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Total System Health Management And What It Means To The Maintenance Engineer Pages 26-27


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P:56-58 Pumps & Valves Feature

P:59-62 Buyers Guide

Boilers & Burners Condition Monitoring Industrial Cooling Drivers & Control

Materials Handling Building Maintenance Maintec Review

Latest Industrial News

Caerphilly Company Wins Prestigious National Pressure Relief Services From Lloyds Register Manufacturing Award
Nuaire Ltd is National Winner of the Environmental Efficiency Award at EEF Future Manufacturing Awards 2012
Caerphilly-based Nuaire Ltd has been unveiled as the national winner of the Environmental Efficiency Award at the EEF Future Manufacturing Awards 2012 for demonstrating a clear journey to improve Environmental Efficiency and reducing their energy bills by an impressive 92%. Nuaire, which designs and manufactures energy efficient domestic, commercial and renewable ventilations systems, won the award, sponsored by ENER-G, for its successful campaign to reduce waste to landfill and recycle tonnes of metals, wood, cardboard, plastic and paper. It also invested 2m, with funding from the Welsh government, to upgrade its plant machinery to ensure higher efficiency and reduce carbon emissions. Alun Jones, Nuaire Director of Manufacturing said: This award is very important to us. In order to sell our energy saving range of ventilation equipment, we need to show our commitment in our own actions. Running an energy efficient plant to produce energy saving equipment is the sustainable solution our customers are looking for. Visit

Lloyds Register works with upstream, downstream and speciality chemical companies to cost effectively solve their relief system challenges.
With our combined experience in relief systems as well as mechanical design, we go beyond basic calculations to identify and mitigate operating risks and ensure safety of your people and processes. Pressure relief systems provide the last line of defence against equipment overpressure and loss of containment. Lloyds Register pressure relief experts identify all related pressure sources and focus on ensuring adequate overpressure protection for systems of piping, vessels and equipment.

Palintest Partners Up with Durham Wildlife Trust for Environmental Monitoring Project
Palintest Ltd, the leader in water analysis, is delighted to support the Durham Wildlife Trusts Living Waterways Project with its portable water chemistry analysis equipment.
of urban water bodies across the North East. This is The project is an Environment Agency initiative that aims to find sustainable solutions to the problems caused by urban diffuse pollution in our local rivers. Living Waterways Project Officer, Michael Rogers, A major part of the project requires the analysis of water chemistry at a number of project sites. To facilitate this, Palintest Ltd has loaned a Macro 900 WQS to the Wildlife Trust, enabling project staff to carry out easy, accurate and reliable testing of key parameters such as Dissolved Oxygen and pH level. The study aims to help improve the ecological status states that the data gathered in the field is invaluable, as it provides a base from which all our work will be monitored in the future, to see and show the real difference we are making! The company has also supplied a set of additional visual test kits for the project. done through wildlife habitat creation coupled with efforts to raise community awareness and interest in local streams and waterways. Reliable, accurate and easy-to-use on-site testing is crucial to the education process and on-going environmental upkeep.

Tel: +44 (0)191 491 0808 Fax: +44 (0)191 482 5372 E-mail: Website:

EMS Magazine | February 2013

Latest Industrial News

Fixed Appliance Testing With The New Apollo 600 Sherborne Sensors Announces Record Sales for 2012
Seawards latest multi-purpose portable appliance tester is specially equipped to carry out the point to point testing of fixed appliances, as recommended by the 4th edition of the IET Code of Practice.
Specially designed for risk-based portable appliance testing, the new Apollo 600 is also equipped to carry out the earth continuity and insulation tests required on fixed appliances. The new Code of Practice recognises that the inspection and testing of appliances such as hot air hand dryers and water boilers can be more complex than portable and non-fixed equipment but this does not mean that only visual inspections are required. A full combined inspection and test is required at relevant intervals, performed by a person competent to carry out this more complex arrangement of work, also involving safe isolation procedures. The ability of the Apollo 600 to undertake these tests means that the inspection and test results can be stored and used for complete traceability and assessment of risk to determine re-test periods. As well as fixed appliances, the Apollo 600 incorporates a comprehensive suite of fast and accurate electrical safety tests to enable all workplace appliances to be tested, including 3 phase equipment and RCDs. Special features include a built-in digital camera enabling visual evidence to be taken during inspections, and an integral universal risk assessment tool allowing hazards to be recorded, risk scores to be calculated and re-test intervals to be determined. For broader health and safety management applications, the new instrument also hosts a range of onboard reports for fire detection and emergency lighting. For full details of the new tester visit Seaward Group | | Tel. (0191) 587 8744

London, UK, 1st February, 2013 - Sherborne Sensors, a global leader in the design, development and manufacture of sensors for military, aerospace and industrial applications, has enjoyed its most successful year to date, achieving a record year globally in terms of booked sales orders and turnover.
Growth was in part driven by the launch of Sherborne Sensors new website, which showcases the breadth and depth of the companys product range and experience across a number of industry sectors including transport, mining, space and civil engineering. The successful launch of the T333 Tri-Axial Linear Servo Inclinometer also had a significant impact on sales over the course of the year, and demand for this product continues to prove extremely strong. Despite the challenging economic climate, 2012 was another record year for Sherborne Sensors and we have been delighted with our growth, which is testament to our commitment to providing unrivalled high-precision sensors and customer service, says Robin Butler, Sales and Marketing Director, Sherborne Sensors. We look forward to supporting all of our customers during 2013 and will continue to look for every opportunity to improve our industry-leading products and services.

User Satisfaction With BOP Handling Equipment In Offshore Environment

Four J D Neuhaus EH 60 air operated monorail hoists supplied for offshore BOP handling have completed 12 months satisfactory operation to customer requirements and have also successfully passed their first annual inspection.
These hoists were supplied and initially mounted in Norway by Westcon Lfteteknikk AS (WCL) at the Westcon yard, and were designated for eventual location on the Seadrill West Epsilon rig, which is classified as DnV, + 1A1 self-elevating mobile offshore unit. The hoists, each providing a 60 tonne lift capacity, were required for the synchronised handling during both pre and post drilling operations of a new 120 tonne BOP unit supplied to the rig. Each hoist was fitted with load eyes instead of hooks, and provided a total lift height of 17.4 metres with four chain falls. Built-in safety features for the JDN products include an emergency air supply shut-off valve in each pendant controller, together with fail-safe brakes They also provide a 0.5 metre/min lifting speed under full load, with a designed trolley speed of 12 metre/min for horizontal travel movements. Each hoist was also equipped with a pendant controller to accommodate synchronised operation of the lift, lower and travel movements for all hoists. The hoists were required to be suitable for use in an Ex area with ATEX zone 1 with gasses IIB, together with full offshore execution for weather protection etc.
Further information is available on request to: J D Neuhaus GmbH & Co. KG, 58449, WittenHeven, Germany Telephone: +49 2302 208-219 Fax: +49 2302 208-286 e-mail:

to hold a load safely if the air supply is interrupted. Both anti-climb and anti-drop devices are also incorporated. The latest JDN emergency lowering device was also specified for the individual hoists.

