hazardous areas. The V100 Ex 2 also includes

Bluetooth and WiFi and is also the only zone 2

hazardous area approved laptop to come with GPS

and intrinsically safe 3G option.

Steatite Batteries has a long history of specializing

in lithium battery packs for use in harsh and

hazardous environments. By working with the

world leading cell suppliers we are able to design

battery packs designed to meet with ATEX and

safety requirements. Our batteries are used in

downhole, subsea, environmental measurement

and monitoring devices.

Following the acquisition of RZ Pressure in 2008,

Steatite has continued to grow and establish itself

as the premier European supplier of battery power

solutions for the energy market.

Steatite designs and builds battery packs to

perform in some of the worlds harshest and most

dangerous environments and is regarded by service

companies and equipment manufacturers as the

largest proven supplier of battery packs for the

EMEA region, offering safe and reliable solutions

with dependable design and assembly.

Steatite provides lithium cells and battery packs that

deliver dependable power on demand, extremely

high reliability and peak performance. Major oil

services companies and OEMs rely on Steatite to

recommend the right battery and portable power

solution.

Battery packs for Down Hole drilling,

Exploration and Critical Monitoring

Custom Engineered Battery Packs

High temperature lithium battery packs up to

200 C

Wide range of battery packs that are UN

approved for transportation

Worldwide channel partner for Electrochem

cells

Steatite offers a wide range of products to suit

a diverse range of portable and fixed industrial

applications. The latest products aimed at explosive

atmospheric environments will be showcased

at Ocean Business 2013 (9th-11th April,

Southampton) and Offshore Europe 2013 (3rd 6th

September , Aberdeen).

Rugged ATEX Computers and Battery Packs

Steatite, through its divisions Steatite Rugged

Systems & Steatite Batteries has a long history

of supplying equipment intended for use in

potentially explosive atmospheres.

Steatite Limited

Ravensbank Business Park, Acanthus

Road, Redditch, Worcestershire

B98 9EX


Tel: +44(0)1527 512400

Fax: +44(0)1527 512419

Web: www.steatite.co.uk


Atex Equipment


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Volvo Construction Equipments (Volvo CEs)

revolutionary extractor for bituminous fumes is

one of three finalists in the machinery component

category of the bauma Innovation Awards. The

system, which is available as an option on Volvo

CEs C-Series ABG pavers, introduces a new way

of removing fumes from the operators working

environment. The innovative feature improves

the working conditions of the operator who sits

directly above the auger channel. By delivering83% efficiency, the system exceeds the National

Institute for Occupational Safety and Health (NIOSH)

guidelines which state that 80% of fumes should be

captured. Volvos results have been independently

certified by an environmental institute.

Behind the breakthrough

The pioneering system works by using a fume

intake, with a fan located directly behind it, on

both the left and right hand side of the auger

channel, explains Anders P. Larsson, executive

vice president of Volvo CEs Technology function.

The fan captures and transports the fumes via two

tubes to the top of the paver where they are then

released. This means that the air in the operators

working environment is significantly cleaner than

was previously the case.

Volvos design is located at the back of the machine

and features a very short distance between

the intake and the fan eliminating the need

for additional piping and funnelling in the auger

channel. This increases efficiency, prevents any

loss of power and ensures that there is no effect

on the operators visibility into the auger channel.Because extra power is not needed, smaller fans

are used. These can be installed horizontally instead

of vertically which offers a smaller, more compact

architecture. This also helps to maintain visibility into

the auger channel which is vital to ensure consistent

material flow and good quality, smooth paving.

Innovative and efficient

During the majority of operating conditions, Volvos

ABG pavers run on smart power which lowers

the engine rpm and considerably reduces fuel

consumption. The new fume extraction system

continues this environmentally friendly and fuel

efficient approach and works just as efficiently when

the machine is operated in smart power mode as

it does when the machine is working in max power

mode.

As well as increased efficiency and visibility, another

benefit of the Volvo design is reduced noise. The

difference in sound between the system being on

or off is insignificant just 0.3 decibels. This means

that there is no risk of the system distracting the

operator or causing fatigue.

Paving the way

Although there is currently no legislation insisting

pavers meet the NIOSH 80% guideline, the Volvo

system has been designed to meet demands from

customers and operators in certain markets. Due to

the modular design of the Volvo system, it can beretrofitted to machines already in the field.

We are thrilled to be a finalist in these prestigious

awards which honor forward-looking developments

and outstanding innovations, says Anders.

