ems november/december 2009

THE INTERNATIONAL MAGAZINE FOR ENGINEERING AND MAINTENANCE PROFESSIONALS

ISSUE 14

NOV/DEC 2009

BUYERS GUIDELEANMAINTENANCECONDITIONMONITORING

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

ENGINEERING MAINTENANCE SOLUTIONS

FIRE SYSTEMS

MACHINING

DUST CONTROL

CHEMICAL CLEANING

MAINTENANCEof wind turbinesTURN TO PAGE 10 FOR THE FULL STORY

For more information quote EMS Enquiry No. 101 on IBC

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EMS, MSL Group, Cobalt House, Centre CourtSir Thomas Longley Road, Rochester, Kent ME2 4BQ+44 (0)1634 731646

www.engineeringmaintenance.info


BEST PERFORMERS

EDITORIAL/CONTRIBUTING EDITORS: Jon Barrett, Christer IdhammarAlan France, Mark [email protected]

ADVERTISEMENT SALES: Michael Dominguez (Publisher)[email protected] [email protected] [email protected]

WEB MANAGER: Oliver [email protected]

DATABASE MANAGER: Steve Hill

TECHNICAL MANAGER: Igor Seke

CREATIVE:Ric [email protected]

ARTWORK PRODUCTION:Elaine [email protected]


Published six times per year by EMS

Annual subscription: UK FOC Rest of World £90 © 2009 EMSArticles appearing in this magazine do not necessarily express the views of the Editor or the publishers. Every effort ismade to ensure the accuracy of information published. No legal responsibility will be accepted by the publishers forloss arising from articles/information contained and published. All rights reserved. No part of this publication may bereproduced or stored in a retrieval system or transmitted in any form without the written consent of the publishers.

They keep simple concepts simple.

Best performers do not confuse their organizations with new names onwell known best concepts and practices. They also understand thedifference between a tool or methodology and a complete reliabilityand maintenance program. For example RCM, (Reliability CenteredMaintenance) is a very good methodology used to help decide the rightmaintenance activity and frequency, but it does not deal much withkey elements such as planning and scheduling, store room interfacewith maintenance, technical data bases for maintenance etc. Samegoes for TPM (Total Productive Maintenance) also a very goodapproach, but missing some very important reliability andmaintenance elements.

Best reliability and maintenance practices comprise about 300elements that must be done well if you want to be as good as you canbe. They are the same as they have been for 50 years or more. Forexample; Operating Practices, Alignment, Balancing, Lubrication,Inspections, Planning of maintenance and operations work, Schedulingof maintenance and operations work, Continuous collection of data,Root Cause Problem Elimination etc.

These elements cover very well tested and proven “Right things to do”or elements. They are used to educate an organization and to developmeasurable improvement plans. First you agree on that the element isthe right thing to do. Next step is to decide who shall do it.

FOR THE FULL STORY PLEASE TURN TO PAGE 3


CONDITION MONITORING

Easing the task of integrating AE technology

DRIVE SYSTEMSIndustrial gear units for torque output from 60,000 to 200,000 Nm

RELIABILITYENGINEERING

What’s it all about?

OEEOverall Equipment Effectiveness – Myths and Realities

BUYERS GUIDEThe comprehensive listing ofengineering maintenance suppliers

BEST PERFORMERS

So what are the best performers doing differently than others?

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They keep simple concepts simple.Best performers do not confuse theirorganizations with new names on wellknown best concepts and practices. Theyalso understand the difference between atool or methodology and a completereliability and maintenance program. Forexample RCM, (Reliability CenteredMaintenance) is a very good methodologyused to help decide the right maintenanceactivity and frequency, but it does not dealmuch with key elements such as planningand scheduling, store room interface withmaintenance, technical data bases formaintenance etc. Same goes for TPM (TotalProductive Maintenance) also a very goodapproach, but missing some very importantreliability and maintenance elements.

Best reliability and maintenancepractices comprise about 300 elementsthat must be done well if you want to beas good as you can be. They are the sameas they have been for 50 years or more.For example; Operating Practices,Alignment, Balancing, Lubrication,

Inspections, Planning of maintenance andoperations work, Scheduling ofmaintenance and operations work,Continuous collection of data, Root CauseProblem Elimination etc.

These elements cover very well testedand proven “Right things to do” orelements. They are used to educate anorganization and to develop measurableimprovement plans. First you agree onthat the element is the right thing to do.Next step is to decide who shall do it.

It is very important to keep yourreliability and maintenance process simpleand easy to communicate to yourorganization. Improving maintenance is90% about getting people to workdisciplined in a disciplined system and10% about technology. The easy part isthe technology part, maintenance peoplelike technology and gadgets, sometimestoo much. To get them to break old habitsand work in a planned and scheduledenvironment is more of a challenge. Mostmaintenance employees have been

rewarded and recognized more for reactiveactions than for preventive actions. Manydo not mind reactive maintenance becauseit is 76% likely to generate extra incomethrough overtime pay, and when they fix abreak down they are praised.

If you can make a compelling case ofwhy you need to improve and clearlydescribe what the future will look like, youcan successfully overcome this change.Remember that it is really not much of achange; it is common sense and describewhat your organization already knows anddo to some extent, you will just help themdo it much better.

The following Slide 1 shows a one pagedescription of the essential reliability andmaintenance process. The market governsthe production plan which in turn have tobe coordinated closely with maintenancescheduling of work, especially for work thataffect production run schedules. When youplan and then schedule work, you create asystem that let crafts people become moreefficient when they do the work. When

WHAT ARE THE BESTPERFORMERS DOINGDIFFERENTLY? – Part III

Here a best performer is defined as an industrial plant that has achieved a high

reliability and fast throughput of manufactured products and as a consequence,

manufacturing costs, including maintenance costs, are low.

So what are the best performers doing differently than others? The short answer

is that they do what we all know we need to do; they just do it better and better

over a long period of time

www.engineeringmaintenance.info November/December 2009 EMS � 3


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work is done you should record what wasdone, why it was done etc. This will createa second backlog of well documentedproblems to be solved and eliminated. Ifyour organization is doing all these thingsyou work in a continuously improvingenvironment. Most organizations know allof this and do some of it. A greatorganization works 20% + in the

continuous improvement area with RootCause Problem Elimination, mostorganizations know they should do this,but they do not have time.

The most common reason manyorganizations do not have the time is thatthey work in the red circle, the circle ofdespair. For different reasons yourorganization reacts to problems and repair

them as fast as they can. This often leadsto that they have to return to redo therepair and this process is repeated. Themore work done this way, the less timeyour organization will have to do whatthey should do and after a while you arecompletely reactive.

To improve this situation you need toreinstitute essential processes such asmaintenance prevention, the right prioritieson work requests and condition monitoring.All these activities will prevent work and/orgive your organization the necessary leadtime needed to do good planning and thenscheduling of work. To do effective planninga Technical data base is needed so parts,tools and work descriptions easily can befound in a matter of seconds.

The aforementioned slide describes theessential elements of a good maintenanceprocess. If all elements are executed well,they will deliver increased reliability andlower costs.

A job done in the “Circle of despair”can be described in the left box (Slide 2).A planned and scheduled job is describedin the right box; it is a description of a bestpractice. The difference in efficiency issubstantial. Depending on how much workis done as described in the left box theimprovement potential derived frommoving more work to the processdescribed in the “Best Practice” box is 30% to 60%.

� www.idcon.com

� Reader Reply Number: 300

Christer Idhammaris a worldrenowned expertin Reliability andMaintenanceManagement best practices. He started theIdhammar group of companies inSweden in 1972and IDCON, INC in USA 1985. In 2002 hereceived the Euromaintenance IncentiveAward for outstanding internationalcontributions to improve Reliability andMaintenance in industries world wide. In May 2008 he received the SalvettiFoundation reward for best speakeramong 154 speakers at Euromaintenance2008 in Brussels. He can be reached [email protected]

Christer Idhammar,president IDCON INC

SLIDE 1

SLIDE 2

WHAT ARE THE BEST PERFORMERS DOING DIFFERENTLY? PART III �


supplied with a customised length,ensuring an ideal oil under the oil leveland reduce the risk of foaming.

The filters are compatible withParker’s patented LEIF® elements, whichminimise waste and therefore reduce theenvironmental impact of a system. Theseinnovative elements provide guaranteedhigh quality filtration in line with ISO14001 for complete peace of mind.

The robust STF Series filters are idealfor use in a wide range of applicationsincluding marine power packs, steel mills,mining equipment, and drilling machinery.Thanks to the ATEX certification, the STFfilter can be applied for in potentiallyexplosive atmospheres.

� Parker Hannifin plcEuropean Product Information CentreParker House, 55 Maylands AvenueHemel Hempstead Herts, HP2 4SJ

� T: 00800 27 27 5374

� E: [email protected]

� www.parker.com


Parker Hannifin, the global leader in motion and

control technologies, has launched the STF Series

of tank top mounted return filters, which combine

effective filtration with a cast steel filter head

assembly, making the units ideal for marine and

industrial applications were the use of aluminium

is restricted in accordance to latest regulations

NEW RETURN LINE FILTERSwith cast steel filter head FOR MARINE APPLICATIONS

FILTRATION �

� EMS November/December 2009 www.engineeringmaintenance.info6

The STF filters feature “In-to-Out” filtration toensure contaminated oil cannot leak backinto the system, and are capable of handlingflow capacities of up to 500 l/min at 10 barworking pressure, making them suitable forsevere return line applications, and reducingdowntime due to filter failures.

The filters provide pre-filtration bymeans of a magnet column, improving fluidcleanliness levels and extending elementlifetime with typically over 20%. Aneffective flow bypass with low hysteresisreduces the bypass period and ensures onlya small part of the total flow is bypassingthe element, offering improved protectionfor the system. Additionally, multiple portsin the filter head make it easy to integratereturn line filtration into power packs,reducing cost and space.

The STF range can be customised tomatch the specific requirements of anapplication and facilitate integration. Thishelps minimise initial costs and ensureeffective filtration. Optional air tightdiffusers are available to avoid air ingressin the return line. The funnels can be

On Wednesday 21st October 2009, Belzona, a design and manufacturer of

industrial protective coatings and polymer repair composites, celebrated the launch of

a new Authorized Coating Centre, Knowlton and Newman, at one of their three branches

located in Southampton

NEW BELZONA AUTHORISED COATING CENTRE �

On Wednesday 21st October 2009,Belzona, a design and manufacturer ofindustrial protective coatings and polymerrepair composites, celebrated the launch ofa new Authorized Coating Centre,Knowlton and Newman, at one of theirthree branches located in Southampton.

Achieving the Authorized CoatingCentre Status now means that Knowltonand Newman are recognized by Belzona asa specialist service centre for therebuilding, long term protection andefficiency enhancement of rotatingequipment such as Pumps, Fans &Blowers, Screw Conveyors and Agitators.

It is envisaged that this new partnershipwill further improve the level of supportoffered to customers and offer a full turnkeyrepair service on rotating equipment.

Mike Knowlton, one of the fiveDirectors for Knowlton and Newmancommented about the day, ‘‘I am

extremely pleased as it has been a reallysuccessful day, I don’t think there will beone person who will go away withoutlearning something new which will addvalue to both of our businesses.’

Daniel Knowlton, one of the otherDirectors further commented, ‘I thought thatoverall the day was a great success andcredit is due to all involved. I really lookforward to a bright future for the Belzona-Knowlton and Newman joint effort.’

Belzona introduced the AuthorizedCoating Centre scheme to differentiate andreward specialist service centres thatinvest heavily in surface preparationequipment and are dedicated tomaintaining high levels of applicationprocedures and customer service.

Gordon Cairns, National Sales Managerfor Belzona explained, “The BACC conceptwas created to distinguish betweenregular machinery and equipmentcontractors and a specialist group ofservice centres that go the extra distance.This gives us the platform to target keyindustries that require a “total service”which include Petrochemical, Power, Paperand Water/Wastewater.”

Belzona is represented by a singleAuthorized Coating Centre for each UKregion and BACC status has already beengranted to four companies in Glasgow,Teesside, Manchester and now

Southampton. Belzona are now looking to recruit a final Coating Centre to bebased in the Midlands which willcomplete the network. To receiverecognized status, service centre’s mustdemonstrate high performance equipmentand facilities, a dedicated coating roomwith a temperature controlled area andinvest heavily in Surface Preparationequipment whilst also maintaining highlevels of application procedures and aftersales support.

Knowlton and Newman have been providing industry since 1973 with a wide range of mechanical servicesto minimize downtime for customers and drive down costs, operating fromthree branches, Southampton, Portsmouthand Chatham.

� www.belzona.com


Knowlton and Newman launched asBelzona Authorized Coating Centre


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It follows that on-line monitoring systemsshould be capable of integrating therequired mix of CM technologies for eachparticular spread of machine types in aninstallation. However the use of AE formachinery condition monitoring hashistorically been viewed as a separatespecialist field and it has not been easy tointegrate it into third party or industrystandard monitoring and control systems.To address this issue Holroyd Instrumentshas developed a range of smart AEsensors, which have finally opened thedoor to the wider use of AE for continuousmonitoring alongside, say, vibration, andtemperature sensors.

Holroyd Instruments is a world leaderin the industrial application of AEtechniques to machinery conditionmonitoring and has pioneered autonomoussignal processing algorithms which furtherextend these advantages by removing theneed for machine specific interpretations.Whilst these algorithms have beensuccessfully used for many years in arange of portable instruments it is onlyrecently that they have been integratedinto smart AE sensors (MHC-DS1 and MHC-SM1). These compact sensors providesimple but effective continuous monitoringof rotating machinery from motor speedsdown to 0.25 rpm. They are ideal forincorporating into third party systems fordata acquisition, monitoring and alarm

purposes, since they have high level,slowly varying outputs of field provensignal characterisations.

In some applications however there isno infrastructure to accept trendablesensor outputs and this is typical whenretro-fitting to existing installations. Inthese cases switched sensor outputs arepreferable since they can be readily wiredinto spare input channels on PLC’s.Acknowledging this requirement switchedalarm outputs are also built into the smartAE sensors. The alarm levels and hold-offperiods, to discriminate against falsetriggers, are user adjustable and stored inthe sensors own non-volatile memory.

The interest generated by the successfuldevelopment of these smart AE sensors isfuelling further demands from thetechnology. For example, a growing interestwith some users is in the monitoring of non-rotating and intermittent machine actions.The high signal to noise ratio of AE makesdirect time domain analysis of AE signalsuseful in a very wide range of industrialapplications. To address these applications anew development is the 24/7 Ultraspansensor which continuously outputs alogarithmically compressed dynamicenvelope of the AE signal requiring only a+24 VDC electrical supply. In this way thepertinent features of wide dynamic rangeand high frequency AE signals aretransformed into a very easily handled form.