EMS Magazine | February 2013

Latest Industrial News

Alphatemp Technology Are Exclusive Distributors To The Enviromon Product Range Developed By Pico Technology.
It is an extremely versatile, expandable data logging and alarm system, ideal for real-time monitoring of a wide range of parameters such as temperature, humidity , energy use and can also be used with third party sensors. It can take measurements over large areas such as warehouses, greenhouses, cold rooms and factories. EnviroMon is made up of a number of different modules including sensors, converters, alarms and a logger. You can network up to 15 mixed converters to a logger, and add alarm options if required.

MSR165: data logger records shock for up to six months

Swiss Technology Company MSR Electronics GmbH launched its MSR165 data logger, complete with a builtin three-axis digital accelerometer.
The MSR165 is capable of making 1600 shock and vibration measurements/s in all three axes for up to 6 months. It can also measure temperature, humidity, pressure, light and record 4 analogue input signals. Boasting a memory capacity of over 2 million measurement parameters, the MSR165 monitors shock up to 15 g, 32 measurement values are recorded even before the event takes place. Using a microSD card, the memory capacity can also be significantly increased which is

Amr Ziko - Technical Sales Manager Alphatemp Technology Ltd, Network House, 300-302 Cressing Road Braintree, Essex, CM7 3PG Tel: +44 (0) 1376 344679 Fax: +44 (0) 1376 348976 Mob: +44 (0) 07585 228134 Web:

particularly useful for recording vibration measurements.

North American Distributer European Manufacturer

INTERWORLD ELECTRONICS INC. T: 1-425-223-4311 F: 1-877-FAX-IECI(329-4324) E: W:

MSR Electronics GmbH T: +41 52 316 25 55 F: +41 52 316 35 21 E: W:

Health And Safety Instant Adhesives

With successive introductions to its Loctite Health and Safety range, Henkel has broken new ground. It has become the only manufacturer to offer a comprehensive range of non-hazardous engineering adhesives that cover the lions share of applications.
Now there is even more choice however as this unique range is complemented by three hazardlabel-free cyanoacrylates, more commonly known as instant adhesives. Clean and easy to apply, these adhesives are ideal where aesthetics are important. They are now the Loctite front-line offering for very fast positioning and fixturing of parts. Classified non-irritant, these new additions provide even more benefits than their hazard-labelled forerunners. Their ability to join a wide variety of dissimilar materials extends to the bonding of porous/acidic substrates such as wood, paper, leather and cork as well as plastics, rubber and metals. The resultant shear and tensile bond strength is excellent even on very small bond faces. These new Health and Safety instant adhesives are colourless with low bloom and low odour. All have a typical fixture time of 5 20 seconds dependant on the substrates. All can be integrated into semi- or fully-automated As with all Loctite instant adhesives, these three new Health and Safety products are respectively optimised for specific application requirements. The most viscous is Loctite 403, making it ideal for use where parts are not close fitting or where the product must not run or migrate. Loctite 408 has very low viscosity and comes into its own where capillary action is required. It can therefore be applied to a joint with an interference fit to create an instant seal. Loctite 460 has a marginally higher viscosity. Web link for enquiries: For applications where special application characteristics are required, Henkel can call on its wider range of instant adhesives. As well as products for difficult to bond rubbers and plastics such as PE, PP, PTFE and silicone, the choices include a new product for gap filling and a new series for high temperature applications. production processes for which Henkel also markets a comprehensive range of dispensing equipment.

EMS Magazine | February 2013

Smarten Up Your Boiler Water

ELGA Process Waters new tool provides free assessment for boiler users
If you operate a steam boiler, are you aware of how much money your blowdown is costing you? ELGA Process Water, a Veolia Water Solutions & Technologies company, is pleased to announce the launch of rEcoSMART, a customised solution to optimise your boiler and help you answer that question. Blowdown consists of water, conditioning chemicals and heat energy, all of which you have paid for. But by improving the feedwater quality through softening, dealkalisation, reverse osmosis or deionisation you can reduce blowdown, improve boiler efficiency and save money. ELGA Process Waters experts will work with you using the new rEcoSMART Assessment Tool to calculate exact cost savings and ROI of installing a pre-treatment solution. This in depth assessment is free and you will receive a personalised report to help support your decision making. Visit to register for your no obligation assessment. In addition, we have also developed a free online rEcoSMART calculator. Simply enter basic operational running data for an instant calculation of potential cost savings. Companies are looking to save money, so we created this tool because we believe its important for customers to understand the true cost of blowdown and what solutions are available to minimise this impact. says Jeremy Wakeham, Industrial Sales Manager. Both the online calculator and personalised assessment tools will help educate customers and enable them to make cost saving decisions and improve efficiencies within their business.

For more information on rEcoSMART visit

EMS Magazine | February 2013

EMS Magazine | February 2013

Latest Industrial News

Filter Elements Tested To Ensure Air Quality

As a key supplier of compressed-air filter elements to the UK market, Hi-line Industries Ltd undertake full test and air quality analysis of the filter media that they supply.
Now, however, this valuable service is also available to cover the testing of any filtration media products, including competitors equipment. The choice of the correct filter element has a direct effect on operational costs, and experience shows that the air quality can help minimise or even eliminate unnecessary costs. Following investments in state-of-the-art testing equipment including particle counters, flow meters, mass flow controllers and dewpoint meters, Hi-line provide a test facility to measure the efficiency of filter elements. Tests indicate compliance with ISO 8573-1:2010, being the international standard for During the compression cycle, any inherent air particulates (dust, pollen, water etc) are drawn into the compressor and entrained into the compressed air stream which typically can be at seven times normal atmospheric conditions. Added to this stream is the carbon, oil and metallic debris from the compression process, generating a potentially toxic and destructive cocktail within the compressed air stream. Even for general factory applications, such contaminated air supplies are not acceptable. Further information is available from: Hi-line Industries Ltd, 5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PG Telephone: 01283 533377 Fax: 01283 533367 e-mail: compressed air quality. This standard lays down minimum air quality standards and defines allowable content levels for dirt, water and oil. Where the compressed air supplies are for food contact, dental or breathing air requirements, then stricter quality regulations come into force for these applications.

EMS Magazine | February 2013

Maintenance Best Practice

The Essential Elements of Reliability and Maintenance Management.

absolute key to achieve better reliability and lower

Execute them and you will get guaranteed results. Part 2 By Christer Idhammar
Founder and Executive Vice President | IDCON INC | Raleigh NC | USA

costs. Lubricators must be trained to execute lubrication in a well documented process that describes lubricant, volume and frequency in an optimally laid out route and in work orders for shut down oil changes and lubrication that cannot be done safely when equipment is operating. Filtration of lubricants has to be done to adequate standards
What are The Basics? The most important and essential elements of the basics are listed above and include in more detail: 1. Maintenance prevention With maintenance prevention we include everything you do to prevent problems from occurring. We like to use the term Problems because the context of total manufacturing reliability includes the functions of Engineering, Maintenance, Operations and Storeroom (Spare Parts and Material for Equipment) support. If we use the term Failures instead of problems we often focus our thoughts on equipment and maintenance issues and we mentally exclude operational and other issues such as raw material variances and changes in how a production line is operated. Here we assume your plant is in an operational phase and not in a position to procure new equipment. Instead you have to do better with what you already have. be careful not to paint motors with too many layers of paint. Another benefit of this basic element is that electric motors will pull less energy the cleaner and cooler they are. 1.2 Lubrication and contamination control. Even though awareness in this area increases it is more common than not to find very poor practices. Precision lubrication, which includes the right clean lubricant in the right volume at the right time, is an

e.g. down to 4 microns for many oils and central lubrication systems. Modern tools should be used to measure that the right volume is reaching the lubricated object. To control contamination it is vital that lubricants are stored in a professional way.