This nomination is a credit to our hard working

employees who are helping Volvo CE to deliver

world class innovations. Achievements like this

are only possible thanks to great teamwork. With

more than 180 years of innovation behind us, we

are proud of the companys pioneering spirit and

will continue the Volvo tradition of being innovative

leaders in the construction industry.

Fume Extraction System Shortlisted ForBauma Innovation Award

Volvo Construction Equipments extractor for

bituminous fumes has been shortlisted for a bauma

Innovation Award. The innovative design improves the

operator environment on the companys ABG pavers

by substantially reducing fumes without significantly

increasing fuel consumption, noise or affecting visibility

into the auger channel.

Fume Extraction

22


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The new HE 9 Basic Ex-Hand Lamp is well suited

for inspection, maintenance, control, and repair

work that needs to be carried out in potentially

explosive atmospheres, including industrial

chemicals, petrochemicals, and pharmaceutical

plants, as well as in other potentially explosive

atmospheres such as rescue services, sewerage,

and water treatment plants.

The HE 9 Basic hand lamp is the successor to our

existing HE 8 range of hand lamps, which have

been used in hazardous areas for many years, said

Klaus Weyer, product line Manager at COOPER

Crouse-Hinds GmbH. The HE 9 Basic replaces all

Portable Hand Lamp For Zone 1 And 2 Hazardous Areas

Cooper Crouse-Hindshas launched a new explosion protected

hand lamp certified for use in ATEX Zone 1 and Zone 2

hazardous areas.

three previous HE 8 hand lamps, but is technically

similar to the HE 8 EURO PLUS hand lamp. We are

currently planning to introduce an HE 9 Premium

version that incorporates LED technology and an

emergency lighting function.

The HE 9 Basic hand lamp is certified to the

European ATEX Directive 94/9/EC for use in

explosive gas atmospheres in Zones 1 and 2, in

accordance with the latest IECEx standards. The

lamp uses environmentally friendly, rechargeable,

high-tech Lithium-ion batteries (3.75V / 4.8 Ah),

which provide up to five hours battery life. These

lightweight, high energy density batteries make

handling easier, but also eliminate memory effects,

which ensures a reliable power supply to the lamp.

A protective circuit and electronics guarantee

protection against deep discharge and overcharging

of the Li-lo batteries. The HE 9 can be recharged by

using a separate, compact, plug-in charger unit.

Visit www.crouse-hinds.com.

For information on Eaton visit:

www.Eaton.com.

The solenoid operators are designed for use on

the 327 range of direct operated solenoid valves

and are available in epoxy coated aluminium or

stainless steel. The solenoids are certified to ATEX,

Category 1G/2D and Equipment Protection Level

(EPL) Ga/Db. Both operators are IECEx approved

and certified to IEC 61508 Functional Safety (SIL 3

capable).

The polarity insensitive solenoid operators have a

power consumption of only 0.5W at 24V DC and

feature a newly developed electronic booster coil

and stainless steel core for optimum performance.

Available with either an epoxy coated aluminium or

Intrinsically Safe (Ex I) Direct Acting Solenoid ValvesFor Use In Harsh Environments

ASCO Numatics has introduced two intrinsically safe

solenoid valves with Ex ia IIC T6 certification.

316L stainless steel enclosure rated to IP66 and

IP67. The operator can be rotated 360 and locked

into position to select the best position for cable

entry. Electrical connection is via a cable gland

(M20x1.5) or cable connection 1/2 NPT and easy

access screw terminals.

The 327 series solenoid valves feature a brass,

stainless steel or aluminium (NAMUR) body. These

valves have a large flow rate (Kv 0.45 m/h), operate

from 0 to 10 bar and require no minimum operating

pressure.

The solenoid valves are suitable for use in ambient

temperatures from -40C to 60C, and are rated

to ll 1/2G Ex ia IIC T6 Ga / II 2D Ex tb lllC T85C

IP66/67 Db, Certification: ATEX and IECEx EN

60079-0, EN 60079-11, 60079-31, EN 61241-0

and EN 61241-11.

For more information please visit:

Web: www.asconumatics.eu

Hazardous Area Equipment

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Burkert Supplies Atex Devices For Fuelmatic System

Burkert Fluid Control Systems is providing a

complete package of Atex-rated valves, flow

sensors, level switches, positioner systems and

conductivity and flowmeters for Green Fuels

Fuelmatic system.

Designed to produce up to 20,000 litres per day

of high-quality biodiesel, the fully automated

Fuelmatic is skid mounted to facilitate shipping and

installation.

UK-based Green Fuels designs and manufactures

a range of low-cost processing equipment that

produces biodiesel for small-scale, domestic usage,

right up to commercial production levels.