Another area of growing interestamongst CM specialists, which can also beaddressed with the 24/7 Ultraspan sensor,is in the diagnostic analysis of rotatingmachinery. In this role the dynamicenvelope signal is viewed in the frequencydomain as a spectrum to reveal defectrepetition frequencies. The high sensitivityof the AE technique combined with thebenefits of envelope spectra enable theclear identification of high resolution peaks,even on very slowly rotating machinery.

As exposure to the unique capabilitiesof AE spreads, evermore diverseapplications are being unearthed whichhave previously proven difficult for other CMtechnologies. Our experience is that thechallenges posed by these applications areespecially suited to being solved in a cost-effective way by highly integratedapplication specific (smart) AE sensors.

ABOUT THE AUTHORTrevor Holroyd is the Managing Director of HolroydInstruments Limited and has been continuously activein the development and use of AE for industrialmonitoring since 1974. For more information aboutthe contents of this article he can be contacted byemail : [email protected]

� Holroyd Instruments LimitedMatlock, Derbyshire, UK, DE4 2AJ

� T: +44 (0)1629 822060



It is common knowledge that a range of Condition Monitoring (CM) techniques areavailable such as Vibration Analysis, Oil & Wear Debris Analysis, Thermography and Acoustic Emission. Each of these techniques has its own particular areas of strength andin this regard the Acoustic Emission (AE) technique has the noted advantage of givingreal time information with early sensitivity to faults and applicability to a wide range ofrotational speeds including slowly rotating (source : ISO 22096)

EASING THE TASK OFINTEGRATING AE TECHNOLOGYinto third party monitoring systems

CONDITION MONITORING �



Use of Wind Energy – Future DevelopmentThe share of renewable energy sources intotal energy consumption is to be increasedto 20% in 2020. To achieve this extremelyambitious target, the share of renewableenergy sources in electricity generation inthe European Union has to be increased toapproximately 34% by 2020. Thecontinuing expansion of renewables inEurope and also in Germany will becharacterised mainly by the use of windenergy. 20,301 wind turbines with a totalcapacity of 23,903 MW have been installedin Germany at the end of 2008. 40.2 TWhof wind electricity was generated duringthis year. At this time the installed capacityin Europe amounted to 65,946 MW andworldwide to 120,798 MW.

Maintenance of Wind Turbines The most expensive components of a windturbine, beside tower and blades, aregearbox and bearings requiring about 13%of the total costs. The average lifetime ofthese important components is betweenfive to seven years in Western Europe andabout two to three years in Asiancountries. To replace the main gearmultiplier of a 1.5 MW wind turbine afteran unexpected damage costs about250,000 Euros including crane costs. It alsohas to be mentioned that availability ofgears and bearings is limited. Theoperation and maintenance of a wind

turbine and especially of the above-mentioned components can be supportedby various measures, such as integrating acondition monitoring system or developingappropriate maintenance strategies.

The lifetime of the bearings and gearsin new as well as in existing wind turbinescan be extended by REWITEC’s Nanocoatingsystem even when the first signs of decayappear. REWITEC was founded in 2003 withthe goal of reducing the problem of wearand tear in tribologic systems.

REWITEC Technology – Nanocoating forTribosystems The coating technology is not based onmodification of the oil film, but onmodification of the surface texture offrictional metal parts and the creation of anew very smooth metal silicate coating.This metal silicate coating reduces frictionand increases efficiency, especially in olderengines and gearboxes. Due tooptimisation of compression pressure inengines, oil and fuel consumption will benoticeably reduced (Figures 1 to 3).

The synthesised metal silicatecompound only has to be added to theoriginal lubricant and is carried to theaffected areas of the engine or gear box. Inthe rubbing area, the metal silicates reactdue to friction, temperature and highpartial pressure and bond into the metalsurfaces. They fill the smallest corrugations,

pores or micro cracks in the metal surfaceand build an extremely smooth and solidmetal silicate layer. The treated metalsilicate surfaces have a much higherresistance to abrasion and wear, have alower friction coefficient and allow forbetter and faster build-up of a lubricatingfilm. A complete lubricant analysis provedthat REWITEC is not an additive but asurface enhancement treatment. Theimportant oil characteristics such as totalacid number TAN and air and water releasecapabilities will not be altered. Appearanceand colour are changed due to the coatingconcentrate. Viscosity and foam test showonly a slight change in the run-in phase,but within tolerances.

Beside the Nanocoating concentratethat is applied through the gear andengine oils, REWITEC also producesformulated bearing and gear greases. Acomparison of a standard bearing greaseand the same bearing grease formulatedwith the Nanocoating concentrate isillustrated in Figure 4.

Condition Monitoring Different methods for proving thesuccessful outcome of the Nanocoating areuseful: Oil analysis for measuring themetal particles in the oil, silicon imprints ofthe metal surfaces for microscopic analysisof the metal texture, electrical resistanceanalysis of the metal surfaces and the

The lifetime of the bearings and gears in new as well as in existing wind turbines can

be extended by REWITEC’s Nanocoating system even when the first signs of decay appear

Reconditioning and durable wear protectionfor gear boxes and bearings in wind turbines

WEAR PROTECTION FOR WIND TURBINES �

Figure 1. Friction and pressure in engines andgearboxes generates high temperatures on metalsurfaces that trigger the chemical bonding processof REWITEC.

Figure 2. The soft nanoparticles remove dirt fromthe rubbing metal surfaces and react with themetal atoms to form a smooth and protective layeron the surface.

Figure 3. The final result is a new and very smoothmetal surface structure. These properties, in turn,give the machine more power, higher efficiencyand longer life.



condition monitoring by noise andvibration harshness analysis before andafter REWITEC treatment. The projectpartner in condition monitoring analysis isthe company μ-Sen GmbH. Since 2001, μ-Sen has established itself as a solutionprovider for fault detection systems forwind energy plants (WEP). Along withvibration reports for WEP, this includes aservice concept for turbine conditionmonitoring via the Internet. Since 2001,condition monitoring systems developedby μ-Sen have been installed in more than700 WEP (21 different types of windturbines from 11 manufacturers).

Condition Monitoring via Body SoundAnalysis for Wind Energy Plants Body sound is a very sensitive indicator forchanging conditions of moving machinesand system components. Body soundsensors can be easily retrofitted, becausethey do not influence the measured objectdue to the relative small size and mass.The advantage of the acceleration sensorsmostly used for recording of the bodysound is, beside the big dynamic area, thecalculation of acceleration in speed andamplitude. Thanks to these advantagesacceleration sensors are ideal for recordingbody sound signals.

Due to the fast development in thefield of wind energy area since the mid-nineties and the simultaneous rapidincrease in the power output of windenergy plants, the measuringrequirements at these plants are alsogrowing. Beside the monitoringtechniques, mainly body sound baseddiagnosis systems (Condition MonitoringSystems – CMS) are increasing, whichallows early failure detection on the maincomponents of the drive train. Theincreased use of computer based CMS for

different manufactures has alreadyreduced the cost of such a system toaround 10,000 Euros, cost that is amortisedin one to two years.

For a better understanding of theresults of the REWITEC Nanocoating viacondition monitoring, the measurementdata recording and measurement dataanalysis is explained below.

Measurement Data Recording for BodySound Analysis Condition Monitoring Systems are used forearly failure detection in wind turbines inGermany. These systems are installed inthe nacelle of the WEP and the bodysound sensors are at the main components(main bearing, gearbox, generator) of thedrive train (compare Figure 5/schematicdescription of drive train).

For verifying the effect of REWITECNanocoating, the sensor position wasabove the high speed shaft at the secondspur gear stage of the WEP. Besides otherpoints, the trend of the spectralcomponent (amplitude of rotary frequencyof the intermediate shaft in envelopespectrum) was also measured. Theenvelope algorithm is a very successful

method for early failure detection ofbearings and toothing damage.

The spectral components in theenvelope arise due to impacts whichhappen during roll over of chips on therunning trace of rolling bearings. Theseimpulses stimulate structure resonancesand allow a very early detection of suchdamage. The same applies tocorresponding damage on gear teeth.

CMS are mostly configured so that ondays without special incidents (no violationof the limit) four time series will berecorded. Out of these 300 to 400 specificvalues in the time- and frequency domain,the single specific values will becalculated. In the trends of the supervisedspecific values we get four new measuringpoints every day.

Practical applications and results of theREWITEC treatment in different windturbines are illustrated in the next section.

Flender Gearbox of TACKE TW 250 WindPower Plant � Date: August 2007 � Data: TACKE TW 250, Flender gearbox, oil

content: 75 litres Mobil oil XMP SHC 320Target of application: � restoration of worn gear surfaces, � reduction of micro pitting, � wear protection and extension of

lifetime of the gearboxes Application method: � neutralisation of the oil fine filter, � using main filter > 60 µm for

approximately 500 running hours, � application of the REWITEC concentrate

to the gear oil, � reactivation of the standard oil filters

approximately 500 running hours aftertreatment (Figure 6).

TACKE TW 250 – documentation of thegearbox conditions before and after thecoating (Figures 7 to 8).

Conditions before Coating The gears were showing significant wear

Figure 5. Illustration (scheme/left) of wind turbine drive train with acceleration sensors; (right)Gearbox with acceleration sensor (sensitivity: 100 mV/g).

Figure 4. a – This ball bearing shows damage due to wear and tear. The running surface of the balls clearlyshows pitting. Bearing type: Nr. 6205 (d = 25 mm, D = 52 mm) Lubricant: Special bearing grease Operatingtime: 50 hours Rotational speed: 500 min-1 Nominal load: 5.000 N radial (range of fatigue)

b – This ball bearing does not show any wear. The running surface of the balls clearly shows a wearresistant coating. Bearing type: Nr. 6205 (d = 25 mm, D = 52 mm) Lubricant: Special bearing greasetreated with REWITEC Operating time: 50 hours Rotational speed: 500 min-1 Nominal load: 5.000 N radial(range of fatigue)



and tear and fragments from the toothflanks had broken off. The bevelled edgesand tooth tips were sharp edged. Replicaswere taken from the marked tooth. Themeasured values of the resistances of thetooth surfaces were 0 Ohm.

Conditions after 1400 Operating Hours The teeth have a smooth and shinysurface. Replicas were taken from themarked tooth again. They were showingsignificant smoothing of the surfacecompared to the replicas that were takenbefore. Values of about 50 Ohm weremeasured for the resistances of the toothsurfaces due to the formation of theREWITEC coating. The highest values ofresistance were measured at the lowerpart of the teeth.

Results� restoration of worn gear surfaces, � reduction of micro pitting, � the wind turbine has been running

without any mechanical problems untilDecember 2007.

Flender Gearbox of TACKE Wind PowerPlant TW 600 � Date: February 2008 � Data: TACKE TW 600 with 360 litres

Mobil oil Castrol Optimol X320

Target of Application � restoration of worn-out gear teeth surfaces, � reduction of grey stoking, � protection against further wear and

prolongation of life time

Conditions before Treatment Wear traces and grey stoking on gear teethsurfaces. Replicas were taken from themarked gear teeth. Measurement of theelectrical resistance on gear teeth surfaceresulted in 0 Ohm.

Conditions after Two Years The gear teeth are still much smootherand shinier. Replicas were taken againfrom the gear teeth. In comparison to theearlier replicas there was an obvioussmoothening of the teeth surfaces.Because of the REWITEC Nanocoating theelectrical resistance of the gear teethsurface has increased up to 100 Ohm. Thehighest values were measured on top andon bottom of the gear teeth.

TACKE TW 600 – Documentation of GearCondition before and after REWITECTreatment through Replica Analysis(Figures 9 to 10) Microscopic analysis on the replicas of thegear surfaces: The REWITEC coating isclearly visible. The grooves are smaller andthe tooth surface much smoother and greystoking was nearly completely gone.

Results � restoration of worn out gear teeth

surfaces, � reduction of grey stoking, � the wind power plant is operating since

the REWITEC coating without anymechanical problems.

AN Bonus 1.0 MW with Flender Gear Box � Date: August 2008 � Data: AN Bonus 1.0 MW with Flender

gear box PEAS 4355.7, 150 litres Triboloil 1710/320

Target of application: � restoration of worn out gear teeth

surfaces, � reduction of grey stoking, � protection against further wear and

prolongation of life time, � analysis of REWITEC Nanocoating with

CMS of µ-Sen GmbH

Documentation of Gear Condition beforeand after REWITEC Treatment

Conditions before the Treatment Different wear traces, partly due to metalshavings passing through the gear teeth.Imprints were taken from the gear teethmarked, and measurements of theelectrical resistance on the teeth surfaceshowed 0 Ohm.

Conditions after about Seven Monthsafter the Treatment Gear teeth surfaces are clearly muchsmoother and shinier. Replicas were takenagain from the gear teeth, and comparedto the earlier replicas. There was a clearsmoothening of the teeth surfaces.Because of the REWITEC coating theelectrical resistance of the gear teeth hasincreased up to 50 Ohm.

μ-Sen – Condition Monitoring System(CMS) Results The frequency spectrum after =REWITECtreatment from the μ-Sen ConditionMonitoring System (CMS) shows that theamount and level of the peaks of therotary frequency of the high speed shaft isreduced by about 20% (Figure 11 ). Theacoustic analyses show also that theconditions of the gear box and bearingsare clearly improved, even thoughreadings after the REWITEC treatmentwere taken in the time of the year withmore wind and higher load. This newreport indicates the first, much promisingresults of the use of REWITEC Nanocoatingin wind turbine gearboxes, analysed viathe condition monitoring system. Thecondition monitoring system furthervalidates the positive results measured byother means. The intention of the co-operation between μ-Sen and REWITEC isto increase the lifetime of the existingwind energy plants. The intent is to provethat it is possible to effectively reduce theinitial damage in wind energy gearboxes(grey stoking, micro pitting, micro cracks)

Figure 6. Optimising the metal surfaces of tribologicsystems will increase the parts life time. If the WindTurbines life is only prolonged with about six daysthe product costs are already paid. Furthermorethere is a targeted exchange and maintenance ofthe gear box and bearings possible.

Figure 7. Conditions before the coating Figure 8. Conditions after the coating


and also to prevent or delay largerdamage and failures.

The targeted combination of REWITECand CMS can provide the followingadvantages to the plant manager: � optimised use of REWITEC via body

sound analysis, � increased efficiency due to reduction of

friction, � minimising of load due to reduction of

rotor unbalances and adjustment failures,� early failure detection.

Conclusions The results from the imprints, electricalresistance measurements and the CMSanalyses confirm that there is a clearimprovement and smoothening of the wornout gear surfaces and load-carrying areaswill be clearly enlarged. These all togetherwill lead to a prolonged gear box andbearing lifetime. The treatment of generatorbearings, pitch bearings and open pitchgears with the REWITEC coating grease willprevent wear in all grease-lubricated wind

Table 1. Nano coating payback analysis forprevention of downtime.