Figure 4 shows a world-class storage and contamination control of lubricants.

1.1 Cleaning is an important basic element. Here we do not talk about general housekeeping but detailed cleaning of equipment and components. When detailed cleaning is done you cannot avoid but also doing visual inspections. When you clean you also inspect. When equipment is clean it is easier to see abnormal conditions such as loose fasteners and leaks. Another benefit is longer life of for example electric motors. It does not take much contamination on an electric motor to increase temperature in windings and rotor by 10 C or 18 F. a 10 C increase in temperature will shorten electric motor life by 50%. For the same reason you should Figure 4. What good looks like. Courtesy After review of all 43 lubricants used in this plant an expert narrowed it down to eight including hydraulic fluids. The lubricant storage has direct access from outside building. All eight lubricants are automatically circulated and filtered periodically to assure cleanliness of 4 micron or less. Each container has a decadent breather to keep all moisture out and filter incoming air to 1 micron. To have lubricant storage like this cost some money but it costs much more over time not to have it. And the reduction of number of lubricants from 43 to eight is an immediate saving.


EMS Magazine | February 2013

Maintenance Best Practice

1.3 Alignment is another important element of the basic elements that prevent problems from occurring. Alignment should be done when equipment is in operating temperature or with compensation for thermal growth. Jacking bolts should be installed to make precision alignment possible. (You cannot align to 0.001 of an inch or 0.0254 of a millimeter with a sledgehammer). More than three shims should not be used as more than that can cause a soft foot. Today most plants use laser alignment tools that make it easier to align and also keep track on alignments that have been done. Alignment with precision does not only prevent problems and extend life of the aligned component such as sprockets, chains, sheaves, belts and couplings. Precision alignments also prolong life and prevent problems in bearings and mechanical seals. Another benefit is reduced energy consumption for electric motor drives. A misaligned coupling increases temperature in both coupling and bearings significantly. A brief and fast check of alignment can be done using a handheld basic infrared thermometer. Increases in temperature of couplings, V-belts and chains indicate misalignment. Explain to the operators that a steam system must start up slowly. This is because you want to avoid water hammer and consequences from too rapid thermal expansion. In a cold steam system steam will condensate and steam traps must have time to trap the condensate and discharge condensate from the system. If too much condensate is built up in the system it can fill up a pipe to form a water plug which travels through the system with 85 90 miles per hour or 135 150 kilometer per hour. When this Many plants have redundant equipment for critical steps in production. For example duplicate lubrication pumps for central lubrication. It is necessary to operate these pumps equal amount of time. Mark redundant equipment A and B and then I have been told to not let cold water come in contact with the drier cans when they are hot. Why is that? Why should I not try to start up electric motors too frequently? Why do we need to run redundant equipment equal hours? Etc. Cold water on a dryer can or other hot object can cause deformation and/or cracks because of uneven shrinkage cause by thermal shrinkage. plug hits a pipe elbow it can damage the pipe. If the system provides rotating dryer cans with steam for heating, the steam inlet is through a bearing journal shaft. If system is heated too fast this journal heats up and expands faster than inner race of the bearing and this can lead to that the inner race of the bearing cracks.

I know it is important that people are trained not only in How but also in Why. We call the training we do in equipment care for operators and others Know Why training.

When an electric motor is frequently started the consequence is that windings might burn. This is because when starting up an electric motor, the Amperage (I) spikes by the square. Q = Heat, R = Resistance (Joules law Q = I2 X R).

1.4 Balancing of components such as an assembly of shaft and impeller for a pump, electric motors, rolls and other rotating equipment also prevents problems from occurring. Balancing of rotating equipment prolong life of components and prevent problems from occurring. Vibration measurement should be part of quality control for any rebuild of these components.

1.5 Operating practices is often a forgotten part of maintenance and problem prevention. It is common that over 50% of equipment failures and breakdowns are caused by poor operating practices. This is because operators are seldom trained in the function of the equipment they operate and what impact wrong startups and shutdowns have on components. Nor have operators been properly trained in how to inspect components. Let me emphasize this with some examples on questions I often get from operators: Why can I not heat up the steam system faster after a shutdown? Figure 5. This example is compiled three months after a process for basic inspections by operators and maintenance crafts was implemented. Vibration analysis and oil analysis had been in use during more than three years before this study. Operators and maintenance crafts was trained in basic inspection techniques and routes detailed routes were documented and executed with a compliance of over 90 %.

EMS Magazine | February 2013


Maintenance Best Practice

make sure operators shift to run only A equipment and then B equipment. This will prevent moisture build up in electric motors and bearings to be destroyed from brinelling caused by vibrations when bearing rolling elements are in same position for a long time. Packing material in glands will dry up and leak when pump is started after being idle for long time.

All of the above are examples of the basics of what we call Maintenance Prevention.

2. Early identification of work. This part of the basics is very critical and if not done well, it is one of the major reasons why many maintenance organizations are reactive and very inefficient. It includes: Disciplined and right priorities on requested work. Condition Monitoring. If your common goal is to improve manufacturing reliability and roles between partners are clearly 2.1 Disciplined and right priorities. One of the two top reasons as to why maintenance work is not planned before the work is scheduled and then executed is that priorities are too emotional and not based on objective judgment on what is most important for the business. I have reviewed many backlogs in maintenance organizations all over the world and often find that the majority of work in backlogs has been assigned highest priority; and many of the high priority work requests are over two years old! Two common reasons for this phenomenon are: The maintenance organization is viewed as a service provider to operations. The requesters of maintenance work do not trust work will be done unless they assign priority 1 to the work request. Do not make this too complicated. I have seen 19 pages long documents used as a guideline for assigning priorities on maintenance work and it is obvious that will not work. In my opinion there are only two priorities: Do the work now or at what date it has to be completed; Very simple but it works because people understand the logic. The overall criteria for setting priorities should include risk for: 1. 2. Environmental or personal injury. High reliability cost for Quality, Time or The following is an example of a basic inspection of a heat exchanger: In several studies we have found that most problems are detected through basic inspections. The example below demonstrates this. Figure 5. defined and adhered to you have laid out the foundation for success. As one of the first steps in creating this partnership you should together agree to criteria for deciding priorities of maintenance work. 2.2 Condition Monitoring I like to use the term condition monitoring because the term Predictive Maintenance excludes the very important part of basic inspections that includes See, Listen, Smell, And Touch. When I here use the term Condition Monitoring I include all tasks you do to discover problems early. E.g. Basic objective inspections. Basic Subjective inspections Vibration Analysis, Infrared measurements, Wear Particle Analysis, Ultrasonic material testing, Acoustic emission testing and other methods. Above: figure 6

Speed losses. If your maintenance organization is viewed as a service provider you want to provide good service and this often leads to that you obey to requests from operations. This view must change to a working relationship where the maintenance organization is viewed as an equal partner with operations. The role of maintenance is to deliver manufacturing Equipment Reliability and Operations deliver manufacturing Process Reliability. To get examples of priority guidelines please email Remember that the discussions you have between operations and maintenance to arrive to the agreed upon priority guideline is important because this is one step of many you do to build the operations maintenance reliability culture. 3. High cost for maintenance repairs.