The advanced technology integrated into Green

Fuels systems enables customers to produce their

own high-quality biodiesel inexpensively and safely

for use as a sustainable road transport fuel.

The Fuelmatic system is suitable for the medium-

scale commercial production of biodiesel.

Designed to produce up to 20,000 litres a day, the

Fuelmatic offers key advantages in that, as a skid-

mounted unit, it can be transported to the source

of the feedstock material from which biodiesel is

produced.

This is said to compare favourably with larger

fixed biodiesel plants, where feedstock has to be

transported to a central location - a process that is

costly and, in view of the emissions from the many

trucks required to transport the feedstock, non-

ecological.

In its redesign of the Fuelmatic, Green Fuels

stipulated working with a single source for the

supply of all valves, sensors, flowmeters and

positioners.

However, all the products had to be Atex-approved

EeX lA devices, powered via safety barriers.

In addition to finding a company with the required

products, Green Fuels also required the supplier to

provide technical support to assist in the integration

of the Atex equipment into the redesigned

Fuelmatic.

Burkert offers a range of Atex products and

can provide consultancy, system design and

manufacture and installations and testing.

The fully automated Fuelmatic is controlled by a

PLC that interfaces with Burkerts 8640 pneumatic

valve islands.

These units are built to specific requirements and

save space by providing for the actuation of up to

24 valves on compact modular backplanes.

The Type 8640 provides users with a combination of

pilot-valve input/output (I/O) modules and fieldbus

communications for the control of process valves.

On the redesigned Fuelmatic, the 8640 system

provides the actuation of Burkert pneumatic angle

seat, globe and diaphragm valves, all with Type

1062 electric feedback switches, and the Type

2712 modulating globe valve with an Atex electro-

pneumatic positioner.

Completing the package are Atex-approved flow

and displacement sensors, a vibrating level switch,

positive displacement flowmeters and a conductivity

transmitter.

We offer global experience you can

rely on. Brkert is an adaptable

organisation with flexible processes.

We are continually committed to

achieving success, both for our

customers and ourselves. Consistent

and continuous investment in

research & development and in

staff training enables us to offer

our customers the very best in

technology and services. For any

request or goal you might have for

your fluid process control, Brkert

can be relied upon; working together

with you, well find the best solution,

both from a technical and an

economical point of view.

As Brkert has grown, sales

activities abroad have expanded,

supported by an increasing number

of subsidiaries in key industrialised

countries. Our global presence

enables us to focus on the most

topical problems in specific markets,

whilst offering our customers the

most efficient solutions in their

country.


Atex Valves


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The 94/9/EC compliant range options include

temperature class to T4 (135C) and both non-

conductive and conductive dusts.

The ATEX classification 2G/Zone 1 geared motors

available from the UK assembly service suit IEC

frame ATEX rated motors in both standard and IE2

high efficiency classes, for frame sizes 80 through

180. Geared units include a broad selection of

foot and B14 or B5 face mount versions with a

wide choice of motor mounting positions. With

torque output from 32 to 3200 Nm, options include

synthetic and food grade oils, Viton seals and

backstops. Motor options include a wide choice of

voltages, thermistors,

IP66 sealing,

encoders and

auxiliary fans.

NORD

SK 200E

decentralized

frequency

inverters are also suitable

in ATEX classification 3D/Zone 22 in IP55 & IP66

enclosures, available with output ratings up to 22

kW.

NORD DRIVESYSTEMS UK Geared Motor

Same Day Assembly Service Expanded For

ATEX Gas And Dust Up To 18.5 kWNORD DRIVESYSTEMS has expanded its

fast assembly service for ATEX geared motors

to include Gas Zone 1 & 2 and Dust Zone 21 &

22 for nominal motor power ratings up to 18.5

kW. Consolidating NORD as one of the leading

ATEX drive suppliers in the UK, the geared

motors are available with a wide selection of

options for standard delivery within 3-days or, for

very urgent requirements, a same day assembly

and despatch service.

NORD also supplies a complete programme

of geared motors for more demanding ATEX

Category 2D and 3G/Zone 2 applications that are

available with quick turnaround from its German

manufacturing facilities. Covering EX d & de

pressurised encapsulation, EX e increased safety

and EX n non sparking motors, a wide range of

options are available including pressure resistant

encapsulated motors, motor brakes, special

voltages, reinforced gear unit bearings, and many

more. Users interested in the complete NORD

ATEX range can download or request the G1001

catalogue for gas atmospheres or the G1022

catalogue for dust atmospheres from www.nord.

com or email [email protected].