Turbine power 1,500 kW

Output per year 4,500,000 kWh

Output per day 12,329 kWh

Commission 9.1 Ct/kWh

Commission per day 1,121 Euro

Costs of treatment 6,400 Euro

Amortsation time 5.7 days

* Output related to reference location with amedium yearly wind speed of 5.5 m/s

turbine applications. Increasing wear can bestopped and already existing damage can be“frozen”. Optimising the metal surfaces oftribologic systems will increase the lifetimeof wind turbine components. The cost of theREWITEC treatment is recovered within justsix days! The increased uptime of a windpower generator will result in substantialsavings for operators and greatly diminishedmaintenance intervals (Table 1).

ABOUT THE AUTHORSDipl.-Ing. Stefan Bill, Managing Director REWITEC GmbH Lahnau/Germany

Dipl.-Phys. Holger Fritsch Managing Director μ-Sen GmbH Rudolstadt/Germany

� Mr Stefan BillRewitec GmbHDr. Hans Wilhelmi Weg 135633, Lahnau, GERMANY

� T: +49 6441445990 Germany


� Dermott Reilly, UK & Ireland

� T: +353 8790 10419




Figure 11. µ-Sen – Condition Monitoring System (CMS).

Figure 9. Before December 2006 Figure 10. After November 2008.

Tentec’s tools designed for onsite maintenance

AND SO REDUCE DOWNTIME

friendly. Unlike other tools on the market, theTentec equipment can be serviced in situeither by Tentec personnel or by the operatorsown engineers. The modular design of thetensioners means that replacing seals andworn or damaged parts can be accomplishedon site with no need to return the tool to themanufacturer or supplier. In addition the baseof the Aero tensioner is fitted with an easilyreplaceable wear plate that again can be veryeasily replaced if damage to the base of thetool occurs. “We listened to the marketwhen designing these tools.” explains RoySheldon, Business Manager for the WindTurbine business at Tentec. “A real concern

was that with competitive tensioning tools,the equipment had to be sent back to themanufacturer for maintenance and repair.This resulted in costly downtime.”

The in situ maintenance of the Tentectools allow wind turbine installers andmaintenance engineers to keep control oftime and costs and enables them toschedule tool maintenance and repairs tosuit their project timescales.

� Tentec Ltd� T: + 44 (0)121 524 1990� E: [email protected] � www.tentec.net


In these cost conscious times there is aneven greater emphasis on reducingdowntime and ensuring that any repairs ormaintenance are carried out swiftly and cost-effectively. This is particularly relevant in thewind turbine industry where activities suchas bolt tensioning ensure the effectivenessand the integrity of the structures. However,after vigorous use, even bolt tensioning toolsthemselves begin to show wear and tear andafter a specified number of pressure cyclesall tools require routine servicing.

With these issues in mind, Tentec’s Aerorange of bolt tensioning equipment isdesigned to be extremely maintenance

WIND TURBINE MAINTENANCE �


For more information quote EMS Enquiry No. 108 on IBC For more information quote EMS Enquiry No. 109 on IBC

With the assistance of ABFAD Limited of Sunderland, E.ON has reduced the carbon footprint

and running costs of its 4 gas fired power stations at Connah’s Quay, North Wales

Tube blastingREDUCES EMISSIONSat Gas Fired Power StationsCarbon footprint has beenreduced by 246 tonnes perweek and cost savings of£640,000 per year have been made on the 4 stationsas a direct result of pre-heatercondensate tube blasting inthe boilers, using ABFAD’ssurveying, grit blasting andclean up services, with results as shown in the

images of Pre Heater Tubebefore and after blasting.

As well as pre heater tubeblasting using a fairlyaggressive medium, ABFADconducted more delicateblasting of the condenser itselfinside the turbine, using amore refined blast medium.

ABFAD specialises inengineering services to the

power industry, includingabseiling rope accessinspection, maintenance and coating services.

� Chris Haritou

� Abfad Ltd

� T: 0191 516 6223


� www.www.abfad.co.uk


for the experienced engineer and is an excellent tool for the training of younger engineers.

For further information on MAS orETD’s Risk Based Maintenanceprogrammes/projects for power plantsplease visit www.etd1.co.uk

� European Technology Development 6 Axis Centre, Cleeve Road, LeatherheadSurrey KT22 7RD, UK

� T: +44 1372 363111 � E: [email protected]� www.etd1.co.uk� Reader Reply Number: 307

MAS has been developed by experts tohelp and advise power plant engineers.MAS helps and guides maintenanceengineers on what to do when things go wrong. It is already in use in anumber of plants in Europe. MAS has awealth of knowledge and database

POWER STATION MAINTENANCE �


Maintenance Advisor Software (MAS) has four modules dealing with

conventional Power Plants and HRSGs when operating in base-load or cycling mode

BEFORE

AFTER

As part of its comprehensive range ofNORDBLOC industrial gear units for torqueoutput from 60,000 to 200,000 Nm, NORDsupplies complete modular sub-assembliescomprising UNICASE gearbox, motor andcoupling with a broad and flexible range of options and accessories. Fully pre-assembled on torsionally rigid motor swingbase or base frame mountings, thecombined units require no complexalignment and are supplied fully tested.

These ready to install modular gear unitsystems are completely scalable andcustom built to suit specific load,mechanical interfacing and environmentalspecifications for heavy-duty conveying andlifting applications throughout industry. Byspecifying a complete sub-assembly,customers are able to reduce their projectmanagement burden, timescales and costsusing the NORD design service to manageall aspects of the application – as well as making system commissioning more straightforward and simplifying purchasing.

Each modular system comprisesgearbox, motor and base frame withoptions of elastic or fluidcoupling, drum or discbrake, radial or axialfan, auxiliary drive,torque support withattachment plate andprotective covers aswell as sealing systemoptions. Furthermore, abroad choice oftemperaturemanagement optionsinclude fans,external oil/air oroil/water cooling,and severalmeasuring devices and sensor options

are available for oil inspection, temperatureand bearing condition monitoring.

The modular system design, covering 6 basic installation configurations withidentical installation dimensions for all 2 and 3-stage gear ratios, allows analmost endless combination of powertransmission sub-assembly options withfast delivery assured from standard offthe shelf components. The symmetricalUNICASE gearbox design permits mirrorimage installation for dual driveapplications. NORD’s own wide range of IEC frame energy saving three-phasemotors are used throughout, and NORDSK 700E frequency inverters are availableto offer complete gear unit and drivesolutions with high performance motor control, and connection to allcurrent factory networkingcommunications systems.

NORDBLOC industrial gear units drawon the well proven benefits of theUNICASE housing system – a onepiece design produced onspecialised CNC machines whichoffers the highest levels of

precision, rigidity and strength. With allbearings mounted directly into the castiron UNICASE housing, and with no dividingseams between the drive and gear unit,the design allows shaft axes to bestaggered in a more compact space-savingarrangement; also allowing the use oflarger roller bearings to ensure a longeroperational life with quieter running andreduced maintenance burden. Available infour frame sizes form 60,000 Nm to200,000 Nm, with helical and bevel-helicalgear stage designs, the range includes awealth of options for mechanicalinterfacing, performance, safety andenvironmental conditions.

� NORD GEAR LTD. (U.K.)11 Barton LaneAbingdon Science Park, Abingdon OX14 3NB Oxfordshire United Kingdom

� T: +44 (0)1235-534404


� www.nord.com


NORDBLOC Industrial Gear Unit range provides integrated motor swing base sub-assembly

for 60 to 200 kNm torque output

NORDBLOC INDUSTRIAL GEAR UNIT RANGE

DRIVE SYSTEMS �


� Single casting with integrated bearing seats minimises oil leakage possibilities� Helical gear stages can deliver superb energy efficiencies of up to 96%+

HIGH-TORQUE INDUSTRIAL GEARBOXEScome in high-integrity single-piece housings

ratios can be specified using two-, three-,or multi-stage reductions. The gearboxesare ideal power transmission solutions formaterial handling and processingequipment in applications such as steelmanufacture, aggregates, mining and grainhandling. The low losses of the helicalgearing technology means that Unicasegearboxes can deliver excellent energyefficiencies of up to 96%-plus.

The gear units conform to NordDrivesystems' modular design concept.This provides a plug-together approach toadd-ons that makes it extremely simple toconfigure gearboxes for specificapplications. A wide range of accessoriesincludes brakes, backstops, a drywellsolution, condition monitoring equipment,and a choice of cooling systems. Combinedwith the flexibility to be mounted on sixsides, or via an optional flange, the new

gearboxes can be adapted easily toprovide customer-specific powertransmission solutions.

Because of the gearboxes' inherentlyhigh efficiencies, Nord Drivesystems expectsthe units to appeal strongly to therefurbishment and repair market, especiallywhen replacing older relatively inefficientworm gear units. In such applications, theenergy savings will often provide a paybackon the investment measured in months. Aswith all Nord Drivesystems gearboxes, thecompany's production line is set up for rapidmanufacture of application-specific solutionsinline with customer requirements.

� NORD GEAR LTD. (U.K.)

� T: +44 (0)1235-534404


� www.nord.com


Nord Drivesystems has extended its familyof high-integrity industrial gearbox units,adding a family of high-power models withmaximum torque ratings up to 200000 Nm.

The new gearboxes employ Nord'sproven Unicase concept. The gearbox caseis a single piece casting, with all bearingseats integrated and machined in a singleprocess. This optimises strength andeliminates sealing surfaces that coulddeflect under the effect of torque or radialforces — minimising the possibility of oilleakage. The resulting high-integritygearboxes deliver smooth, low noiseoperation with a long product life.

There are four choices in the new HighPower Unicase family, offering maximumtorques of 60000, 90000, 135000 or200000 Nm. Available in helical-parallelshaft or helical/bevel right-angled driveconfigurations, a very wide range of gear

www.engineeringmaintenance.info November/December 2009 EMS �

DRIVE SYSTEMS �

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

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

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

alarm signalling

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

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

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17

FIRE SYSTEMS �

There has never been a more critical time for work’s production operations to drive costs

down, achieve greater efficiencies whilst at the same time maintain manufacturing quality

MQL DRIVES machining costs downWith bielomatik Minimal Quantity

Lubrication (MQL) system oil consumption candrop significantly to between 100 and 150millilitres/hour. Apart from reducing theamount of lubricant used, any machine shopthat switches to MQL benefits from mucheasier disposal of metal cuttings since they arevirtually oil-free and machine performance isenhanced, particularly production time.

Another important feature that allows neardry machining is the elimination of coolantcarryover in component pockets aiding fasterprocessing times between operations.

Up-grading to the Bielomatik MQL systemwhich delivers precise measured quantities oflubricant to the cutting tip offers tremendousbeneficial financial gains. Also, in hard turningapplications, achieving slower tool wear whilemaintaining cutting forces/power atreasonable levels, provided that the MQLparameters can be strategically tuned.

With MQL manufacturing costs can be

reduced by up to 15% without detriment tothe quality of the finished component.Recognition of the financial andenvironmental benefits of MQL systemsmean that nowadays new machine buildsoften come complete with MQL technology;it has invariably been more difficult andmore costly to add to ‘older’ machines.

The latest Single Channel MQL systemfrom Bielomatik overcomes most of thedifficulties, enabling existing machiningoperations to be converted to MQL and thusenjoy all the inherent benefits.

For companies genuinely interested inswitching to MQL technology Bielomatik isable to provide a test rig allowing users tojudge for themselves the environmental andcost savings to be made.

� T: 01480 408500 � F: 01480 403808� E: [email protected] � www: bielomatik.co.uk � Reader Reply Number: 311

It is estimated that on large scale productionsites cooling lubricant can make up nearly20% of the total manufacturing cost. Atypical ‘wet’ machine may use 10 to 10,000litres/hour of lubricant depending onapplication; whilst much is recycled, due tonatural wastage as aerosol spray into theatmosphere and adherence to swarf, overalllosses can amount to between 3 and 15litres/hour.

NASA selects STAT-X FIRE SUPPRESSION SYSTEM

said James Lavin, CEO of Fireaway. “Stat-X firesuppression systems were invented toaddress these types of challenges.”

On an agent weight basis, Stat-Xaerosol is ten times more effective thangaseous agent alternatives. Another benefitis that all units are environmentallyfriendly with zero ozone depletion and zeroglobal warming potential. It has ultra fastfire knock down and possesses long postfire security due to the potassium aerosolbeing suspended in the air of the enclosurefor up to an hour. In the event of firebreaking out, suppression is rapidlyachieved through interference between theultra-fine aerosol particulate and theflame’s free radicals, terminatingpropagation of the fire.

Stat-X is available in five pre-engineeredsizes for operation and storage intemperatures in the range, -40 degrees to+ 54 degrees Centigrade.

Ben Parker, Commercial Director of NobelFire Systems, the UK’s exclusive Stat-Xdistributor said, “Stat-X is being recognised asa world leading fire suppression product andthe fact that NASA has selected it for its giantcrawler transporters underlines its growingreputation. In the UK, its effectiveness is alsoapparent as more businesses continue toinstall Stat-X across a wide sector of industriesand applications.”

� T: +44 (0)1706 625 777 � F: +44 (0)1706 625 325� E: [email protected] � Reader Reply Number: 310

Designed and manufactured by FireawayLLC in the USA, Stat-X kills fires quicklywithout harming the environment and isavailable in the UK through its exclusivedistributor, Nobel Fire Systems.

NASA has ordered Stat-X generators forthree areas in both its crawlers andapproximately 100 fire suppression units willbe installed in the control areas, machinerooms and communication rooms of thecrawlers which carry the space shuttles tothe Kennedy launch pads for lift off.

“NASA’s crawler transporters are two ofthe world’s largest moving machines. Theyare complex environments with a great dealof equipment packed into tight spaces whichmakes the piping for gaseous fire suppressionsystems very cumbersome and expensive”


When NASA Kennedy Space Centre’s fire safety experts decided to replace the fire

suppression system in its giant twin crawler transporters, it turned to the next generation

firefighting system for enclosed spaces – a clean, compact,

cost effective, safe and simple system called Stat-X

MACHINING �

WFE Hydraulic Services Repairs department has over 30 years experience in the

manufacture and repair of bespoke and standard hydraulic cylinders

Performance under pressure

done in-house all within our 35,000 sq/ftfactory based in Sheffield off J34 M1.

WFE can arrange for any cylinder to becollected and delivered to and from ourcustomer’s depot if required.

WFE are proud of the fact that all of our customers are long standing, and the ones who have used us for thefirst time always come back to us. Many hydraulically operated plantmanufacturers; mobile crane operatorsand offshore companies rely extensivelyon our service to cover their vast needs.