Many Preventive Maintenance inspection programs might describe the inspection of a cooler for a hydraulic unit as Inspect Cooler without any further explanation. I have used this example in numerous plants and most mechanics and operators admit they have no clue what to look for more than the obvious such as leaks and looseness and perhaps temperature of the cooled outgoing media.

EMS Magazine | February 2013


Maintenance Best Practice

Some tools that can be used to enhance basic inspections include: High intensity flashlights will highly improve visual inspections. Inspection mirrors and fiber optics to enable inspections of areas difficult to see such as under coupling guards and inside components. Ultrasonic leak detectors are especially useful to detect vacuum leaks. Ultrasonic material testing can be used to discover thinning material in areas of high wear. Infrared thermometers are used to discover misaligned couplings, leaking valves and other components in hydraulic and media systems. Stroboscopes are used to visually stop moving parts to enable inspections while equipment is in operation. Above: Figure 7 Dye penetrant can be used to discover micro cracks in material. more heat, faster deterioration, and then the system function ceases. Tensiometer to check and set tension of V belts right. The sacrificing anode is made of a short bolt with an The function and components of the blue cooler, Figure 6, is described in the diagram, Figure 7. Most important is that the outgoing temperature of the cooled hydraulic fluid does not exceed maximum allowed temperature and system shall not start to operate before the hydraulic fluid has reached a minimum temperature. If a temperature gauge can be mounted on outgoing hydraulic fluid and marked with lower and upper temperature limits it is good. A handheld infrared thermometer can also be used. If the person doing the inspection is taught how the system works it is easy for him/her to understand that it is important to track the position of the control valve. If the control valve is fully, or almost fully open it is time to report this condition so planning and then scheduling of replacement or cleaning of cooler can be done before the system overheats. Explain that the consequence of operating the system above the maximum temperature will lead to a break down. This is because seals in cylinders and valves will deteriorate fast at high temperature. This will lead to internal leaks in system, which in turn will generate Inspections with the right method reveal latent problems at an early stage and this provides the necessary lead-time needed to plan and then schedule work before execution of corrective action to avoid breakdowns. The above are examples on basic inspections and Know Why training. When done this way, not only will problems be discovered early, the inspection is also meaningful and more interesting to do. The link Early Discovery of a Problem Prioritize urgency - Plan Corrective action Schedule Corrective Action Execute Corrective action is a vital foundation for any maintenance organization. It is often referred to as Condition Based Maintenance. (CBM). Inspections do not prevent anything at all unless the problems discovered during inspections are corrected before breakdowns occur. inside inch (12.7 mm) hole in which a rod made of zinc is inserted. The zinc rod will corrode before any other material in cooler corrodes, thus protecting corrosion of material in cooler. In this example it is designed in such a way that no one can see if it is gone or not. It shall instead be made in one piece of zinc, and then a small weeping hole is drilled about 1.5 inches (38.1 mm) into it. When the zinc rod is corroded to this point it will show as a small leak and replacement can be planned and then scheduled before any damage is done to the cooler. Most common technologies often referred to as Predictive Maintenance include: Vibration Analysis mostly used to analyze condition of bearings and unbalances in rotating equipment. Wear particle analysis including ferrography and spectrometric oil analysis. Acoustic emission used to discover early cracks in material. Infrared cameras used to visualize temperature patterns in equipment. Gauge to measure elongation of chains. Etc.

First you need to explain how the cooler, Figure 6 works. That can be done with a simple sketch as in the example in Figure 7.


EMS Magazine | February 2013

EMS Magazine | February 2013


Compressed Air Feature

Put Performance Into The Spotlight With BOGE Air

The new S-3 series screw compressor combines efficiency and silence: welcome to effilence.
Top quality has surpassed itself again, the new S series compressors from BOGE.
The S series has set standards in efficient and reliable compressed air production. Now BOGE has made one of the best screw compressor ranges on the market even better. While retaining the proven design philosophy and efficiency the smooth-running properties and sound pressure levels have been significantly optimised. machine in the S-3 series, BOGEs effilence increases free air delivery (FAD) and combines improved oil separation system creating the highest level of efficiency ever achieved by BOGE. As well as the innovative BOGE effilence air end, a new redesigned cooling fan makes the BOGEs S-3 series quieter than its predecessors. The fan speed has been halved resulting in reduced noise levels while the cooling air has been improved at the same time to provide a consistent cooling performance. The result speaks for itself: the quietest S series ever! A new level of efficiency: efficiency + silence = effilence. The new premium air end from BOGE, effilence is the most efficient air end ever used in a BOGE compressor. Its name stands for two of its hallmarks: efficient compression (efficiency) and incomparably quiet operation (silence). This wholly


Even more efficient and even quieter.

The new 3rd generation BOGE S series uses the most efficient air end ever developed by BOGE BOGE effilence. Included as standard in every

Proven control and design.

The compressor control in the standard version uses the proven intuitive FOCUS control which provides numerous monitoring and control features and allows for easy connection to master control systems. Irrespective of these modifications, the classic proven design features of the S series are still retained: providing the advantages of the efficient cooling air circulation, the effective optimised oil separation system with horizontal receiver and the premium quality making this one of the most reliable screw compressors now available on the market.

BOGE-developed air end, manufactured in-house, guarantees the highest standard, state-of-the-art technology.

Long life.
The BOGE effilence air end is designed for long operating life: this is an integral part of BOGEs quality promise. At the same time, the air end is very low maintenance. The advantage for you is that if you use BOGE effilence to compress air, you will definitely be on the safe side benefit from this new level of longevity.

Made by BOGE.
BOGE effilence is wholly designed and manufactured by BOGE. Temperaturecompensated processes which lead to particularly low manufacturing tolerances are used during production. BOGE effilence has attained new heights, setting a new benchmark in the development of efficient and quiet compressed air production. You can look forward to the best S series of all time! To find out more about effilence and other BOGE products visit or call 0800 318104


EMS Magazine | February 2013

Compressed Air Feature

Compressed Air Filter Replacement:

More Safety and Efficiency
The right timing is what matters
of expectations. The pressure losses through leakages are high and the compressed air pressure in the piping system is contaminated. When the compressed air filters at the points of use are heavily contaminated, the differential pressure rises faster. This problem significantly clarifies the complex interactions of the components in compressed air supply systems. Experienced engineers know that the condition of a compressed air system can be seen on the filters. They are the best indicators of compressed air quality without considering complex equipment. However, these monitoring functions can only be met by coalescence filters with a differential pressure indicator (Fig 3).