In addition to the fast turnaround service

for Category 2 ATEX geared motors, NORD

DRIVESYSTEMS also offers a rapid assembly

service across its full range of NORDBLOC.1 and

UNICASE geared motors from its Abingdon facility

including helical bevel and helical worm designs

spanning output torque from 90 Nm to 3200 Nm.

For technical information, please contact

Andrew Stephenson at:

NORD GEAR LTD. (U.K.)

11 Barton Lane

Abingdon Science Park, Abingdon

OX14 3NB Oxfordshire

United Kingdom

Tel: +44 (0)1235-534404

E: [email protected]

Web: http://www.nord.com

Atex Equipment


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With this in mind, South Korean company Samsung

Heavy Industries (SHI) is developing a 7MW offshore

wind turbine that promises to be the most powerful

of its kind when its demonstrated towards the end

of 2012. The firm plans to test the new generation

of wind turbines at Fife Energy Park off the east

coast of Scotland before taking orders to build them

at its European facility in Methil, Scotland.

In order to help SHI achieve its goal, David Brown, a

company that is perhaps best known for having its

initials on the back of several Aston Martin models,

will be delivering an innovative new gear system that

will be able to generate three to five per cent more

energy than existing gearboxes.

This increase in energy output could be key

to energy companies that are deciding which

gearbox to go with in an age when government is

desperately trying to bring down offshore winds

cost of energy from 150 per megawatt hour to

100 per megawatt hour by 2020.

Ian Farquhar, managing director of wind energy at

David Brown, said: Weve probably got in David

Brown the most comprehensive gear-making

capability in the world.

Farquhar explained that David Brown works in an

environment where in the design and production of

a gearbox, the cost or consequence of failure, in

relation to a wind turbine, is extremely high.

But how exactly did David Brown end up in the

wind-energy market? Scottish entrepreneur, Jim

McCull, bought the 152-year-old Huddersfield-

based gears company back from the US after it had

a 10-year-spell at Textron. The 368m sale went

through in November 2008 and the company is

now targeting new and developing markets.

David Brown began assessing the performance of

the existing gearboxes in wind turbines and found

some alarming statistics.

Offshore wind turbines are designed to survive for

more than 25 years. But we found that there was

a very high rate of interventions related to gearbox

issues between six and 10 years, said Farquhar.

Our estimates tell us that the market for gearbox

repair was $150m last year. By 2020 that will grow

to $2bn Farquhar went on to establish a business

unit of David Brown that specifically looked at post-

warranty inspection work, which helped the firm to

identify a lot of common gearbox failure issues.

We saw that because of the very variable and

poorly understood loads that the winds drive into

these gearboxes, there are a lot of misalignment

effects in the forces going through the gearboxes

and therefore a lot of bearing failures and gear tooth

failures, he explained.

The costs of repetitive gearbox failures are enough

to plunge wind-energy companies into spiralling

financial difficulties. One manufacturer quoted to

me the cost of an insurance claim for one written-off

gearbox can be up to $500,000, said Farquhar.

Our estimates tell us that the global market for

gearbox repair was maybe $150m last year. We

believe that by 2020 that market will have grown

beyond $2bn.

David Brown spotted the gap in the market for

more reliable gearboxes and launched a service and

repair business to mend broken gearboxes. This

enabled it to gain additional valuable experience on

the trends and failure modes of existing equipment,

which it used to provide a series of upgrades to

existing turbines, for companies such as Vesta,

one of the worlds oldest and largest wind-turbine

companies.

But as you may have guessed by now, in addition

to repairing gearboxes it is also manufacturing

customised gearboxes for new customers, such

as Samsung Heavy Industries. Having seen all

of these different design models, common failure

Manufacturer Gears Up For Record-Breaking Turbine

Offshore wind turbines have been getting bigger and better

since the first wind farm was installed in Denmark in 1991.

Nowadays, the general rule is the bigger the wind turbine the

more energy it can produce, reports Sam Shead.

Wind Turbines

28


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modes, and having an understanding for some of

the challenges that exist offshore, we can design a

specific application for a customer, said Farquhar.

Were very much like the Saville Row of gearboxes

in that we will design something specific to the

customer.

Building a gearbox for the worlds most powerful

wind turbines Farquhar explained that one of the

key criteria for wind turbine gearboxes is that they

are as light as possible.

Heavy gearboxes require stronger tower structures

and present greater transportation and erection

issues. Approximately 20 per cent of the mass of

a wind turbine is associated with the gearbox, the

largest single contributor after the blades.

The compact, low-weight gearbox that has been

designed for SHI will still weigh between 50-90

tonnes but Farquhar claimed it is 10 to 15 per cent

lighter than any competitor product on the market.