Every Hydraulic cylinder repaired byWFE is fully pressure tested, and paintedor sprayed to meet the customer’srequirements. All work is carried outunder the scope of ISO 9001:2008 qualitymanagement system.

� Gary Marsh (Service Manager)

� WFE Hydraulic Services LtdTyler Street, Sheffield S9 1GL

� Tel: +44 (0)114 2430936

� Fax: +44 (0)114 2425516

� www.wfehydraulics.co.uk


WFE have the expertise and capability toundertake any cylinder repair irrespectiveof length or diameter. We can straightenrods, hone cylinder bores, machine newparts if required, and all of which are

“An excellent repair, a fast turnaround, collection and delivery and very competitive prices.”

Telescopic Jib before & after straightening Remanufacture of original components

Replaced body on a rotary coupling

Dixon Group Europe offers a comprehensive range

couplings and hose fittings for your plant maintenance

and fluid handling requirements

offer interchanges with other manufacturers.The ISO7241 ISO A interchange series offittings has recently been revised forsuperior wear resistance and to offerastounding performance results.

Dixon also offers a full hose range tocomplement their already longestablished couplings sales, this isinclusive of composite, rubber, metallic,PTFE, food & beverage, anti static andspiral PVC hose.

Visit www.dixoneurope.co.uk to viewthe full range of products.

� Contact Gill Brown, Dixon Group Europe Ltd

� T: +44 (0) 1772 323529



A wide selection of materials includingSteel, Aluminium, Brass, 316 & 303Stainless Steel are available, together withthread configurations including BSP & NPTand body sizes ranging from 1/8” andhigher to ensure compatibility in a varietyof installations.

Stainless Steel hygienic fittings areavailable in a variety of fitting types (RJT,SMS, DIN, IDF & Triclamp) with sizes from ½”-12” that meets or exceeds 3A standards.

The Dixon range of hydraulic &pneumatic quick connect/disconnect fittings

HYDRAULICS �

COUPLINGS �


Objectivity. Do not let the fox in the hen house.

IDCON prides itself by being Totally Objective. We are not associated with any organizations including suppliers of com-puter systems, engineering services or out-sourcing companies.

Use IDCON’s 280 Predefined Current Best Reliability and Maintenance Practices as an evaluation, education and imple-mentation guide to close the gap between how good you are and how good you can become.

visit

download our new brochure to learn more

IDCON, INC.7200 Falls of the Neuse RoadSuite 200Raleigh, NC 27615Phone: +1 919 847 8764 fax: +1 919 847 8647 www.idcon.com email: [email protected]

IDCON, INC.7200 Falls of the Neuse RoadSuite 200Raleigh, NC 27615Phone: +1 919 847 8764 fax: +1 919 847 8647 www.idcon.com email: [email protected]


Applied Traffic has decades of field experience, test and design of High Speed

Weigh in Motion. 2009 sees the launch of the VIPERWIM® classifier which has been

the innovation from the collective knowledge and experience gained by our team

Applied Traffic BRIDGE PROTECTIONSpecific Assessment Live Loading. We havea long history of working with bridgemonitoring in the UK, including both SevernBridges and the QE2 Bridge in Essex. Wehave a specialist team in place for datacapture, analysis & reporting who can runthe information on a weekly or monthlybasis, depending on your requirements.Our services also include proactive

maintenance and regular inspection, alongwith routine calibrations.

� Applied Traffic LtdUnit 5 Southview Park, Marsack StreetCaversham, Reading RG4 5AF

� T: 0118 9461900� F: 0118 9461862� www.appliedtraffic.co.uk


Over the last 18 months the product hasprogressed from prototype stage and betatesting of pre-production units over a widerange of conditions on various road types,traffic patterns and volumes, to productionand launch at the recent Traffex show.

The system can interface with ANPR orCCTV cameras and can be used for weightenforcement & monitoring as well as Bridge

RAILWAY MAINTENANCE �


MACHINE

LINE No.

DATE

NAMEPRIORITY

EST. TIME

HIGH / LOW

SHIFT

DESCRIPTION OF FAULT AND POSSIBLE CAUSE:

INV No QTY. DESCRIPTION COST

SPARES REQUIRED

MACHINE

LINE No.

DATENAME

PRIORITY

EST. TIME

HIGH / LOWSHIFT

DESCRIPTION OF FAULT AND POSSIBLE CAUSE:

INV No QTY. DESCRIPTION

COST SPARES REQUIRED


INDUSTRIAL CAMERA �


True 3D industrial camera sees three dimensions at once

Seeing three dimensionsvalues. The image of theobject on the matrix and therespective distance valuestherefore gives a 3D image.The geometrical characteristicsof the object or the scene canbe read from these values.

This means the object and the camera can bestationary, a single camera willsee the three-dimensionalscene directly.

With its own powerfulbuilt-in infrared light sourcethe PMD 3D Camera providesthe user with real time imagedata, from as far away as

6.5m, comprising 3072 gray-scale and distance values for alow-cost solution to a varietyof applications in all manner ofwalks of life. The 30° x 40°aperture means a large areacan be viewed, leading to usesso far tested varying frompeople counting or detection,in one case for securitypurposes, to vegetable picking.

The applications are limitedonly by the imagination; theycould range from packaging,storage and materialshandling, through airportlogistics, vehicle detection,collision avoidance androbotics, to just monitoring if aspace is occupied.

Designed for OEM use the O3D201 PMD 3D Camerautilises a downloadablesoftware development kit,which provides all toolsnecessary for the systemdesigner to integrate the 3D information into the controlsystem. This gives thedesigner scope to create theright unit for the task. It thuscomplements the O3D200 unit designed for end userapplications, where all evaluationis carried out internally.

The device has digital andanalogue outputs for the userto scale or configure, andinputs for triggering orsynchronisation. For interfacewith the eventual users thereare two pushbuttons alongsidethe 10-digit display, or thedesigner could opt to leave theinterface only at the ethernetprogramming level.

Naturally, the housing isrobust, die-cast zinc withpolycarbonate optics making itsuitable for industrial use. Thetwo connections on the

housing, for power with inputsand outputs, as well theethernet programming port, useindustrial standard M12connectors for a good seal,maintaining the overall IP67environmental protection rating.

The 3D vision camera thusprovides illumination, depthmeasurement and evaluationin one industrial housing.Exceptional technology in avery small space, for asurprisingly low cost – madeby ifm of course.

Of course ifm electronicalso supplies a range ofmounting accessories to aidinstallation and connection ofthe O3D201 3D camera.

ifm is committed to workingclosely with its customers todevelop products whichprecisely match their needs,and the company providesexpert, readily accessibletechnical support to help usersmaximise the benefits theygain from ifm products.

� Mel Lewis

� ifm electronic Ltd., Efector House,Kingsway Business Park,Oldfield Road Hampton,Middlesex TW12 2HD

� T: 020 8213-0000

� F: 020 8213-2228

� www.ifm.com/uk � Reader Reply Number: 314

The truly innovative efectorpmd 3D camera from ifmelectronic is the first industrialcamera that sees in threedimensions at once. Integrationof their unique PMD (photonicmixer device) time-of-flightmeasurement sensingtechnology into a full visionchip, has allowed sensor marketleader ifm electronic Ltd toproduce a truly amazing device.

The image sensor has 64x 48 pixels. Each pixel of thischip matrix evaluates itsdistance to the object,resulting in 3072 distance

Supremely easy software

Take control!Increase uptime,reduce costs,enforce complianceand prove duediligence. To find out more,visit us online.Call today

CMMS

+44 (0)23 8022 [email protected]

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‘Thermoteknix has been supplyingskin temperature monitoring systems toairports and public places since the SARSepidemic in 2004 so we were ideallyplaced to respond immediately to thepublic need for for low cost skintemperature monitoring systems. Ournew FevIR Scan equipment is an evenfaster to install accurate, high resolutionsystem which needs an absoluteminimum of operator training and isreliable and simple to use. We aredelighted to say that we have beeninundated with enquiries from allquarters of the globe for our FevIR Scansystem and havejust shippedmultiple units toMexico where thedisease initiallybroke out.’

ThermoteknixFevIR Scan infraredthermal imagingcameras can detecttemperaturedifferences assmall as 0.05°Cand with their

Thermoteknix Systems Ltd reacted to the ongoing H1N1 swine flu outbreak with

the rapid launch of their new, low-cost FevIR Scan Skin Temperature Measurement

system for mass screening of high pedestrian areas such as airports, train stations,

factories and other public places. The system is shipping immediately ex-stock.

Now Thermoteknix have announced that FevIR Scan is available on a rental basis in

mainland UK for a modest monthly fee

FevIR Scan– YOUR FIRST LINE OF DEFENCEagainst the H1N1 Swine Flu outbreak, now available to rent or buy

high resolution detectors and lens options cover a wide or narrow field ofview as required for transit monitoring. A calibrated temperature reference source is included in the scene for thehighest temperature measurementaccuracy extending the performancebeyond that of industry standard thermal cameras.

� Thermoteknix Systems Ltd

� T: 01223 204000

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

The miniature, discreet and ultra portableFevIR Scan Skin Temperature Monitoringsystem provides peace of mind with highspeed sensitive temperaturemeasurement for high volume pedestriantransit areas. The system is based on aThermoteknix thermal imaging cameraworking in conjunction with a blackbodycalibration unit for high accuracytemperature measurement and with theoption of a colour visible video cameradisplay for simultaneous subject visualidentification. FevIR Scan is a tried andtested screening system which is servingin numerous countries including Thailand,Mauritius, Angola and in Mexico – whereunits have been installed at multiplelocations for national screening.

FevIR Scan thermal imaging andtemperature measurement system fromThermoteknix is easily installed, operatedand re-located with the very minimum ofsetup time and operator training. On-screenalerts identify one or more individuals in alarge crowd situation, aiding rapiddectection and maintaining passenger flow.The system is password protected toprevent unauthorised changes.

The SARS, Bird flu and now H1N1 swineflu viruses have affected tens of thousandsof people and businesses with massivedisruption to all people in all walks of lifeand FevIR Scan ensures that a high rate ofhuman transit is monitored effectivelywithout slowing queues in busy areas.

Thermoteknix Systems Ltd ManagingDirector Dr Richard Salisbury said:

IR �


Michell Instruments has added to its range of Easidew dew-point transmitters with the

Easidew PRO I.S., a rugged, intrinsically safe transmitter suitable for use in the natural

gas, petrochemical and process industries where a rugged transmitter is required

Rugged I.S dew point transmitter withATEX certification from Michell Instruments

sensor technology. All the calibration datais stored within the transmitter’s flashmemory and so calibration exchange, orservice, can be affected in seconds, evenby untrained personnel. The Easidew PROI.S. is simply disconnected, removed fromits sampling block and replaced by a newfully calibrated unit.

The Sensor Calibration ExchangeProgram for Easidew PRO I.S. makes it theperfect choice for measurement of dewpoint or moisture content in all hazardousarea applications where a calibrationtraceability of the used equipment iscrucial. Specific applications include CNG(compressed natural gas) dryers,hydrogen coolant in power generators,industrial gas manufacture and supplyand many more.

� Nick Malby, Global Product Manager

� Michell Instruments48 Lancaster Way, Ely, Cambridgeshire CB6 3NW

� T: 01353 658 000� F: 01353 658 199� E: [email protected]


A natural progression from the Easidew TXI.S., the Easidew PRO I.S. is certified byATEX for use in hazardous area zone 0, aswell as for use with galvanic isolators.

Like the other transmitters in theEasidew Range, the Easidew PRO I.S. ispart of the Sensor Calibration ExchangeProgramme – enabling customers tomaintain traceability through periodicrecalibration while keeping the process inoperation. Signing up to the programmemeans that customers can order a newsensor, install it and then send back theold one to Michell for recalibration at afraction of the cost of completelyreplacing the sensor – with the addedbenefit of no down-time.

The key to the success of the exchangeprogramme is the innovative Easidew

ATEX �


We can show you the way...

Proviso Systems Ltd provide condition monitoring and predictive maintenance productsand services predominantly to the UK market. We utilise techniques including vibrationmonitoring, thermal imaging, oil analysis and integrated plant management philosophies.

Let us light the way to protecting your business...

Tel: +44 (0)1777 817536 Email: [email protected] Web: www.proviso-systems.co.uk

Vibration AnalysisThermographyOil AnalysisHydraulic Circuit TestingRCM

Balance & Laser AlignmentPulley AlignmentElectrical Inspection & TestingMotor Current AnalysisEquipment Criticality Audits


Unbalanced rotating bodies cause vibration and mechanical stress which is

transmitted to the machine’s entire structure

N300 Portable balancing and vibration monitoringThe quick coupling connectors connect

two independent and simultaneousmeasuring channels and a photocell. Thedata can be transferred to a PC via the miniUSB port. The N300 is equipped with N-Pro,Professional Environment software for N-Instruments. This software can transfer allof the data recorded by the instrument andautomatically file it by simply pressing abutton. It can be displayed, processed,analysed and employed to generate reports

in PDF format or on paper at any time.For all your condition monitoring and

balancing requirements visitwww.cembhofmann.co.uk

� Mark DaviesCEMB Hofmann UK Ltd1 Longwood Road, Trafford Park,Manchester M17 1PZ

� T: 0161 8723123� www.cembhofmann.co.uk


Field balancing reduces the amount ofvibration and improves the machinesoverall condition. In addition, fieldbalancing reduces stress on the bearings,temperature, energy consumption, noise,maintenance frequency and operatingcosts. With the N300, CEMB meets theneeds of engineering companies andmaintenance personnel who need acompact and ergonomic balancer. TheN300 can be used to measure the overallvibration value (ISO10816-3), takesynchronous measurements (1xRPM) andfor field balancing of rotating bodies onone or two planes.

Thanks to the backlit graphic displayand intuitive “step-by-step” software,even occasional users will find the N300easy to use.

VIBRATION MONITORING �



CONDUIT �

DUST EXTRACTION �

Nederman have launched a new

free test service to provide accurate

measurement of airborne contamination

FREE AIR QUALITY TEST SERVICE from Nedermanextraction if required. We’re concentratingon weld fume as a first phase.”

The devil is in the detail as whilst HSEGuidance Note EH54 specifies an 8 hourTWA WEL of 5mg/m3 for particulatewelding fume, it’s a ceiling level that’sdramatically reduced by the presence ofmore harmful elements in the consumableand it can also be impacted by thewelding method. Nederman considers allthese factors to establish appropriate testparameters. If limits are exceeded, there’sthe option of commissioning more detailedanalysis of component concentrations orimplementing improved local exhaustventilation (LEV). Either way, action will berequired to avoid the legal risks associatedwith employee exposure to hazardouslevels of dust and fume.