The potential savings are at several thousands of Euros

The Fraunhofer Institute for Systems Technology and Innovation Research (ISI) discovered the following in a study in the course of the German Compressed Air Campaign Druckluft effizient in 2003: In the field of compressed air treatment, it is primarily important to achieve the compressed air quality required for the application. It is best for energy and operating costs to meet the requirements of the applications. Exceeding or falling below the airquality requirements results in increased operating and energy costs. The current potential savings per component part are thereby up to several thousand Euros (Fig 4). Regularly changing the filter elements within the recommended intervals achieve significant savings and thereby minimize the operating costs. This statement has not lost any of its topicality against the backdrop of rising electricity prices. This means for the practice of compressed air filtration: Compressed air filter elements must be replaced to improve the energy balance: Below: Figure 2

It could all be so simple in compressed air filtration: The comparison of filter performance data is today possible with standard ISO 12500 and registering operating hours is as easy as reading the differential pressure indicator. However, the energy conditions of air filtration still receive very little attention in practice (Fig 1). The reasons are as varied as the complexity of compressed air conditioning: The compressed air filters are a part of the system and use only indirect energy based on the differential pressure, which is applied by the compressor. The dimensioning of a compressed air system, and therefore the capacity and number of filters used, is based on the required compressed air quantity and quality, the location of the compressed air purification system and the type and age of the compressors used. The contamination of the ambient intake air and the humidity, which varies depending on weather conditions, must also be considered, just as the impurities that are introduced by the compression process. Especially in existing compressed air systems, it is recommended to call in filtration experts to measure the contamination that may be caused by the compressors (Fig 2). The contamination by the lubricating oil alone amount up to 40 mg/m3 depending on the type of oil-lubricated

Above: Figure 1 compressors; this may increase to more than 100 mg/m3 in older compressors. Even in oil-free compressors, abrasion, moisture and contamination by water injection and contamination through the lubricants of the gears and bearings can add to this depending on the model. In older compressed air systems with compressed air pipework that can be several kilometres long and disregarding leaks, can also be susceptible to corrosion, the use of modern energy-efficient compressed air systems frequently falls far short


EMS Magazine | February 2013

Compressed Air Feature

Contamination of the compressed air can occur at any point of the compressed air purification system. That is why it is so important that the filters have reliable differential pressure gauges. The Economizers, which indicate when the differential pressure reaches the limit value and an element replacement is advisable for reasons of operational safety and energy efficiency, so that the operating costs caused by the filter do not exceed its cost, are easy (Fig 5).

Is the differential pressure alone important?

Although long-term experience shows that an element replacement in the coalescence filters is useful when the differential pressure limit is reached, it is not the sole decision criterion. A sudden steep increase in differential pressure, for example, is a warning sign for increased contamination by particles. Therefore, one cannot solely rely on the differential pressure. Even quality filter elements with their great contamination retention capacity and the high resistance of their filter media against the constant exposure to corrosive substances should be replaced at the latest after 8,000 operating hours or twelve months. Below: Figure 5

Above: Figure 3 if they are not validated according to ISO 12500 and an objective performance comparison is impossible or when the differential pressure of coalescence filters for the separation of aerosols and liquid oil/water contents exceeds the limit or if they have been used for more than twelve months or 8,000 operating hours. The specification of value 350 mbar within the scope of the above-mentioned campaign Druckluft effizient is a reference value, and reflects the differential pressure curve of compressed air filters. The differential pressure of a new filter element initially increases very slowly. With increasing operating time, the differential pressure rises more rapidly and then reaches the point at which the filter element replacement is necessary. The recommendations for differential pressure limits vary depending on the filter manufacturer and may well be at 500 mbar.

Above: Figure 6

This is how damages can be prevented

In compliance with the replacement intervals and differential pressure limits, the user can be sure that the productivity and efficiency of his systems, which rely on compressed air, are maintained or increased and the optimum protection of the workers is ensured. A worst case scenario with a production loss or unusable products can result in unpredictable consequences for the company. Good advice and a reliable service, the monitoring of functions in the central control systems and ultimately a clear responsibility for the compressed air supply and the timely replacement of filter elements prevent economic damages.

Filter element replacement made easy

Replacing a filter element is easier today than ever. In a cross reference table (http://b2b.emea., the user will find energy-saving filter elements validated under ISO 12500 for most filter housings, the quick availability of which is guaranteed by Donaldson by the European Distribution Center (Fig 6). Orders received by 1 pm will usually be shipped the same day. This eliminates the necessity of own warehousing for compressed air users and compressed air resellers. The filter replacement is also offered by a nationwide service network by the Donaldson Service technicians. Author: Donaldson Filtration Deutschland GmbH in 42781 Haan Donaldson Filtration (GB) Ltd Humberstone Lane, Thurmaston, Leicester, LE4 8HP Tel: +44 116 269 6161 Email: Web:

The Best Filter for each Use

Why is it necessary to monitor each compressed air filter in a compressed air supply system? Below: Figure 4 Basically, this replacement interval based on operating hours applies also to activated carbon filters that are used to separate oil vapours and odours. These filters are a standard for operations in sensitive areas such as in the food and pharmaceutical industries and in the generation of process air, in order to achieve a residual oil content of air pressure of 0.01 mg/m3, as referred to in ISO Standard 8573-1 for compressed air quality class 1. Even the use of particularly high quality activated carbon adsorbents that are used as a bed or as an integrated component of filter media, lose effect, despite their high adsorption capacity, which is not reflected in the differential pressure. The recommendation for the filter element replacement is at a maximum of 2,000 operating hours or three months. Depending on the prevailing oil vapour content and at inlet temperatures above 20 C, a replacement is recommended at an earlier time.

EMS Magazine | February 2013


Compressed Air Feature

Dropout Releases A Product Designed To Revolutionise Liquid Water Removal In Compressed Air Applications
DROPOUT are delighted to announce the release of The worlds most effective point of use water separator on the market
After 4 years development and with patent registration on a global basis Dropout has now released a product that is designed to revolutionize water separation in the compressed air industry. Not only will it remove 99.999% of the liquid water in compressed air but also removes solid contamination down to 1 micron. ZERO maintenance further makes this a very attractive alternative to current industry standard water separators that require frequent replacement of costly consumables. Yes thats right this solution really is installed once for life! Customers are already experiencing amazing results in electronics, automotive and painting applications but the applications are limitless! Chris Hall New Forest Stone says: We almost bought a refrigerant dryer before we found Dropout. We are very pleased with the DO600A it basically does every thing it says on the can. Very simple to install and removes all noticeable water from the line without the cost of an expensive dryer We just empty it once a day.