The gearbox is a multi-stage epicyclic (planetary)

unit, which means it has several outer gears

revolving about a central or sun gear. The planet

gears will be mounted onto a movable arm or

carrier and provide a link to the outer annulus

gear, which will have a diameter of approximately

3m. David Brown claims the system will offer a

combination of high power density, efficiency and

structural integrity.

Our motivation is not purely about maximising the

selling price. Were taking a whole-life cost view

The gearbox will initially cost somewhere between

500,000 and 900,000 but the company hopes to

reduce this over time.

Farquhar said: Our motivation is not necessarily

purely about maximising the initial selling price.

Were taking a whole-life cost view. The way in

which were working with our customers means

we are all motivated to try and make continuous

improvements.

Samsung has elected and signed a memorandum

with Methil and Fife Council to potentially set up a

100m assembly facility in Scotland for 500 people.

David Brown has an agreement with Samsung

that it will set up an assembly facility in the same

location if Samsung goes ahead with this plan.

On a more immediate note, David Brown is planning

to expand its Yorkshire facilities in order to meet the

demands of the new partnership with SHI.

Two new buildings that are being built in Mirfield

will include a gearbox research and innovation

centre, as well as a gear-manufacturing centre of

excellence.

Farquhar said this one project could increase the

current size of the company by three to four times.

David Brown is seeking to draw on its gear history

to solve a relatively contemporary issue. The

company is looking to make a significant difference

to the wind energy market and its new gearboxes

could help to reduce the price of wind energy,

making this renewable source a far more attractive

option.

Wind Turbines


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Brand new for this year is the complimentary

Business Strategy Conference. Theres tremendous

value to be had from listening to the experience of

peers especially if they are some of the biggest

brands in the UK today. Based on this idea, the

Business Strategy Conference will feature experts

from many of the UKs brightest companies. From

a special theatre on the show floor, names such

as Britvic, Pepsico , Alcon, Experian and Scottish

& Southern Energy will explore how they are

addressing the maintenance issues of the day.

For those looking for practical sessions, there will

also be The Maintenance Exchange featuring a

rich programme of 38 learnShops. Delivered by

some of the shows most innovative exhibitors,

these will provide visitors with unique insights into

the very latest innovations, products and services

to be found within the maintenance and asset

management arena.

These free learning opportunities will run alongside

an exhibition packed full of exhibitors, many of

whom, like CorDEX Instruments, are using the show

to globally launch new products.

James Walker, Decksafe Solutions, AW Chesterton,

Metool, SAACKE Combustion, Intertek, Keytracker,

REBO BV, MOLYDAL Lubricants, Lubricus Grutzner

and Ernst Schad are just some of the many names,

from both the UK and overseas, making their

MAINTEC debut. They will join MAINTEC veterans

such as Schaeffler (UK), Flowcrete UK, R.Stahl,

ERIKS, Idhammar Systems, SPM Instruments,

PRUFTECHNIK and Prevost UK.

Indeed there is so much to see and do that the

Institution of Diagnostic Engineers (IDE) has decided

to host a spring gathering during MAINTEC. This

will also be attended by members of the Institution

of Local Exhaust & Ventilation Engineers, another

show supporter. IDE Chief Executive, Bill Parker,

says: Wed urge all our members to put the dates

in their diary.

So lets take a closer look at whats on offer at

MAINTEC 2013.

The Business Strategy Conference

The Business Strategy Conference is being run

throughout the three-day show and features a

phenomenal line-up of world-class experts and

major end-user brands. Each day addresses a

different strategic theme. On day one the focus ison Making the Business Case for Maintenance.

Mark Haarman, CEO, Mainnovation will kick off

proceedings by exploring the economic drivers of

a maintenance organisation. For those struggling

to measure maintenances economic contribution,

he will have suggestions and lessons from real life

experiences. Delegates will learn why steering

on value leads to continuous improvement and

what can be learned from leading maintenance

organisations around the world.

In a session moderated by Bill Parker, CEO,

Institution of Diagnostic Engineers, and drawing

on case studies, John Davenport, Operations

Director, Alcon and Paul Dennis, Technical

Facilities Manager, Experian will explore successful

maintenance strategies, how to choose the right

one for your business and the merits of total

productive maintenance versus a reliability-centred

maintenance approach.

There is much debate within the profession about

MAINTEC 2013 PACKED WITHLAUNCHES & LEARNING

MAINTEC, the leading exhibition for the UKs maintenance,

plant and asset management community returns to the NEC on

5-7 March 2013 packed with more learning opportunities and

product innovations than ever before.