Nederman are rolling this initiative outacross Europe, having launched it at the

Schweissen & Schneiden exhibition forwelding and cutting technology in Essen,Germany (September 14th – 19th).Nederman also exhibited a new filter forharmful elements in weld fume that’scompatible with existing FilterBox systemsto provide safe removal and efficientcleaning of hazardous particles from highchrome content stainless steel and otherdifficult material. A new on torchextraction concept for automated roboticwelding equipment was also shown forthe first time. These latest innovations aredriven by Nederman’s continuing aim toimprove workspaces by enabling betterhealth, quality and productivity.

� T: 08452 743436


� www.nederman.co.uk � Reader Reply Number: 319

The new test can measure many types ofairborne contamination including weldfume, vehicle exhaust, oil mist and dust ofvaried particle sizes (1 to 10microns). Theprocess is comprehensive, involving captureand collation of multiple data samplesthrough work cycles and across operatingzones. Overall results are then compared tothe relevant long term (8-hour time weightaverage – “TWA”) or short term (15minute) Workplace Exposure Limits (WELs)to identify if further action is needed.

“We regularly encounter customeruncertainty regarding the contaminationlimits specified by HSE,” said Mark Hodgens,Nederman’s Managing Director. “In manycases, it’s not straightforward, so this freemeasurement and consultation service offersreal benefits. Our analysis not only enablesus to offer qualified opinion, it’s also theperfect foundation for designing effective

Flexicon claims to have launched the most liquid tight conduit system in the UK

by further enhancing its range of compression fittings. It has an IP rating of IP69k

Flexicon launch most liquid tight conduit system in the UK

by a high pressure, hightemperature jet wash. It issuitable for equipment thatneeds regular intensive cleaningsuch as in food processing. TheIP69k rating extends the BS EN60529 rating system to a newstandard DIN 40050.

The fittings include amultipart compression fittingwith a nylon seal, which youcan use for knockout orthreaded entries as it rotatesuntil tightened. Also availableare compression fittings thatswivel about the main bodyeven after tightening, a 90°,45° and a multipartcompression coupler thatincludes seals for joining twoconduits. These fittings can beused with conduit sizes rangingfrom 10mm to 63mm and areavailable with metric, PG andNPT thread variants.

The LTP conduit range has asmooth, wipe clean outer cover,is resistant to oils and greasesand UV light for externalapplications. For applicationsrequiring a wide temperaturerange, you can use the LTPHC

variant for temperaturesbetween -45°C to 135°C.

The LPC spiral reinforced pvcrange is a non-metallicalternative and can accept sometorsional movement. Colourcoded versions provide oilresistance (green), high flexibility(orange) or protection againstwider temperature ranges ofbetween -5°C to 90°C (blue).

It is a lighter weight thanmetallic versions and is fasterto install, particularly whencutting to length. The LPC rangecan also be used with non-metallic or stainless steelfittings making it ideal for thefood processing industry.

� Flexicon Ltd� T: 01675 466900 � E: [email protected]� www.flexicon.uk.com � Reader Reply Number: 318

The compression fittings aresuitable for the company’s LTPgalvanised steel plastic coatedliquid tight range and also forits LPC smooth spiral reinforcedpvc system.

An IP69k rating allowsequipment to be steam cleaned


Rolls-Royce has extended capability at its Distributed Generation Systems business in Winsford, Cheshire, by investing in a fine particle decontamination facility to clean-up military power generators. Diesel powered generator sets, often returning from harsh overseas environments, have to be disassembled and thoroughly cleanedbefore being stripped down and overhauled

DCS bust the dust for Rolls-Royce

discuss their requirements.DCS proposedand installed twelve environmentalcontrol booths (ECBs) and a centralisedvacuum cleaning system to deal with dustlying on the floor.

ECBs feature a unique design that pullsdust filled air away from operatives at a rateof 0.7m/s, providing 99.97% filtrationefficiency. With clean air moving at the samerate, this ‘cross flow’ method of air circulationeliminates the ‘stopping and starting’ causedby dust accumulation and poor visibility.

Chris Goodwin, Works Director at thebusiness, said: “It was vitally important thatwe had an extraction system that wouldensure a healthy and safe environment forthe team working in the area and alsoprotect other workers outside the area fromthe nuisance of dust and noise.”

� Dust Control Systems Limited� T: 0800 040 7116 � F: 01924 482530 � www.DCSlimited.co.uk� Reader Reply Number: 320

Recognising the need for an efficientmethod of removing the dust and fineairborne particulate during the cleaningprocess, Rolls-Royce called in extractionspecialists, Dust Control Systems (DCS), to

DUST CONTROL �


Dust and fume extraction hoses from Masterflex

� Temperature range -260°C to +1100°C

� Size range 38 mm to 900 mm

� Very flexible, small bend radius

� Long service life, low operating costs

� Suitable installation and connecting systems

Masterflex Technical Hoses Ltd

GB-Oldham OL1 4ER

Tel: 0161 626 8066

www.masterflex-uk.com

TUBE PROTECTIONPU / FABRIC HOSES CONNECTIONS

For more information quote EMS Enquiry No. 117 on IBCFor more information quote EMS Enquiry No. 116 on IBC

AWARDS �


Barkston Plastics Ltd, one of the UK's most comprehensive and innovative plastics

companies, has launched an ‘Innovations in Plastic’ awards scheme to help identify

and celebrate the talent pool of designers, engineers, scientists, artists and technology

students in UK universities

Barkston launches‘Innovations in Plastic’ Awards

scheme should be made online by 1February 2010 with final deadline forcompleted entries by 1 May 2010. Judgingwill take place during June 2010. Thewinner of the ‘Innovations in Plastic’ awardwill be offered the chance to benefit fromtheir product being put into manufacture;and marketed through Barkston’s website.

The scheme will also assist Barkston infulfilling its pledge to develop 40 newconsumer products during 2009-10 – thecompany’s 40th year of trading.

Tim Kiernan, Managing Director ofBarkston, said: “The idea behind the

awards scheme is not only to recognisethat we have a wealth of talent comingfrom our universities but also to celebratethe versatility of plastic. Many productsthat have been traditionally manufacturedout of alternative materials are rapidlymoving into production in plastic and thisis great news for our industry and thefuture of British manufacturing.”

For award entry information please logon to: www.barkstonltd.co.uk

� www.barkstonltd.co.uk


Launched 1 November 2009, thecompetition is open to any UK universitywho wishes to enter and products putforward to win the award must be madeentirely or in part of plastic. Thecompetition will be judged by a panelincluding representation from Barkstonand the wider manufacturing industry.

Items entered into the awards schemecan be stand alone products or parts ofproducts; and can be functional or simplyaesthetic. Products can be new inventionsor improved versions of existing products.

Initial applications for the awards

Richard Chambers GmbH has been operating in the quality-conscious German-speaking

world for over 27 years. The company is unique in that it does not concentrate on one

technology, but with five offers as its real product "Saving with more Performance".

This programme was recognised with an award at a leading maintenance show in 2009

medium-sized firms. With software added,the SPY offers much more informationthan vibration analysis, at a fraction of thecost and much simpler.

Friction reduction in industry andtransport can save significant energy costs."SX-6000" is certified to reduce wear by upto 88%, compared with oil alone. Simplyadded to the oil system, it produces a long-lasting coating on the friction surfaces. Thisproduct is the only one in the world usinghigh-density PTFE (CoF 0.02), not to beconfused with Teflon (CoF 0.04).

With the death sentence for inefficient,hot-running lights in the EU, the "Intelli-Light" series offers savings of up to 80% inwarehouses, 60% in production areas. Eachlight unit has its own "intelligence", whichhas been proven to offer significant savingscompared to even the most efficient unitsworking in groups.. Installation is possible

up to 26 metres and office and loadingramp lighting is also available.

Regulating current to constant-speedelectric motors which work cyclically orunder their rated performance, the"Powerboss" can save energy too. Andwith soft-start, soft or braked stopping andseveral other programmable features suchas idle-time limit and dry pump stop, theinvestment can be well below that of anew high-efficiency motor when the otherfunctions have to be bought seperately.

Oil leaks can be eliminated with"LecWec", now being exported to 26countries for use in vehicles and industrialmachines. Down-time, often more costlythan the repair itself, is eliminated - simplyadd 3% to the oil and carry on.

� www.chambers-company.com


As the European importer of the"Ultrasonic SPY", a device which locatesdefects in all industrial systems, and ofwhich two have been working on the ISSsince 2001, the company counts ascustomers nearly every big and many

CONDITION MONITORING �

Halliburton ChemicalCLEANING SERVICES

Adler and Allan Group

preoperational, operational anddecommissioning cleaning operations.Halliburton’s single-fill methodsdramatically reduce waste volume and

cleaning time when compared totraditional multi-fill cleaning methods.Single-fill methods are available forcleaning a broad range of equipmentincluding boilers, process tanks, transferpiping, pipelines, refinery processequipment, heat transfer systems, utilitysystems and pulp and paper processequipment. Proven technologies includethe citric acid-based MagSolvTM cleaningprocess that provides degreasing, scaleremoval, neutralization and passivationwith only one solvent fill. Technicalsupport centers in Houston, TX, Duncan,OK, and Pune, India combined with fieldlaboratories in most operational locations,enable Halliburton to design the mostcost-effective approach to virtually anyprocess system cleaning challenge. Formore information about Halliburton’schemical cleaning capabilities, phone (44) 1224 350118 in Aberdeen or email [email protected]

� T: +44 (0)1224 350118


� www.halliburton.com� Reader Reply Number: 323

Almost 50 years of chemical cleaningexperience enables Halliburton Pipelineand Process Services to provide best-in-class, proven technology for

Adler and Allan is the market leader in theprovision of rapid response services to thepublic and private sector. Operating froman unrivalled network of bases, werespond quickly and effectively to customerrequirements from oil and chemicalspillages, critical fuel deliveries and tankservicing to managing major turn-keyinstallation and dismantling projects,disaster recovery and industrial cleansing.

� Spill Response Services Resources andskills to tackle the most challenging ofsituations from domestic tank leaks tomajor industrial disasters

� Fuel Services For challenging fueldeliveries and providing a 24 hour callout service for retained customers

� Fuel Installation Services Expertise toservice, design and install all fuelequipment

� Tank Services Experience of cleaningall types of storage tanks from smallindustrial to major refinery holding tanks

� Industrial Water Jetting and Cleansing� Separator Services Pollution Prevention� Oil & Hazardous Waste

Management Services

For a free, no obligation quotation please contact Adler and Allan:� T: 0800 592 827 � E: [email protected]

More detail on our services, locations and contacts view: � www.adlerandallan.co.uk � Reader Reply Number: 324

CHEMICAL CLEANING �


WORKWEAR �


Rugged & Tough Ltd consists of Rugged &Tough Sourcing and Rugged & Tough WorkWear Stores.

Rugged & Tough operates upon aplatform to provide you, our clients with“Best in Class: - Professional and IndustrialGrade Work Clothing and Kit”. We offer theflexibility of being able to source large andsmall volumes. Our client base covers allthe major industries and professions fromthe Multi-National Heavy Industries to SMEs.

Our Sourcing Division works with youto meet your specific requirements, findingyou the right products and the right prices,from fire/ mosquito repellent clothing foruse in Africa to arctic clothing for Russiaand everything in between.

Our main showroom in Bedfordshireoffers around 4,500 products and operatesan on-site embroidery and personalisationworkshop. We are authorised dealers and distributors for Carhartt Workwear,

Walls Industries, Jobman Workwear,Blaklader Workwear and U-Power to name just a few.

For more information about how we canhelp you, please contact Chris Turowska.

� T: 07743 816632


� www.ruggedtough.com


Are you providing your workforce with the correct level of hand protection? Looking for

specific, industrial work gloves? Well look no further as you have come to the right place

HAND PROTECTION SPECIALISTSWe provide a wide range of industrialgloves including chemical resistant gloves,specialist handling gloves, general purposegloves and much more to assist people invarious industries, such as the below.� Sharp-edge Steel and Glass handling� Building and Construction Areas� Mechanical Assembly Lines� Heavy Industrial Works

� Wiring Industry� Car Industry� Food Processing

Spontex is committed to providing and finding cost effective solutions to allyour hand protection requirements. Asmuch as a task can be carried out and toa satisfactory level with bare hands, itcould be performed far more efficiently,

safely and easily due to the enhancedmanual dexterity that the right glove can provide.

� Spontex Workwear

� T: 0151 486 6540


� www.spontex-workwear.co.uk � Reader Reply Number: 325

WORKWEAR �


Interactive Wear AG playing a significant role in a new ZIM/AIF funded project

DOCKING TECHNOLOGY APPLIED TOintegration of computing equipmentin work garments for industrial use

Interactive Wear has extensiveexperience in developing electronicproducts and integrated solutions forapparel and accessories. However, theindustrial garment market requirementsare very complex and demanding.Computing equipment integrated into theindustrial work wear for either technicalservices or fire fighting personnel must beeasily detachable and interchangeable. Inaddition to straight forward mounting andconnectivity, the user must be able tooperate the equipment while wearinggloves. Moreover, the garments must bewashable with the fasteners andinterconnecting wires in place.

This project aims at developing anarchitecture comprising three coremodules, cabling, and the connectors forperipheral equipment and input devices,like textile sensors. The three coremodules consist of a Central ProcessingUnit (CPU), a universal power supply witha semi-flexible rechargeable battery

module that can be easily adapted todifferent operating conditions andoperating time requirements, as well as adisplay unit that can be integrated intothe garment's fabric. Optionally, a headmounted display can also be used.

Each participating partner brings tothe project its unique expertise, andmaintains focus on the particular projectdevelopment segments accordingly.Interactive Wear's contribution is in theareas of modular power supply, theuniversal interface development, andhardware/textile integration. TeXXmo'sresponsibility concentrates on the CPUand display technology with interfaces,while Plastec defines material propertiesand takes charge of the interfaceencapsulation and mechanicalconnectors. Finally, Starringer providesthe ergonomic apparel design.

"By taking part in this ambitiousproject, we reaffirm our position as awearable electronics technology leader",said Andreas Röpert, founder and CEO ofInteractive Wear. "The main objective ofthis development is to find the optimumcombination of textile components, actualgarments, modular hardware units andtheir performance. In contrast, the similarproducts currently existing on the marketare either highly specialized niche items,or systems built with components thatwere not necessarily specifically designedfor this kind of applications."

The project duration is set to be 18months, and its completion is scheduledfor September 2010. The launch of thenew development, for example as arugged PC alternative, is anticipated tobegin in late 2010.