Available in a range of different flow rates to suit your individual application For more details contact: Dropout UK Tel:01572 338041 or contact: PCL to find your local stockist


EMS Magazine | February 2013

Compressed Air Feature

New ABB App Highlights Potential Compressed Air Energy Savings

Users of pneumatic valve positioners can now assess the energy efficiency of their valve installations with ABBs new compressed air calculator app for the Apple iPhone and iPad.
Based on the amount of compressed air consumed by conventional positioners, the app shows how using the latest smart positioner technology can help operators to dramatically reduce their energy costs Easy-to-follow instructions show the user exactly what parameters are needed to calculate any potential savings. The user is prompted to enter the number of pneumatic positioners on site, air cost per standard cubic foot and the percentage of time spent at a steady state to calculate the users current compressed air energy costs. These costs are then compared to the potential savings that could be achieved using ABBs TZID-C and EDP300 intelligent positioners, where compressed air is only consumed when required. At present there is no other app on the market that can show positioner users the significant energy savings that can be made by using smarter Consider a positioner which spends 50% of its operational time in a steady state position (steady set-point). Assuming a compressed air cost of 1p per scfm (standard cubic feet per minute), the cost of this wasted energy, in the worst case, can be as much as 2,106.78 per year. Replacing this positioner with a smart positioner could save between 500 and 1,200 per year per positioner through reduced compressed air consumption. The app also allows you to measure savings in different currencies, including Sterling, Euros and US Dollars. To find out more information Call: 0870 600 6122 Email: ref: Compressed air calculator app. To download the ABB app, please visit the Apple App store and search for ABB Compressed Air Calculator. technology, says Jo Kirkbride, ABBs Product Manager UK & Ireland, Actuator & Positioning Products. As conventional valve positioners can typically consume compressed air even when not in operation, many sites could be racking up thousands of pounds in wasted energy.


At MAINTEC we BEKO TECHNOLOGIES will be showing the METPOINT OCV which detects oil vapour down to 0.003 parts per million or in terms of the ISO standard better than class 1 to ISO 8573.
The oil carry over from compressed air is very important to certain industries such as the food and beverage, pharmaceutical for example. The consequences of oil contamination for these industries end products is unthinkable yet very few companies today are measuring the vapour carry over. BEKO TECHNOLOGIES use Photo Ionisation Detection to measure the oil in compressed air. Many users of oil free compressors are unaware of the amount of oil vapour that can be sucked in by a compressor in an industrial location and readings that have shocked end users are very common but normally easily fixed by the installation of a carbon tower or equivalent oil removing system. The device is simple to install and has compatibility with all advanced BMS systems and gives a constant read out. The devices are working well in several blue chip companies making mineral water, pharmaceutical products and laboratory testing. The METPOINT OCV is available for sale as a permanent installation or for rental whereby BEKO TECHNOLOGIES will make readings for an agreed period with a mobile device which can also test for flow, dew point and pressure. For more information come and see us at stand H5a or call us on 01527 575778. BEKO TECHNOLOGIES Ltd E-mail:

EMS Magazine | February 2013


Compressed Air Feature

Smart Compressors & Equipment Ltd.

Smart Compressors & Equipment is a new company to the UK, Irish and European markets, offering a wide range of air compressors, refrigerant dryers, ancillary equipment and other parts and machinery. Although new by name, the company has a ready-established industry pedigree in the form of husband and wife team Graeme and Meltem Middleton-Duff.
Managing Director Graeme has 27 years experience in the compressed air industry, the past 4 of which having been dedicated to developing Hertz Kompressoren UK into a highly successful and well-respected brand. Meltem also has wide experience in the air compressor and related equipment marketplace. During her 15 years in the business she has managed all matters concerning engineering, import & export, logistics, finance & accounting and sales & marketing and customer service. With Hertz now firmly established, Smart Compressors & Equipment has been launched to supply a complementary and extensive portfolio of equipment. The company offers state-of-the-art, quality, reliable air compressors, refrigerant dryers and related equipment designed and manufactured by some of Turkeys very best suppliers, and all equipment is available at a highly attractive price point. Smart products are also easy to maintain and install, as well as being highly energy efficient. All equipment is manufactured to the latest ISO and TUV standards, and is fully PNEUROP- and ATEXcompliant. Where required, Smart Compressors & Equipment can customise its products in order to best suit the individual requirements of the end customer. Graeme continues: The Turkish market is booming at the moment, and is not directly affected by the Euro crisis. In addition to the cream of Turkish engineering talent, many other leading international companies have or are investing in Turkish industry, and this has played a significant role in elevating design and manufacturing standards to a level that can easily hold its own against many of the longestablished global brands. More information For more information, please contact:Address: Smart Compressors & Equipment Ltd. Unit 13 Peel Mills Industrial Estate Chamberhall Street Bury Manchester BL9 0LU Phone: +44 161 764 41 60 Fax: +44 161 764 28 90 E-Mail: Website: Our mission statement is to supply the very best selection of air compressors for optimum use in any industry sector, explains Graeme. Some industries, particularly offshore/oil & gas, require a particularly demanding specification of compressor and related equipment in terms of ruggedness and durability in extreme environments. They also need to be fully fire-tested. Our wide range of compressors has been compiled to provide the ideal solution for these environments. Smart serves customers throughout the whole of the UK and Ireland and Europe. Industry sectors covered include construction, agriculture, manufacturing/engineering, offshore/marine, oil & gas and leisure. All products, together with genuine spare parts, are delivered to the customer either by Smart directly, or by a member of its highly experienced network or resellers and distributors within a very short timeline often within 24 hours of first receiving a sales order. Smart Compressors & Equipment and its partners also offer a first-class sales and aftercare service. and lathes to pressure washers and laser cutting machines, and much more. support, either directly from our own team or via one of our dedicated reseller distributors, she says. Smart can also supply full equipment training and, where required, we can also arrange for users to receive training directly from our Turkish equipment suppliers.

Warranty and support

Smart Compressors & Equipment offers a five-year warranty on all major parts on the companys screw compressor range and refrigerant dryers, and a standard 12-month warranty on all other equipment. All products are built for a broad range of applications, are easy to maintain and service, and are designed to offer long maintenance intervals and low operating costs. Smart ensures that only genuine spare parts and oil are supplied to the customer and, wherever possible, looks to deliver most spare parts to the customer within 24 hours of receiving a sales order. Smart also provides reliable support from an expert and friendly team, with the experience and skills to provide excellent technical, sales and after sales support.

Extensive product range

Smarts full product range includes: rotary screw compressors, variable speed screw compressors, belt-driven screw compressors, direct-driven screw compressors, VSD direct-driven screw compressors, mobile screw compressors, breathing air compressors, reciprocating/piston compressors, HC oil-free systems, refrigerant dryers, in-line filters, spare parts and other ancillary equipment. The company also supplies and maintains a wide range of other types of machinery and parts that are critical features within the modern manufacturing/ engineering environment everything from presses

Customer service and training

Meltem adds that looking after customers and their specific requirements is a core focus for Smart Compressors & Equipment. All our equipment comes with full nationwide delivery and aftersales


EMS Magazine | February 2013

EMS Magazine | February 2013


Maintec Preview

A World First At MAINTEC

CorDEX Instruments, the UK manufacturer of instrumentation and equipment for hazardous environments, is introducing a new intrinsically safe product at MAINTEC 2013 that is a well suited for anyone involved in predictive maintenance.
It takes a proven method of inspection and not only extends its scope of application into explosive environments but also adds in RFID technology so that findings can be tagged to a location and trends easily documented. The world launch platform for this development is the CorDEX Instruments stand at the MAINTEC show. The company will also be showcasing several other products in its popular range of handheld inspection and NDT devices for operation in hazardous areas. Visitors are invited to test drive CorDEX Instruments other ATEX certified products including the ToughPIX series of digital cameras, the LaserMETER 3000XP Tel: +44 (0)1642 454373 Email: laser distance meter and the UT5000 intrinsically safe ultrasonic thickness gauge. The companys IW Series Intelligent IR Windows with locking mechanism and multiple identification system will also feature.