Hazex/Maintec Show Preview

30


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which is better control maintenance or a reactive

maintenance operation. Mark Thompson, Head of

Wastewater Assets, Southern Water will explore the

merits of each. Drawing on his own experience he

will look at how you decide which one is the right

strategy for your company. He will then explore the

idea of whether there is a third way that involves a

mix of asset management systems and reactive self

monitoring devices.

The theme for day two is Innovation in Action

with Steve Statham, Manager, Manufacturing

Technology Centre starting the day by exploring

the latest effective methodologies and high-

impact technologies. As innovations go, social

media has been transformational for many areas

of business; Steve will outline its implications for

maintenance professionals, specifically social

medias role in providing feedback and alerts for

building maintenance. He will also give examples

of where innovation in asset management is helping

to overcome those thorny maintenance issues of

legacy systems & obsolescence.

Condition-based monitoring is a hot issue. Is

an evolutionary or revolutionary approach to

implementation best? Which assets and equipment

should be included and what about all the data

you are likely to gather? Any attendees struggling

with these and other questions will get the chance

to learn firsthand from

Dr Sethuraman Muthuraman,

Condition Monitoring

Engineer, Scottish &

Southern Energy.

He will even have

some suggestions

for those daunted

by condition-based

monitoring, outlining

the occasions

when reactive

or preventative

measures may suffice.

Many wonder whether formal

standards really add value to an organisation.

This day will be your chance to find out as in his

talk Daniel Pairon, Global Head KPMG Asset

Management will outline the core standards in

asset management and how PAS 55 / ISO 5500x

certification might actually empower your company.

A panel discussion featuring David Smallbone,

Head Asset Management, AMCL closes day two.

In a lively session the cost of asset failure versus the

cost of condition monitoring will be debated.

People, processes and legacy sit at the heart of

good maintenance management and day three

focuses on these elements. Keynote speaker,

Wayne Curry, Engineering Team Leader, Britvic will

outline how the company manages the impact of

new processes and KPI reports on maintenance

staff. In a highly practical talk he will also cover

the usability and access issues you face when

rolling out new devices and equipment to a

mobile work-force. This people focused day

closes with Ian Rigby, Engineering Manager,

Pepsico, who will look forwardto 2017. Ian will predict what

shape, dynamics and focus the

maintenance team will have

by then.

The Maintenance

Exchange

Complementing the

Conference will be

The Maintenance

Exchange, featuring

38 free-to-attend

learnShops, designed to help plant

and asset managers, engineers and maintenance

professionals save money, improve efficiencies and

enhance asset care.

For instance John Roberts, Managing Director at

Idhammar Systems, will give an insight into the

OEE concept and how it is linked to return on

investment. The concept is based on the availability

of the plant for production and the performance

of the plant. This is determined by the rate that

units are produced and the quality of the saleable

product. When these elements are considered

together, and the current and desired efficiencies

analysed, strategies to reduce energy usage can

emerge.

Managers of Energy from Waste (EfW) plants will

be interested in the talk by Robin Buller, Director of

Business Development at KRR ProStream. Using

smart technology to maintain these specialist

systems can result in more efficient outputs,

explains Robin Buller. He will be focusing on three

cleaning technologies, in particular, for boilers, bag

house filters and heat exchangers. KRR ProStream

specialises in power generation facilities and this

talk will give delegates the opportunity to discuss

specific efficiency issues with industry experts.

Condition based maintenance offers many

economic benefits, as Stan Jackson, Managing

Director from SPM Instrument UK will explain. The

concept focuses on using staff more effectively on

routine inspections to determine possible corrective

maintenance. This is said to increase reliability and

ensure maintenance work is planned.

Similarly, Roy Davis, Senior Consultant at MCP,

will speak about how Operator Asset Care


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is implemented to complement maintenance

excellence and the benefits to a business when

asset care is carried out. He explains: The

increased awareness and machinery-based

knowledge of production operators will ensure that

any machinery failures or malfunctions are detected

at an early stage, so that planned actions can be

implemented.

For those who have a health and safety agenda,

Sira Test and Certification Ltd will hold a seminar

on the worlds first international scheme for

the certification of personnel associated with

equipment, installations and servicing used by Ex

industries, known as IECEx.

Any uncertainty of hazards associated with static

electricity will be clarified by Mike OBrien, Product

Manager from Newson Gale. Sometimes thought

to be witchcraft due to its invisible nature, static

electricity can spark an explosion in combustibleatmospheres, explains Mike OBrien. The highly

dangerous charge can be built up by the movement

of powder and liquids in a plant. Using a video to

illustrate the dangers, he will be discussing practical

measures on how to manage static electricity.