� Andreas Röpert

� Interactive Wear AG

� T: +49 (0) 8151-55506-0

� F: +49 (0) 8151-55506-60


� www.interactive-wear.com


� Entry point into industrial projects inthe area of wearable computing

� Project funded by Central InnovationProgramme (ZIM) for SMEs of GermanFederation of Industrial ResearchAssociations (AiF)

� Interactive Wear project partners:teXXmo, Plastec and Starringer

A wearable electronics pioneer, InteractiveWear, plays a significant role in a newZIM/AIF funded project dedicated tointegration of wearable computingcomponents into garments for industrialuse. Together with their partners teXXmo,Plastec and Starringer, Interactive Wearembarks on developing a docking conceptfor portable computer equipment use inindustrial work wear. The objective of thisproject is to integrate rugged computingcomponents into a flexible wearablearchitecture based on the "Plug 'n Wear"project by wearable computing expertteXXmo. Ultimately, the developed productswill be transferred into mass production.

INDUSTRIAL PAINT �


World class repair & maintenance products for all types of industry

FLOOR COATINGS GUARANTEEDfor 10-20 years

contractor can apply if necessary; we are proud to include a number ofprestigious hotels and leisure complexesamongst our extensive client list. All ofour coating systems are based on theRobex 20/10 Macro Molecular ResinTechnology, have no smell and will bondto almost any surface.

� T: 01462 422 260

� www.robex.co.uk


Robex, now celebrating our 29th year and to complement our superb range ofbuilding maintenance and repair products, have developed a range of‘fluid applied’ floor coatings that are sohard wearing they are guaranteed for inexcess of 10 years! The top of the range‘five star’ system can be guaranteed for20 years and is available in a wide rangeof colours and safety non-slip finishes. All of the coatings are suitable for ‘DIY’application or an approved Robex


I believe Reliability Engineering is thebackbone of a Professional Maintenanceorganisation providing structured methodsand tools to maintain assets in a consistentand cost effective manner. It can not alsoyield financial benefits through reducedcosts and increased asset utilisation butcan provide an invaluable audit trail ofdecisions made to satisfy regulators andboth internal and external bodies.

So why do so many organisations stillnot have the capability and processes inplace to meet this objective? This may bebecause they do not truly understand therequirements, potential benefits and thelevels of maturity that can be achieved inproviding an effective Reliability Function.It may well be they are so reactive thatthey can not identify available resource tofocus on what the business really requires.

Professional Asset Managementinvolves not only doing things right butdoing the right things.This poses a numberof questions for the modern maintenancemanager wishing to optimize his assets:� What value is added by the

maintenance plans? � How can the utilisation of assets

be maximized?

The contribution of maintenance to an organisation is unfortunately too often not fully

understood until something goes wrong e.g. a failure of a significant plant item or asset.

This will inevitably result in a consequential loss through the inability to produce or

provide a service or the occurrence of an environmental health, safety or quality incident

RELIABILITYENGINEERING–What’s it all about?

RELIABILITY ENGINEERING �



� What is the optimum level ofmaintenance?

� How do I comply with regulations?� What is the impact on production?� What spare parts are required to

support business?To answer these questions and simplify

the requirements for anyone consideringon embarking on a Reliability improvementprogramme I believe this can be bestexplained by breaking the requirementsdown into some logical steps:

Step1: Business AlignmentThe starting point must be to ensure thatthe objectives of the Maintenance functionare closely aligned with those of theBusiness. The decision to focus onReliability Engineering must be appropriateand based on the dominant drivers for thebusiness and its current market situation.The level of ambition of the organisationto create a Reliability Engineeringcapability must consider current and futurecapability, technology levels and bothfinancial and organisational constraints.

Many external factors are clearly out ofthe control of a business but there issignificant opportunity to take control ofthe maintenance function and ensure thatit is doing the right things in the mosteffective manner

Step 2- Calculate the Value PotentialThe use of benchmarking and auditing is auseful mechanism which will allow anorganisation to assess gaps in performanceversus best in class and if executedcorrectly should identify the priority areasfor improvement and quantify the potentialbenefits based on realistic target setting.

Clearly, maximising the use of scarceresource requires an assessment of thevalue potential of the asset base and bythis I mean determining which assetsdeliver the most to the business andranking them based on their valuecontribution and impact.

Step 3: Know your PeopleEach organisation will have developed itsown culture based on geographical,historical and financial factors. To ignite thedesire to change it is imperative the changehistory of the organisation is understoodbefore embarking on an improvementprogramme. This will allow realistic andachievable targets to be set that match thecapability and desire of the organisation.

If goals are over ambitious thenmotivation will be impacted and if tooconservative benefits may not be realised.

In developing the Reliability functiontheir must be close alignment betweenthe people, processes and tools deployed.

To be sustainable the aim must be tobuild competency at the right levels ofthe organisation.

Step 4: Know your AssetsOne of the initial tasks of reliabilityengineering is to adequately specify thereliability requirements and systemboundaries. To do this will require readyaccess to accurate drawings, assetperformance data and technical manuals.

Recording the right data in the rightway in the Enterprise Asset ManagementSystem is a prerequisite to performadequate analysis. EN/ISO 14224 providesguidelines for collection and exchange ofreliability and maintenance (RM) data forequipment. You need to start with theright definitions, formats of:� equipment data, e.g. equipment

attributes;� failure data, e.g. failure cause, failure

consequence;� maintenance data, e.g. maintenance

action, resources, consequences, down timeIt is necessary to ensure that a

comprehensive asset base is establishedso that all assets can be assessed basedon their value to the organisation. Thisassessment may be quantitative orqualitative depending on the availability




of asset data and is typically conducted bya mixed team of Engineers, Operators,Technician, and Production staff.

It is important to remember that theinitial criticality ranking based on value ismerely a tool to determine the beststrategy for the equipment and in itselfwill yield no financial benefit.

Clearly, an asset with little impact orvalue to the organisation will notcommand the resource for a detailedreliability study. As the criticalityassessment progresses, natural grouping ofassets will be determined which shouldallow the appropriate strategy to beselected. Thus a decision can be made toundertake a detailed study for high rankedassets, perhaps some PM optimisation formid ranged and a simpler PM approach orrun to failure for lower ranked assets.

Step 5: Select the right Tools There are many well documented methodsand tools available to assist organisationsin enhancing the reliability of their assetsyet so many organisations still have a veryunstructured approach to determining thelife plans for their assets resulting in eitherover or under maintaining and high levelsof breakdowns and corrective maintenancetasks. The key challenge is to find the rightbalance between preventive and correctivemaintenance tasks.

Even the more developed organisationsthat have adopted processes such asReliability Centred Maintenance ( RCM)and Failure Modes Effect & CriticalityAnalysis ( FMECA) can often fall short. Thisis because in their desire to improve andmitigate all identified failure modes theyoften forget to assess the financialimplications of the decisions made andmake an informed decision balancing therisks to the business versus the costs. Thiscan have a cumulative impact on theMaintenance budget across the life of theassets assessed.

The underpinning feature of the mostcommon reliability tools is that they allowan organisation to determine theappropriate strategy by considering in aproactive way the potential functions,failure modes, cause and effects and thendetermine the necessary defence strategy.

The process for selection of theappropriate strategy may vary eitherthrough flow charts, decision trees, riskmatrices but provided there is a soundunderstanding of the underlying principlesthen the right tasks should be improvedfrom a reliability best practice principle.However, to provide a sharp business focus

the best tools should consider not just themitigation against the identified failuremode but the ongoing maintenance costand resource burden to conducting thetasks. Thus, consideration should be given asto whether the risk of failure is acceptableor not and if not what is the most costeffective strategy to be implemented.

Step 6: Resource Planning As the Reliability function develops andstudies are created there will be a need toconsider the impact of the selectedstrategy on resources. Typically, this willimpact in a number of areas. Firstly,Inventory management, changing orintroducing new tasks will challengewhether the right type and quantity ofspares is held. This issue is normally bestresolved by assessing risks of stock out,versus cost of holding and any decisionsmade must be aligned with themaintenance assessment.

Critical spares are often expensiveparts that are rarely used and as suchjustification for holding on stock is notalways obvious. Secondly, there may wellbe a significant impact on themanufacturing plan and thus assetavailability and it will be necessary to takea pragmatic approach bundling taskstogether to allow execution with minimumimpact, or identifying non intrusive tasks.

Step 7: ImplementationTo build capability and confidence a pilotapproach is the most cost effective way tovalidate the methodology, processes andtools to be used. It is imperative thatadequate preparation and prioritisation isdone upfront to ensure the pilot istargeted correctly. This will provide anopportunity to gain buy in from relevantstaff, demonstrate the improvementpotential and allow any necessaryadjustments to be made based on realexperience. It will also allow confidenceand competence to build in a relativelycontrolled environment.

A pilot study will allow relevantlearning’s to be captured and translated intofuture activities. If external support isinvolved in supporting this process, thedeliverable should be to leave anorganisation with competence at the desiredlevels, provide a good understanding of theunderlying principles of reliabilityengineering and a process that is easy tounderstand and deploy in a timely fashion.

For the benefits to be realised it isimperative that the hard work gatheredthrough studies is captured in an efficient

manner that can be readily transferred tothe maintenance system. If this process isnot efficient then there is danger that thefinal stage will not be completed andbenefits not realised. More commonlyintegrated software is now available totake output from studies and transfer in anefficient manner to the EAM, utilising bulkuploads of data.

Finally, the processes must be clearlydefined to support the Reliability activitiesand transferred to the organisation bycarefully defining roles and responsibilities.

Step 8 : Monitor and Review progressTo maximise the benefit from a reliabilityprogramme there is a need to provide anefficient means of accessing and analysingdata. Too often the work undertaken aspart of a reliability improvementprogramme is viewed as a one off activitybut in truth needs to be managed muchmore dynamically based on equipmentachieved levels of performance.

The quality of data gathered will bebased on the experience and knowledge ofthe staff involved and the integrity of thedata utilised. As both of these continue todevelop, then it is vital that the initial workis revisited based on new information andin doing so will continue to validate thereliability study and continue to driveincreased levels of performance.

Unfortunately, this improvement cycleis often not fulfilled due to poormotivation, lack of integration of systems,and inadequate reporting and functionalityof systems used.

The best performing organisations willhave clearly designed targets based onbenchmark data and realistic levels ofimprovement, processes firmly embeddedin the organisation at all levels andefficient data capturing and reporting.

Ideally, the performance indicatorsselected to drive improvement should notjust focus on cost reduction and assetutilisation. They should highlight theeffectiveness of the maintenance tasksdeployed in reducing failure rates and thesubsequent impact on the works ordermanagement process. In reality manyorganisations struggle to extract data in away that makes it transparent to themwhat the real trends and issues are.

Step 9: Design for ReliabilityAs an organisation becomes more maturein its level of reliability competency, theirwill be more focus on the total life cycle ofassets. This will drive more involvement ininvestment and acquisition decisions based



on sound knowledge and data. Equipmentwill be specified more frequently usingreliability and maintainability criteria thatmeet the desired performance levels ofthe business. There will be closer workingand transferring of information withsuppliers and OEM’s to drive up standardsof components and systems. Morecomplex techniques, simulation modellingand scenario planning may be arequirement for more complex systems.

Reliability studies will in time becomeless reactive and more proactive anddelivered earlier in the life cycle wherethere is opportunity to redesign atminimum impact and cost. Levels ofstandardisation will improve and theReliability Function will be trulyembedded in the organisation as a valueadded activity.

ABOUT THE AUTHORMick Saltzer is a Managing Consultant forMainnovation, a leading consultancy firm withoffices in the UK, US, Sweden, Belgium andNetherlands. Mick has over 20 years experience inAsset Management and is leading businessdevelopment in the UK.

MORE INFORMATIONDo you want to know more about the way in whichReliability Engineering gives you insight informationin the added value of maintenance,please contact:

Mainnovation at www.mainnovation.com

Mainnovation is a leading consultancy organisation,specialists in maintenance improvement projects,from audit right through to implementation. With the Value Driven Maintenance® methodology,Mainnovation innovates organisations in themaintenance market.

� www.mainnovation.com


www.engineeringmaintenance.info November/December 2009 EMS �

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Picks up the hard stuff: rocks, bolts, nuts, nails - most things that a conventional vacuum system misses.Uses a replaceable brush system that is mechanically driven. Magnetic Sweeping Bars also available.

Shipped internationally - in airports all over the world.


37

AIRPORT GROUND REPAIRS �

excavation, which is expensiveand time-consuming.

AdvantagesURETEK’s unique technologiesare particularly effective andthere are a number ofadvantages that are not offeredby alternative methods.

Universally acceptedOur methods are universallyaccepted by architects, nationaland international authorities andare even recommend by insurers.

Phenomenal lifting capacityOur methods have a liftingcapacity of 40,000 kg persquare metre. We can restoreyour concrete to full workingstrength no matter how heavya load it supports.

Environmentally friendlyOur resins are without CFCsand can be applied inpractically all circumstances.They do not pollute and do notaffect the quality ofunderground water. They areeven allowed for applicationsin the food industry.

Minimal disruptionFast installation, curing andcleanup equals minimaldisruption Also we causeminimal dust and noisepollution. After only 15minutes our material hasalready reached 90% of its full strength, so load canimmediately be restored to a treated area.

ACT NOW!! Take the first step to solvingyour problem.

� www.uretekworldwide.com


MethodAfter detailed analysis of theproblem, we drill small holes tothe appropriate depth above ornext to the problem area. Nextwe inject specifically developedenvironmentally friendlymaterial with uniquely strongand expansive properties.

This material expands at a100% predictable rate, fillingunderground voids,consolidating the soil andstabilising the surroundingarea. The process can also beused to lift sunken concrete orfoundations with greataccuracy; to within a toleranceof 5mm per metre.

All this can be achievedwithout the need for

THE TIME SAVING SOLUTION for airport ground repairs

INDUSTRIAL DOORS �

Rowland Doors– 23 Years of Excellence

UES Technology UK Limited

Specialists in the industryThe success of the company comes fromtheir thoughtful and insightful approach toall jobs undertaken. Before any task theRDS team undertake an in-depth sitesurvey to advise the best course to take and products that best suit theirclients requirements. Their services cover site surveys, product supply,installation, maintenance and a true 24/7 emergency callout.

Every conceivable loading bay andIndustrial Door product can be offeredfrom dock levelers, roller shutter doors,traffic light systems to a replacement nut or bolt!

Rowland doors are a true total IndustrialDoor and Loading Bay Solution.

� T: 0121 328 8403

� www.rdsindustrialdoors.co.uk


Rowland Doors was founded in 1986 with the concept of adding a level ofservice and professionalism that was not yet offered In the industrial door andloading bay industry. 23 years later thisapproach has seen them secure blue chip clients such as Land Rover, BMW,Argos, Birmingham International Airport,DHL and Tesco who rely on RowlandDoors for all their loading bayinstallations and maintenance.

skilled, experienced personnel along witha strong management team and soundfinancial backing permits first rate serviceto be offered across a wide range ofproducts. Primarily, we maintain loadingbay equipment and industrial doors, butour expertise has a far wider scope. So justabout any type of equipment for whichyou need spares or repairs is likely to bewithin our capability.