EMS Magazine | February 2013

Maintec Preview

Total System Health Management

And What It Means To The Maintenance Engineer
In todays challenging economic landscape, where budgets are being constantly reduced, maximising asset life is paramount to achieving streamlined, cost efficient operations and protecting precious resources.
Compliance with stringent market requirements and legislation in the market has left designers and end users with a vast range of product components to choose from. This has resulted in a holistic approach to filtration and condition monitoring has become vital in improving hydraulic and lubrication system productivity and profitability. Parkers Total System Health Management (TSHM) provides a complete approach to improve the productivity and profitability of mobile and industrial equipment. This approach focuses on three crucial areas: Varnish is attracted to metal surfaces. This can result in an overall decrease in productivity EPF High Pressure Filter Range with iprotect elements fluids can result in oil damage. Thermal and oxidation processes can create varnish in the system and negatively impact system responsiveness as valves may be subject to the slip-stick effect. Coolers and other vital components can become blocked by varnish. Parkers static control filter media minimizes electro-static damage. To ensure the quality of filtration is maintained, Parker applies patented solutions to many of its products. The iprotect filter element is a newly designed, patented, cartridge that reduces environmental impact by more than 50%. Once an OEM or system builder implements Parkers patented filter element, it can typically triple their filter element market share but most importantly, the quality of system protection is safeguarded as no filter media with unknown quality can be applied.

Prevention Diagnostics Therapeutic

Prevention focuses on foresight and employing a good selection of products to prevent system damage and component wear and tear due to contamination. It comes together with tools and equipment ideally suited for direct, in-time reporting and enhancing system performance. Using filtration and monitoring equipment that provide continuous and real-time updates of system activity will ensure that maintenance staff are alert to any abnormalities in performance. While filters have traditionally been used to prevent contamination from wear and tear processes, this still causes more than 80% of the failure of hydraulic and lubrication systems. TSHM goes beyond protecting individual components and analyses the entire system, the environment in which it works and specific requirements regarding machine availability and productivity. Installing filters is not only about blocking the contamination generated by the system itself, but also the contamination absorbed from the environment. Apart from extending the lifetime of system components and routine maintenance, the oil itself also needs to be monitored to decide how its lifetime can be extended. Electro-static charge from hydraulic and lubrication

Technologies that enable condition monitoring are being more often applied in the market, but this is essential to ensure that system performance targets are being met. Certain technologies can detect negative trends but are often too late. Even if no catastrophic failure has occurred, then the end user can be confronted with high maintenance costs for replacement parts. It is important to detect, at a very early stage, accelerated damage to components including aging oil, leakage of seals, bearings, water in oil or deviations from the target fluid cleanliness levels. Parkers TSHM approach is to provide a dedicated package of sensors supplied as a one unit ready for installation. One example is the Parker

icountOS Portable Oil Sampler


EMS Magazine | February 2013

Maintec Preview
Standards Organisation), NAS (National Aerospace Standard) or SAE (Society of Automotive Engineers). For OEMs and end users, this technology is a great step forward to verify the condition of the hydraulic system and to anticipate any potential failures. Continuously measuring oil cleanliness provides important insight into the overall condition of the system and can prevent the consequences caused by ignoring the filter warning. An excellent complement to oil analysis is the MHC Bearing Checker, which uses acoustic emission (AE) monitoring to provide an early indication of machine degradation. As the mechanical condition of machinery deteriorates, energy loss processes such as impacts, friction and crushing generate sound wave activity that spans a broad range of frequencies. By detecting only a specific range of frequencies with special AE sensors, it is possible to detect miniscule amounts of activity, such as a slight rub, a brief impact or the crushing of a single particle in the lubricant. It does not require an acoustic emission technology specialist to determine the health of a bearing within 10 seconds. Parker Kittiwake ThrusterSCAN Parkers PVS Oil Purification System As operators continue to demand more from their hydraulic machinery, attention to monitoring, maintenance and protection is increasingly important. Unplanned downtime caused by equipment failure costs money and in the drive to maximise productivity and quality, users demand equipment that can generate ever-larger forces with ever more precision. Increasing equipment durability and reliability by taking preventative measures can significantly improve profitability.

The therapeutic approach is a corrective plan for when prevention and diagnostic functions have not been integrated into the system design and maintenance strategy. Parkers third pillar of the TSHM approach consists of an offering of portable or mobile oil filtration and condition monitoring solutions. An example is the PVS mobile purification system, ideal for removing water from oil to extend the assets lifetime and reduce additional damage to system components. (Image 6. Parkers PVS Oil Purification System) However, sometimes the oil can be damaged beyond repair. Instant verification of water content can help end users decide if oil treatment is advisable. Filter trolleys with ultra-fine filters are used as an additional support to clean the oil. Even for the mobile market, considering the use of a portable trolley that cleans oil can be helpful during a service event. The therapeutic approach can be seen as a last resort in case the prevention and diagnostic functions have not been integrated up-front. Parkers easy-to-use products provide instant results and are crucial in asset maintenance and care. Complicated systems requiring specialist training are time and resource intensive while relying on a set number of people, increasing the risk of human error. Parkers TSHM approach removes this risk by supplying portable, on-site and reliable help for maintenance staff.

ThrusterSCAN, which can be applied to a ship propulsion system. This consists of condition monitoring sensors assembled into one compact unit that measure the quality of the oil and the presence of metallic wear debris. For instance, if the water content in the oil increases due to a seal failure, it will be detected and a warning will be broadcast to the master control system. Instead of facing system damage due to the increased water content, pro-active maintenance

Parker will be exhibiting at MAINTEC 2013 at the NEC, Birmingham, 5-7 March. It will have a selection of their products on display, including the MHC Bearing Checker as well as the water-in-oil testing Easyship DIGI field kit. Visit their stand in Hall 6, booth H21.