Attendees who work with fragile substances will not

want to miss the talk by David Furley, Distribution

Manager at CorDEX instruments. He will explain

how to control the deployment of standard

thermography equipment. Visitors will also be able

to hear about web-based predictive maintenance

systems, from Dr John Atkinson, Technical Director

from C-Cubed.

Andy Parkinson, Business Development Manager

from James Walker will speak about improving

efficiency and costs by reducing maintenance

downtime, while Ian Pledger, IAM Product Specialist

from Schaeffler will discuss the implementation of

an efficient asset management system using plant

condition monitoring. Dr Trevor Holroyd, Technical

Director at Parker Kitti Wake Holroyd, will speak

about the application of acoustic emission to detect

ineffective lubrication in operating machinery.

Marketing Manager at Ernst Schad, Ram

Greenshpon will explain how to keep your good old

gearbox in service at a fair cost, whilst Reliability

Maintenance Solutions will be speak about

improving reliability by correcting the big four:

balancing, shaft/belt alignment, looseness and

resonance. Flowcrete will hold a seminar about how

to get more from your floor.

Packed Show Floor of Innovating

Exhibitors

Exhibitors sit at the heart of MAINTEC and this

year is no exception. Many are using the

show to launch new products or showcase

their very latest work. For instance BEKO

Technologies will be outlining how it has

helped one of the largest car manufacturing

plants in the UK replace its old dryers and

thus reduce running costs significantly and

improve air quality. The initial project was to

replace just two dryers but projected energy

savings provided a sound case to change all four

existing dryers.

Thermal Energy International will show how a FLU-

ACE Condensing Heat Recovery System which it

implemented for Premier Foods saved the company

110,000 per year, which is approximately 7.5

million kWh of annual gas savings.

First time exhibitor, SAACKE Combustion, recently

helped Harveys Brewery improve the operation of

its boiler plant. SAACKE recommended fitting a

burner with a superior turndown, thus allowing the

boiler to match the sites steam demand massively

improving efficiency.

Those in the food or drink sector should also check

out CRC Industries UKs new StopLight Food

Safety Programme. Developed specifically for

MRO chemicals, its a leap forward in the control of

chemical product movements.

Among the vibration monitoring products from

Hansford Sensors making their UK show debut

will be the new HS-109 Triaxial accelerometer. This

allows three axes to be monitored simultaneously,

plus a new version of the companys spot facing

tool, which has been re-engineered to extend its

operating life even further.

Maintaining reliable RH measurements

in harsh or corrosive environments

is notoriously difficult as the


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conditions themselves degrade the sensors andequipment, often in short time-periods. Michell

Instruments will be showing how its DT722 RH and

temperature transmitter provide a solution to this

problem.

Ocip Energy will outline how a recent project to

install new LED fittings at Fletcher Moorlands site

is on target to save the company 70% of its lighting

costs.

There will be a unique demonstration of Schaeffler

FAG WiPro s condition monitoring system for wind

turbines. Via a live remote link to a wind farm

based in Scotland, visitors will be able to see in

real time how the main rotor bearings, gearbox

and generators on five wind turbines are being

monitored 24/7.

Fluke UK will show its Fluke CNX Wireless

System. This is the first set of test tools that

wirelessly connects multiple measurement modules

and sends simultaneous readings to a master

device up to 20 metres away, allowing users to

troubleshoot problems quickly and efficiently.

Steam system and flow control specialists

Valveforce has created pneumatic control valves to

handle a wide range of fluids such as thermal oil,

steam, water, nitrogen and natural gases.

Dust extraction specialists, Dustcontrol UK, will

showcase their latest centralised dust vacuum

system - the DC 11 Module. By reducing noise

to 65 dB(A), the DC 11 Module is easier to fit in a

building where noise is a challenge.

MAINTEC will be the first opportunity to see

Idhammar Systems new Maintenance Management

System V11. This offers a number of new

benefits including minimized downtime, improved

maintenance planning, audit compliance and

greater control over budgets and stock.

T-Cards Direct is launching the latest upgrade to

its new T-Cards Online at the show while Xetec

will show its FlexMaint computerised maintenance

management software.

James Walker has successfully tested Supagraf

Premier, a premium fugitive emissions valve

packing, to ISO 15848-1 2006 Class A at 690bar.

It will be showing visitors how this is the lowest

rating of leakage definable under ISO 15848-1 and

demonstrates a step change in performance for

braided graphite fugitive emissions packing.