Our central location and proximity tothe motorway network enables us toservice a wide range of sites within easytraveling times.

For Service and Repairs:

� T: 01789 800218

� F: 01789 764276

For General Enquiries:

� T: 01386 555804

� UES Technology UK Limited

Severn Court, Tything Road East,

Alcester, Warwickshire, B49 6ET

Customer Support:


General Information:



Our missionSimply to offer you the best spares, serviceand repair facility for industrial doors andloading bay equipment at the keenestprices, without ever compromising onquality or safety.

Company ProfileDrawing on over 25 years of experience inthe loading bay industry, we offer aMidlands-based spares, repair and servicefacility that can provide a first-time fix formost equipment breakdowns, atcompetitive prices.

An engineering base comprising


Excellence in industrial equipment repairs and maintenance

AUTOMATIC INDUSTRIAL ROLL-UP AND FOLD-UP DOORS

Website: www.insightautomation.co.uk Email: [email protected] Tel: 01767 315 402 Fax: 01767 601619

Please contact us for a quote for a completely customised

automatic door

Ditec Industrial Doors have a wide range of customisable options, including:

Coloured polyester curtains and clear PVC window sections.

With or without counterbalance.

Galvanised or Powder-coated frame.

Many safety features are available including photocells, electronic safety-edges and ground loops.

Sizes of up to 11m wide or 8.5m high available.

Opening speed of up to 1 m/s.

TÜV certified, and in compliance with 98/37/EC and 89/106/EC.

Very Heavy Duty 400v 3-phase gearmotor.

IP55 rated electronic panel.

Semi-automatic emergency re-opening system supplied

as standard.

“One focus of development was toimprove device handling. As a result, thehandwheel is now activated with onehand by simply pressing a button; valveconnection is more flexible and a newlydesigned electrical connection facilitatesthe linking of cables with large crosssections. Operation is made easier by anew, enlarged and illuminated graphicdisplay. The display texts are shown inplain text, available in a wide range oflanguages. Graphic display features areprovided e.g. torque curves. Operation,setting, diagnostics and the memorisationof all actuator data is facilitated wirelesslyvia the AUMA PC ToolSuite.”

Joachim Rist, the Product Manager ofthe new AC controls, reports that theinnovative developments are the result ofan intensive exchange between valvemanufacturers, consultants, plant operatorsand control/communication systemmanufacturers. It was recognised thatstandards should be followed as closely aspossible for all developments outside ofthe products’ new intelligent functions. Forexample, the status signals of the AC 01.2are classified in compliance with NAMUR

recommendationNE 107. Consequently,the plant operatorreceives clearlyinterpretable signals from the actuators and all other field devices andnew diagnostic features of the actuatorsare supported.

Temperature/vibration sensors andapplied torque recording are used tocontinuously monitor all parameters whichcontribute positively to the actuator’s life.If an actuator is operated outside thespecified operation conditions, forexample with an impermissible highnumber of starts, the plant operatorreceives advance information enablingappropriate action to avoid malfunction.

In line with AUMA’s previous products,the new controls are available withdifferent fieldbus interfaces, including theProfibus DP interface with V2 services.

� Auma Actuators Ltd � T: +44 (0) 1275 871141 � E: [email protected] � www.auma.com


The new Generation .2 multi-turn actuatorrange SA 07.2 – 16.2 and new actuatorcontrols AC 01.2 have been launched byAUMA: the products will be ready for orderand delivery from first quarter 2010.Designed to cater for existing market needs,and next generation requirements,capabilities include the integration of fielddevices into Asset Management Systems.AUMA has introduced a number of enhancedfeatures and expanded the functionality ofits range, while retaining proven designprinciples. Commenting on incorporatingmodularity as a fundamental principle of thenew products, and additional advancements,Peter Malus, the AUMA Product Manager forthe actuators, said: “The new Generation .2devices, both actuators and controls, arefully compatible with our previous products:this ensures low-risk investment andguarantees that we will always be at theforefront of technological development.

“Mechanical enhancements improvepositioning accuracy, the output speedrange of modulating actuators and theextension of the expected actuatorlifetime. These advancements are backedby improved corrosion protection.



ACTUATORS �

AUMA launches Generation .2

The solution “Coswin was already successfullyimplemented within the Sanef group soSiveco Group consultants had alreadydemonstrated that they could under-stand strategic objectives, and thenquickly adapt and implement apersonalised Coswin system. That’s thereason why we selected their solutionagain; to save time for the rest of theproject By following a provenmethodology proposed by Siveco, theimplementation and training programswere completed in just 4 months,including analysing and automating allthe working procedures, collating andinputting data and customising theCoswin screens to suit the needs ofdifferent users.”

Today Coswin manages almost 50 000 pieces of equipment includingoptical fibre, pylons, emergencytelephones, dynamic and toll equipment,and Sanef are creating more than 800Work orders and 450 Job Requestsmonthly. The implementation involvedthe training of more than 400 web basedJob Requestors and 150 Coswin users.

The benefits of Coswin The KPIs for the maintenance team arenow monitored using Coswin; theseinclude the “maintenance cost per type ofequipment”, and the “downtime peroptical fibre network”. Much of this

Driving France's motorwaysinformation is used at a board level toprovide the facts needed to decide on theright corporate strategy.

Sanef intend to use more functions ofCoswin to provide further businessimprovements - for example Sanef haverecently implemented Coswin’s repairmanagement module. This will allowengineers to track the movements andcosts associated with assets under repair,ultimately resulting in faster repair times,less replacement stock and lower costs.

“Coswin has improved the efficiencyof our engineering team, and provided allthe facts we need when we make adecision on whether it is better to repairor to replace a piece of equipment.Coswin has become the backbone for ourbusiness, and helps to share bestpractices within Sanef”.

Coswin 7i : the first web application at Sanef Sanef has already upgraded to Coswin 7i.“This is the first Web application goinglive”, Mr Robert, CIO. The native webarchitecture (JAVA/HTML) will reduce theoperational cost of the system, whilstmaking the power of Coswin available tomore personnel. Coswin 7i will also providefurther significant security and usabilityimprovements for the business.

� www.siveco.com


The Challenge Sanef is one of Europe’s leadingconstruction and maintenance companies,specialised with highways and relatedinfrastructure. In France Sanef managesand maintains some 1700 Km of roadswith 60km of roads under construction. Toensure the highest levels of service SanefTelecommunications and Tolls Divisionoperates a Central TelecommunicationsStation to manage, monitor and maintainall of the highways electronic andtelecommunication equipment e.g.roadside messages signs, emergencytelephones and CCTV.

Objectives In 2001 the Telecommunications & Tollsdivisions initiated a project to standardisetheir maintenance activities, to improveservice levels and to reduce costs. “Wewanted to implement a software systemto help us achieve our maintenanceobjectives: to optimise the performance ofthe technicians and maximise ourprofitability. The first stage was to manageall the planned maintenance activitieselectronically and to ask our engineers todirectly feedback work information. At thesame time we wanted to implement anelectronic Job Request system to track therequests for reactive activities and ourresponses.” Patrick Cremmer, Head ofNetworks Management,Telecommunications Division.

CMMS �


The products being launched at the UK’s leading maintenance and assetmanagement show on 2-4 March 2010 aredesigned to improve plant performance,reduce costs and deliver energy savings.

PCB Piezotronics is releasing severalnew products including Echo™ WirelessVibration Sensors. These can “interrogate”a machine several times per day andtransmit the data to an existing vibrationor plant monitoring system withoutvaluable manpower being tied up in the process.

PCB is also unveiling a range of USBProgrammable Vibration Sensors. The newrange of Smart Vibration Sensors fromPCB® allow the end user to adjust multiplemeasurement parameters in situ tooptimise the sensor to get the most out ofan application.

There are two launches from C-Cubed.The developer of PocketVibrA, the lowcost, easy to use vibration analysis systemfor maintenance engineers will launchversion 10 at MAINTEC 2010. PocketVibrAis a unique tool that combines machinecondition analysis, balancing,thermography and process parametertrending in a handheld, rugged (IP67) unit.C-Cubed will also be using the show for itsglobal launch of a vibration analyserspecifically designed for the monitoring ofmachine lubrication.

Whitelegg, the sole UK distributorsand sales support for Baker, is launchingBaker’s new on-line Motor AnalysisSystem, NetEP. This will be the UK debutfor the fully automated, network-basedsystem for electric motor monitoring. Thesystem works on a continuous basis andcan test 40+ parameters on up to 32motors continuously, giving live evaluationof critical equipment from any location inthe world.

On display for the first time will be thelatest Fluke Ti32 Thermal Imager and theTiR32 Thermal Imager, the first industrialgrade, high-performance imagers on themarket to incorporate a powerful 320x240sensor to provide high-definition, strikinglycrisp, detailed images for under £7,200.Their superior image quality helps toidentify even the smallest temperaturedifferences that could indicate problems.

Idhammar Systems is exhibiting twonew products designed to improvecontinuous asset monitoring, provide realtime intelligence and business alerts. Byclearly and continuously indicatingavailability and performance against keymetrics, Idhammar Andon and IdhammarBusiness Alerts modules enablemanufacturing and maintenance managersto take greater control of daily plantmanagement. The Andon software deliversreal-time intelligence on the overallequipment effectiveness of a plant,allowing decision makers to proactivelytrack, monitor and respond to plantfailures and process issues.

MCP Consulting & Training islaunching a new, 2-day training courseentitled ‘Maintenance Explained’. MCP will teach how the fundamentals of good maintenance management in amanufacturing or service environment can lead to cost savings and efficiency improvement.

easyFairs® UK Managing Director MattBenyon, said: “This is just a taster of whatwere expecting at the Show. The fact thatwe have been given advanced warning ofso many launches this early on illustratestwo things – firstly the vibrancy in thesector and secondly the importance ofeasyFairsMAINTEC as a global launch padfor products and services aimed at factoryand plant managers.

“While the show has an impressive 35 year history, our accent is firmly on the new.With capital spend being kept to aminimum; managers are trying to squeezethat last bit of value out of their currentplant. To do this they need new products,new services, and new thinking. These earlyannouncements highlight that easyFairs®

MAINTEC will be serving up plenty of all three.”To underscore the central role MAINTEC

is playing in the sector’s calendar TheBritish Compressed Air Society (BCAS)has confirmed that it is hosting its 80thanniversary Spring Conference at MAINTEC.This will be the first time it has co-locatedits March conference at any show.

There will be a ‘leak detectionchallenge’ staged on its standdemonstrating a mix of detection solutions.BCAS experts will provide an on the spotestimate of what leakages are likely to becurrently costing visitors. There will also beCompressed Air Advice Clinics for visitorswith any compressed air queries.

The Show will also play host to anInnovations Pavilion, the MAINTEC SummitConference - Chaired by Steve Morris,Deputy President of the Institute of AssetManagement - plus a packed programmeof over 30 expert-delivered learnShops.

Companies interested in exhibiting atthe Show or appearing in the InnovationsPavilion should contact Rabinder Aulakh on T:0208 622 4463 or [email protected]

Register to attend for free by going towww.easyfairs.com/maintecuk. To book aplace at the MAINTEC Summit Conference,and to take advantage of ‘early bird’ delegateprices, call Lucy Daley on 0208 622 4468 oremail [email protected]

� www.easyfairs.com/maintecuk


Organisers of easyFairs MAINTEC 2010 at the NEC in March have

announced that over 10 new products are making their UK

or global debuts at the show and that many more will follow

GLOBAL PRODUCT LAUNCHESat easyFairs® MAINTEC 2010

MAINTEC 2010 2-4 MARCH 2010 NEC BIRMINGHAM �


INTRINSICALLY SAFE SENSORS �

SEALED CIRCULAR CONNECTORS �


Monitran’s Group I intrinsically safe sensors

are awarded ANZEx for use in mining

applications in Australia and New Zealand

Certified for use DOWN UNDER

and New Zealand, andcompanies based elsewherewishing to supply machineryinto these countries.”

Eight products have beencertified to ANZEx. Of these, four are from the MTN/1100family of general purposeaccelerometers with isolated AC outputs, which are ideal forvibration analysis. Includedwithin the family, and certified toANZEx, are the MTN/M1100I andMTN/M1100IC which are top-entry devices with integral cablesand connectors respectively. Both have a temperature rangeof -55 to 140°C and are sealed to IP67. Also included are the side-entry equivalent devices,

the MTN/M1100IS andMTN/M1100ISC.

Two ANZEx-certified sensorscome from Monitran’s MTN/1185family of general purposeaccelerometers with DC outputs,which are ideal for machineprotection. These are theMTN/M1185IC and its waterproofvariant, the MTN/M1185IWC,which are both top-entry deviceswith integral cables and whichhave an operating temperaturerange of -25 to 90°C.

The remaining two sensorscome from Monitran’sMTN/1187 family. Again, thesensors have DC outputs but thistime proportional to RMSacceleration. The ANZEx-certified

devices are the MTN/M1187ICand its waterproof variant theMTN/M1187IWC.

Anthony concludes: “OurANZEx-approved sensors can beused for vibration analysis withintrinsically safe data loggers orintegrated directly in machinecontrol circuitry (such as PLCs) toafford machine protection – andtherefore mine safety.”

� Monitran Ltd

Monitor House, Hazelmere

Road Penn, Bucks HP10 8AD

� T: +44 (0) 1494 816569

� F: +44 (0) 1494 812256


� www.monitran.com


All of Monitran’s Group Iintrinsically safe accelerometersand velocity transducers havebeen approved by certificationbody Simtars to ANZEx for use inmining applications throughoutAustralia and New Zealand. Thiscertification is in addition to the(EU) ATEX and (International)IECEx approvals Monitran’s GroupI sensors already possess.

Andy Anthony, Monitran’sOperations Director, comments:“Many countries, whilstacknowledging internationalstandards like IECEx, still imposetheir own standards for certainapplications. We sought ANZExin response to requests fromend-users based in Australia

aluminum, and titanium. SRIHermetics also utilizes copperalloy pins for maximumcurrent carrying capabilities.

SRI Hermetics can create afully custom connector andmate or manufacture

connectors that will interfacewith standard matescommercially available.

Our hermetic 38999 circularconnectors are fully compliantwith the interface requirementsof MIL-DTL-38999.