Recently launched, Agility 4.1 from SoftSols is

the latest version of its Agility Computerised

Maintenance Management System and builds

on the introduction of dashboards and key

performance indicators in earlier releases.

Hayley Groups brand new SmartVendTM eliminates

the need for RFID tags, barcodes and the

requirement to manually account for inventory. This

automates data-collection and provides the user

with real-time intelligence on inventory use.

For those focused on people development MCP

Consulting and Training will show how an Operator

Asset Care programme equips the very people

operating production equipment to improve its

reliability and performance. MGTS will explain its

unique approach to technical training designed for

both mature and new entrant employees across a

wide range of engineering disciplines.

HAZEX

Successfully launched last year, the HAZEX area

brings the UKs top hazard prevention experts and

innovations under one roof. For instance in a world

first, CorDEX Instruments, the UK manufacturer

of instrumentation and equipment for hazardous

environments, is introducing its new TC 7000

intrinsically safe thermal imaging camera at HAZEX.

Newson Gale is showcasing its Bond-Rite

static earthing clamps plus its Earth-Rite series of

hazardous area static grounding systems. Also

in this area R.STAHL is introducing IS1+ a key

innovation for the companys already leading

explosion-protected remote I/O system IS1.

DENIOS is running a live and explosive free

lecture. Running for all three days this experimental

lecture uses graphic demonstrations to explore the

limitations of flammable materials in the workplace.

And the Winner is

The winners of the first ever MAINTEC

Maintenance Professional Awards will also

be announced live from the show floor.

There are two categories: Maintenance

Professional of the Year and, in support

of newer entrants to the industry,

Maintenance Apprentice of the Year.

MAINTEC is free to attend and pre-

registration is advised to avoid queues on

the day. Register visit www.easyfairs.com/

maintecuk.



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Besides explosion-proof and maintenance-free LED

signal towers of the EDLM and EDWM series, which

achieve ATEX guideline 94/9 EC and are suitable

for zone 1 and 2, Patlite also offers visual, audible

and hybrid products which are suitable for zone 2

and 22.

Safely encased

The innovative, explosion-proof signal towers

EDLM (3 coloured LED modules) and EDWM (5

coloured LED modules) come with a high-strength

main body made of aluminium alloy. Thanks to

their pressure- and flame-proof housing they reach

protection IP66. They have been designed for use in

potentially explosive atmospheres in environments

such as (petro-) chemical industries, handling with

combustible dusts, production of gas and even in

food industries.

The terminal block of the EDLM and EDWM models

is found at the back and provides easy access to

the signal tower. The signal towers are suited for

flush mount, wall mount and horizontal mount.

The EDLM type comes with patented prism facet

LED modules in the colours red, yellow and green.

The EDWM type is available with 5 LED modules in

red, yellow, green, blue and transparent.

The Japanese Tokuyama group is planning to

install a fair quantity of EDWM signal towers at its

polycrystalline silicon production plant in Malaysia.

Besides providing safety for our co-workers and

machines, the explosion-proof LED signal towers

model EDWM-502 helps us to improve quality

control and productivity, explains a company

spokesman from Tokuyama. The company

values the signal towers because they are highly

dependable, maintenance-free and offer a long

lasting serving life.

Energy-efficient LED lights

The series AR-070 and AR-078 are signal towers

with up to five LED modules and a diameter of 40

or 60 mm. The signal lights are resistant against

gas or dust explosions and are approved for zone

2 and 22. The energy-efficient LED modules with a

PATLITE patented prism cut provide full and brilliant

illumination.

Vertical and horizontal cut lenses in combination

with a double-reflection system enhance the

diffusion of the LED illumination. The LED modules

available in the colours transparent, yellow, red,

blue and green - as well as the main body are made

of strong synthetic materials. They withstand even

high pressure and heat as well as damage caused

by acid or bases.

The signal towers reach IP65 protection. That allows

installation even in damp or dusty environments.

The AR-078 and AR-070 series signal towers can

be either flush or wall mounted and are available

with one to five LED modules. They can also be

ordered with a flashing/non-flashing function and /

or two super-loud alarm sounds with an 85dB (at

1 m) output. The type with alarm sound reaches

protection IP54.

Large product spectrum

Explosion-proof products that are suitable for Zone

2 and 22 also include the hybrid type LKEHFE/

EXN and LKEHFV/EXN, the signal horns EWH24/

EXN and PVW04JF/EXN as well as the LED working

lights of the CLA series and the bar lights CLF2024/

EXN and CLT3024/EXN.

All explosion-pro

hazardous engineering solutions - feb 2013

Documents