� Fred Williams, Sales Manager

� T: 321.254.4067



Our exclusive ceramic dielectricmaterial provides unequaledperformance and reliability. SRIHermetics can offer hermeticcircular connectors in variety ofmaterials including, but notlimited to, stainless steel,

SRI Hermetics, Inc uses advanced engineering and material science to create the

world’s leading hermetic electrical connectors

I can understand how views could differ

over how each element should be

applied; for example what is the

difference between a breakdown and a

minor stop? However, sometimes the

calculation itself is questioned. So here

are some guidelines based on content

from experts and organisations which

include the Japanese Institute of Plant

Maintenance (JIPM), Robert C Hansen,

Dennis McCarthy, Dr Nick Rich, Peter

Willmott and of course Seiichi Nakajima

who is credited with using the OEE metric

at Nippon Denso in the late 1960’s.

Let’s start with the basic calculation:

I have had a number of interesting conversations recently with both lean consultants

and manufactures over the way OEE should be measured and applied. Although it’s

a simple calculation it’s often misunderstood and sometimes the differences have quite

an impact on the integrity of the measure

OVERALL EQUIPMENTEFFECTIVENESS– Myths and Realities

OEE �


The critical factor to remember is that

availability losses are measured as time,

whilst performance and quality are both

measured in units. The equipment may

have been slowed down for two hours,

between 10:00 and 12:00, but the

performance loss that results is measured

in units.

The next step introduces the six major

losses of OEE. As a general rule,

breakdowns, set-up, and adjustment fall

within the availability measure, with minor

stops and slow running being part of the

performance loss. Defects, rework, and

start-up losses are part of the quality

measure. Rework can be seen as a

performance loss (the products take longer

to make than usual), but if they are not

right first time (RFT) then they really ought

to be considered a quality loss.

OEE �

Extensive discussion usually takes

place around how to establish the target

speed on which the performance rate is

based. Should it be as defined by the

equipment manufacturer, or should it be

weighted? The basic rule is that the

performance element is always product

and plant specific. It’s a moving target,

so make it more demanding as the plant

performance improves. If all else fails it

can always be set at the best

performance the plant has ever

achieved, but that target may not be as

demanding as it should be. The important

point is to make sure the target is not too

soft as it will only encourage the belief

that the plant is performing better than it

actually is. If the performance rate ever

exceeds 100% then obviously the target

is too low and you are missing the point

of OEE measurement.

This calculation reveals that all we have to do is investigate and fix the one hour breakdown, try and improve thechangeover, see why we had slow running which ‘lost’ 600 products, and resolve the quality issue which rejected 100 units.

Here’s an example

Planned run time 20 hours

Breakdown 1 hour

Changeover 1 hour

Actual run time (20 hrs – 2 hrs) 18 hours

Target rate per hour 200 units

Target products (in 18 hours) 3,600 units

Actual products made 3,000 units

Right First Time Products 2,900 units

� Myth 01 –I plan my changeover for 15:00

so it should be a planned event.

Whilst the changeover is planned to occur

at a set time, it’s still an opportunity for

improvement; for many companies the

biggest opportunity. Let’s say the average

lost time due to changeovers is 1 hour per

day. Now imagine a competitor starts up

next door with equipment that will

automatically changeover at the push of a

button. The competitor can produce for an

extra 7 hours each week. Changeovers

should always be unplanned events.

� Myth 02 –OEE does not work for my industry.

OEE can be applied to most

industries, and no doubt works really well

for your competitor.

� Myth 03 –We have a different,

in-house measure.

One GM told me that their internally

developed measure did ignore some of

the losses but also triggered his bonus, as

long as it remained over 85%. Surprisingly

it always did - so why would he want to

measure OEE?

� Myth 04 –‘No materials’ should be considered

a performance loss.

If we go back in time and separate

production and engineering, rather than

having cross-functional ‘manufacturing

teams’ - we get into arguments. Speaking

as an engineer, the plant is technically

available for production, but Operations has

let the side down by not having the correct

materials available. Measuring engineering

KPI’s is always possible by deselecting

those losses outside the control of

engineering. However, in terms of ‘lost

plant time’, the production process is not

available because there are no materials.

� Myth 05 –Breakdowns and minor stops are

the same.

A breakdown usually requires a careful study

of circumstances and involvement from

several disciplines to identify the root cause

and plan resolution. For instance, a gearbox

failed because we ran out of oil. Minor stops

are usually those annoying conveyor jams

which occur 100 times a shift and lose a

total of 20 minutes. They still need to be

studied and a correction plan identified,

but the techniques are different.


How can a measure that appears so simple have so many myths?

OEE �

� Myth 06 –I have a softer ‘planning

department’ target speed.

That’s fine as it’s a target speed used by

planning to let the customer know when

to expect delivery. But it’s not OEE and

won’t help to discover that hidden factory

– and all the potential savings.

� Myth 07 –I have lots of planned events.

Be cautious, planned events will be

excluded from the OEE calculation, so

keep them to an absolute minimum - zero

is a good start. Any activity classed as

‘planned’ is unlikely to change as there is

no pressure to do so. The only planned

events to consider should be ‘Plant not

crewed for production’ or ‘no sales.’

� Myth 08 –World class is 85%

This is correct for a machining centre, but if

you’re running something like a flour mill

or indeed, most continuous processes,

world class performance is above 90% OEE.

� Myth 09 –We do not need any more output,

so why raise the OEE?

If you have a low OEE value you’re

wasting energy, labour and materials.

� Myth 10 –OEE is a management tool used to

benchmark and compare.

It’s mainly a problem solving tool and it’s

not appropriate to compare the scores of

different operations, but it can be used to

benchmark the improvement trend over

time for different operations.

� Myth 11 –OEE data should always be

captured manually.

It’s always a good start, and gets

everyone into the improvement mindset.

However, as you improve there comes a

point when most, if not all, of the

availability issues and the big

breakdowns have been resolved. What’s

left are minor stops and slow running

which are very difficult to capture

manually, but still have a big impact on

performance. At that stage it’s good to

consider some level of automatic data

capture, at least a product count and a

running/not running signal.

� Myth 12 –With automatic data capture I don’t

need the operators involved.

The operator is a critical element in the

continuous improvement process. If they

are ignored it will be difficult, if not

impossible, to make real improvements.

� Myth 13 –We measure OEE, but ignore the

quality element.

Really, why? The quality element has a

significant impact on the OEE score and if

you don’t measure quality losses how do

you know they are not considerably worse

than you think?

� Myth 14 –We have an Excel wizard on-site

and our spreadsheet system is fit

for purpose.

Spreadsheets are a very good start, but

the single user nature of Excel and the

large amount of data soon means that

people spend more time manipulating

data than working on making

improvements. It’s proven that you’ll save

time and money with a powerful

database based solution and you can use

that time to make production

improvements. Oh, and I hope your Excel

wizard doesn’t leave!

� Myth 15 –Productivity is a more relevant

measure in our environment.

Productivity is a good measure. If you

flood the place with extra crew and

complete a changeover in double quick

time it’s possible to generate a high OEE,

but the employee costs will be pretty

high. As such, on its own productivity

cannot discover those hidden losses, a

better approach is to include a crew size

for each product run and then calculate

output per employee or OLE (Overall

Labour Effectiveness), based on the

number of people and OEE score.

� Myth 16 –Utilisation is a better measure than OEE.

It’s quite a different measure. Plant

employees do not have much influence on

the sales force. If the plant is designed for

24/7 operation but sales can only find

orders for 24/5, then asset utilisation will

be low, even if plant performance when

running is good and generating a high OEE.

If utilisation is 20% and OEE 70% blame

the sales force, not the plant operators.

� Myth 17 –Performance is really bad and we have

to improve before we can measure OEE.

How will you know what to improve if you

don’t measure production performance?

Use OEE as the catalyst for change. If the

first OEE value is very low, say less than

10%, it’s actually good news as there are

lots of improvement opportunities easily

available, and look how people will feel if

you move the value to 20% within a few

weeks – not to mention how much money

you will have saved.

� Myth 18 –A high OEE score is just that, but

where is the cash value?

The cash value is in reduced energy,

materials and labour. If the order is 60,000

units and the target is 1,000 units per

hour (OEE score of 40%) - this means an

extra 34 hours are required to meet the

order. If the score can be improved to

60% the extra hours required drops to just

15. Improve performance, shut down the

plant 19 hours earlier and save money.

� Myth 19 –We’re not ready to measure OEE

or improve?

Well if not now, then when?

I leave you with a final wise comment

from Peter Willmott - ‘adopt OEE, but

don’t corrupt it.’

ABOUT THE AUTHORAlan France is Operations Director of IdhammarSystems Limited. Contact him by e-mail:[email protected], or visitwww.idhammarsystems.com for more on OEE software.

� www.idhammarsystems.com




BUYERS GUIDE �

Company Website Email Contact Telephone Number

ACCESS EQUIPMENT

Planet Platforms www.planetplatforms.co.uk [email protected] 0800 0854161

ASSET MANAGEMENT

Rockwell Automation www.rockwellautomation.co.uk [email protected] 0870 2425004

ATEX EQUIPMENT AND SERVICES

Tech Recovery www.techrecovery.com [email protected] 001 877 837 8872

BOILERS

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

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

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

BOILER HIRE

Kings Boiler Hire www.kingsboilerhire.com [email protected] 01992 451629

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

BOLT SECURING SYSTEMS

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

CMMS

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

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

Logimatic www.logimatic.com [email protected] +45 96 34 70 00

PMI Software www.pmisoftware.co.uk [email protected] 353 (0)1404 0000

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

Shire Systems www.shiresystems.co.uk [email protected] +44(0) 23 80224111

Simplisys Ltd www.simplisys.co.uk [email protected] 0870 626 0766

Siveco UK www.siveco.com [email protected] +44 (0)1256 84 38 33

Softsols Group Ltd www.getagility.com [email protected] +44(0)1924 200344

SolutionsPT www.assetpt.co.uk [email protected] +44 (0)161 495 4600

Spidex Software Limited www.spidex.co.uk [email protected] 0121 779 0888

SRO Solutions www.srosolutions.net [email protected] +44 (0)845 408 4250

FOR FURTHER COMPANY INFORMATION PLEASE VISIT www.engineeringmaintenance.info

TO ADVERTISE YOUR LISTING IN OUR BUYER’S GUIDE PLEASE PHONE +44 (0)1634 731646


BUYERS GUIDE


COMPRESSED AIR

Airchannel Ltd www.airchannel.co.uk [email protected] 0800 526581

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

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

COMPRESSED HIRE

Speedy Compressors www.speedyhire.co.uk/compressors [email protected] 0845 307 0777

CONDITION MONITORING

Alpine Components www.alpine-components.co.uk mike@alpine-components .co.uk 01424 437000

Artesis www.artesis.com [email protected] 0845 634 3854

Diagnostic Solutions www.diagsol.co.uk [email protected] +44 (0)1244 571411

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

Holroyd Instruments www.machinemonitoring.co.uk [email protected] +44 (0)1869 250 801

Machine Monitoring Systems Ltd www.holroyd-instruments.com [email protected] 01629 822060

Monitran Ltd www.monitran.co.uk [email protected] +44 (0)1909 722000

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

Pruftechnik Ltd www.pruftechnik.com [email protected] +44 (0)1543 448350

Richard Chambers www.chambers-company.com [email protected] +49 089 90356 38

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

SPM Instrument UK ltd www.spminstrument.co.uk [email protected] 01706 835331

CONDITION MONITORING EQUIPMENT/SERVICES


DATA ACQUISITION

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

HEALTH & SAFETY

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

HEALTH & SAFETY PRODUCTS


HOSE AND COUPLINGS

Dixon Europe www.dixoneurope.co.uk [email protected] +44 (0)1772 323529

HYDRAULICS AND DRIVES

WFE Hydraulics www.wfehydraulics.co.uk [email protected] +44 (0) 114 2430936



BUYERS GUIDE



INDUSTRIAL COOLING

TPC(Total Process CoolingLtd) www.totalprocesscooling.co.uk [email protected] +44(0)121 711 4014

INDUSTRIAL DOOR SERVICES

BID Group www.bidgroup.co.uk [email protected] 0870 607 5050

INDUSTRIAL HEATING

Ambirad www.ambirad.com [email protected] +44 (0)1384 489700

INDUSTRIAL FLOORING

CG Flooring Systems Ltd www.cg-flooring.com [email protected] 01484 600085

Dura Composites www.duracomposites.com [email protected] +44 (0)1255 423601

INSTRUMENT HIRE

Bisra www.biz.fm [email protected] +44 (0)1344 459314

LUBRICATION

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

PLANNED MAINTENANCE

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

RELIABILITY-CENTRED MAINTENANCE (RCM) SPECIALISTS

Mutual Consultants Ltd www.mutualconsultants.co.uk [email protected] +44 (0)1788 555000

RELIABILITY ENGINEERING SOFTWARE

Isograph Ltd www.isograph.com [email protected] +44 1925 43 7001

THERMOGRAPHY

Express Instrument Hire www.expresshire.net [email protected] 01772 815600

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

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

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

Testo Ltd www.testo.co.uk/testo880 – 01420 544 433

THERMOGRAPHY TRAINING

The Institute of Infrared Thermography www.infraredinstitute.co.uk [email protected] +44 (0)151 424 4060

TRAINING

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

VIBRATION ANALYSIS

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



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PLANT MANAGEMENT

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� Condition Monitoring Consult

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TRAINING

� Institutes and Professional Bodies

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BUILDING MAINTENANCE

� Access Equipment

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ENVIRONMENTAL

� Dust/Fume Extraction

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Health/Testing/Equipment

� Noise Control

� Pollution Control Equipment

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HEALTH & SAFETY

� Communication

� Health & Safety Products

� Legislation & Compliance

� Machine Guards

� Safety Showers & Eye Baths

� Workwear

ENERGY MANAGEMENT

� Boilers

� Burners

� Climate Change Levy

� Combined Heat & Power

� Compressed Air Equipment and Ancillaries

� Energy

� Energy Control Systems

� Energy Metering/Monitoring Systems

� Generators

� Heating, Ventilating and Air Conditioning

� Industrial Controls

� Power Quality

� Steam Traps

EMS November/December 2009

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About usEurope’s Leader in EAM/CMMSEstablished in 198682,000 + users in 65 Countries & 16 LanguagesRepresented by Subsidiaries and Partners around the worldCoswin operates in 30 + industries

Contact (SAM or BARRY)

Siveco UK Ltd

www.siveco.com

View Point, Basing View,

Basingstoke

Hampshire RG21 4RG

E-Mail: [email protected]

Phone: +44 (0) 1256 843 833 (Tony/Sales)

Fax: +44 (0) 1256 843 767

Coswin 7i EAM/CMMS Suite

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Scalable from Single to Enterprise Use

Supports Managed & Shared ServicesSupported on Oracle & MS SQL Server databasesUses standard industry tools such as Crystal and

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Documents

ems november/december 2009