Parker Kittiwake MHC Bearing Checker can be administered. Particle counters are used to measure the cleanliness of the oil and to express this into a cleanliness level class, such as ISO (International

For more information, visit the companys web site at, or its investor information web site at

EMS Magazine | February 2013


Maintec Preview

SPM Instrument Announces The Release Of Leonova Diamond

SPM Instrument, announces the launch of its next generation of handheld measuring devices, the Leonova Diamond; a portable instrument for condition measurement in rough industrial surroundings.
Alongside SPM HD, Leonova Diamond also offers highly sophisticated vibration analysis capabilities. The instrument boasts an excellent signal-to-noise ratio and provides razor-sharp spectrums even where signals are weak and low in energy content. The wide frequency range, covering from 0 to 40 KHz, enables measurement where absolute position is vital. For machinery This heavy-duty yet sophisticated instrument brings powerful analysis and troubleshooting capabilities to your condition monitoring program, offering unique productivity and efficiency. with journal bearings, Leonova Diamond reliably measures dynamic and centerline movement of the shaft. Multi-channel measurement enables the use of triaxial transducers and multi-axes vibration monitoring while cutting long measuring routes Condition monitoring the SPM way is uniquely easy to learn and utilize. Highly advanced measuring techniques, optimized for a minimal and smooth learning curve, quickly brings your maintenance department up to speed, providing organised management for large numbers of routine measurements. Immediate, on the spot condition evaluation is also a trademark of all SPM measuring devices. Leonova Diamond incorporates highly advanced and innovative order tracking functionality. The powerful HD Order Tracking, applicable in an RPM range from just a few to thousands of revolutions per minute, enables more precise measurements Building on the successful Leonova platform, Leonova Diamond features state-of-the-art digital technology and a robust, rugged design. Leonova Diamond is the first portable instrument offering the recently patented and award-winning SPM HD measuring technique for condition monitoring of rolling element bearings. Capable to reliably measure machine condition in the 1-20.000 RPM range, the method has broadened the potential scope of condition monitoring to include more machinery than ever before. SPM HD brings to light machine problems which are impossible to monitor with traditional vibration measurement techniques. The powerful Condmaster Ruby software fully supports the Leonova Diamond features, providing setup of personalized default settings and more detailed spectrums than ever before. On machinery operating under variable speed, vibration analysis with HD Order Tracking provides reliable data and crystal clear measuring results also under large RPM variations. Corrective maintenance techniques such as run up-coast down measurement, shaft alignment and dynamic balancing can be added to the instrument as optional modules. For technical details, please visit: email down to a minimum of time. Providing maximum value, performance and control, Leonova Diamond is the perfect tool for the beginner as well as the advanced vibration analyst. Stan Jackson, Managing Director of SPM Instrument UK, comments on the launch of the instrument: Leonova Diamond is the latest proof of our commitment to developing first class condition monitoring products for more profitable maintenance. In a direct response to feedback from SPM customers worldwide, we developed a durable, high-performance instrument that will deliver long working life under the toughest, most demanding circumstances.Leonova Diamond puts portable intelligence and productivity in the palm of your hand. Leonova Diamond is engineered for performance. It is a dependable and highly capable analysis tool, addressing all condition monitoring needs. The instrument offers a full range of sophisticated measuring techniques as well as all the supporting diagnostic and troubleshooting capabilities. Designed for heavy industry, the look and feel of the instrument reflects its intended use. For use in hazardous areas and hostile environments, an intrinsically safe version of the instrument is available. for the instrument and all the expert knowledge needed to evaluate machine condition. Condmaster Ruby is modular and system functionality can be tailored to specific customer needs.


EMS Magazine | February 2013

Maintec Preview

New-Format Fluke VT02 Visual Infrared Thermometer Fills The Gap Between Thermometers And Thermal Imagers
Fluke, the global leader in portable electronic test and measurement technology, has introduced the Fluke VT02 Visual IR Thermometer, a troubleshooting tool with an infrared heat map.
Until now, electricians and industrial, HVAC and automotive technicians have had to choose between single-point infrared thermometers and highresolution thermal imagers (infrared or IR cameras). The Fluke VT02 Visual IR Thermometer fills the gap for when a single-spot temperature reading is not enough and a high-resolution thermal image is more than users need. This one tool combines the visual insight of a thermal imager, the visual images of a digital camera, and the point-and-shoot convenience of an IR thermometer. Conducting inspections for electrical, industrial, HVAC/R and automotive applications is far faster with the Fluke VT02 than an infrared thermometer, which requires multiple readings and manually recorded results. The VT02 instantly detects problems using blended thermal and digital imagery. It will display and save images as full visual, full infrared, or in three blended modes (25, 50, and 75 percent). Markers pinpoint hot and cold spots indicating the hottest temperature with a red box and the coldest with a blue box. A temperature reading is provided at the centre point. Images are saved to a micro-SD card, eliminating the need to write down single or multiple measurements. Affordable, compact, and intuitive, the Fluke VT02 operates with focus-free simplicity, expanding the user base from senior to junior technicians and broadening the applications for in-house staff as well as creating new business opportunities for service contractors. Images from the Fluke VT02 can be imported into SmartView analysis and reporting software, included with the VT02, to produce professional reports that document problems detected, or repairs made, for management and customer review. Developing a tool that is easier to manufacture than traditional thermal imagers required significant innovation. Using hyper-thin pyroelectric technology, engineers discovered a way to push the limits of the technology, pioneering an array dense enough to create an infrared heat map.
More information about all Fluke products can be obtained via the Fluke web site at: Tel: 0207 942 0700. Fax: 01603 256 606. e-mail:

Triaxial Accelerometers Among Latest Vibration Products From Hansford Sensors At Maintec Stand Number D5
Hansford Sensors will be showcasing its latest vibration monitoring products at Maintec 2013.
Among the new products on show will be, for the first time in the UK, the new HS-109 Triaxial accelerometer, which allows three axes to be monitored simultaneously, plus a new version of the companys spot facing tool, which has been reengineered to extend its operating life even further. Hansford Sensors will also be using Maintec to promote its complete range of existing industrial accelerometers. These include standard sensors, for use with all rotating and reciprocating equipment, plus submersible and ATEX approved and sensors for specialised applications, multi-sensor switch boxes, vibration sensor modules, portable vibration meters and condition monitoring protection systems. Hansford Sensors will be on Stand D5. Artisan, Hillbottom Road, Sands Industrial Estate, High Wycombe, Buckinghamshire, HP12 4HJ Email: Telephone no: 0845 680 1957

NEW! Retrieval Tools Kit Saves The Day.

Foreign Object Debris can be almost anything, from a lost fastener to a dropped mobile phone, and in many cases the machinery or pipework will take a significant time to open up.
Foreign Object Debris can be almost anything, from a lost fastener to a dropped mobile phone, and in many cases the machinery or pipework will take a significant time to open up. However all is not lost! Now there is a solution to even the most difficult retrieval the viZaar Retrieval Tools Kit. Incorporating both an 8mm motorised jaw and a 16mm motorised jaw, as well as magnets, hooks, snares and a whole host of useful accessories and tools, the viZaar Retrieval Tools Kit is a huge step forward. When FOD shows up results can be destructive, dangerous and massively expensive. viZaar retrieval tools can turn an emergency into a retrieval triumph. Having a viZaar Retrieval Tools Kit onhand during inspection procedures and maintenance overhaul outages should be standard operating procedure for all professional and responsible inspectors. viZaar Retrieval Tools Kits are available from Crimson Industrial Vision Ltd the UK specialist for remote visual inspection equipment. For more information contact

EMS Magazine | February 2013


Maintec Preview


MAINTEC, the leading exhibition for the UKs maintenance, plant and asset management community returns to the NEC on 5-7 March 2013 packed with more learning opportunities and product innovations than ever before.
So lets take a closer look at whats on offer at MAINTEC 2013.

The Business Strategy Conference

The Business Strategy Conference is being run throughout the three-day show and features a phenomenal line-up of world-class experts and major end-user brands. Each day addresses a different strategic theme. On day one the focus is on Making the Business Case for Maintenance.

Mark Haarman, CEO, Mainnovation will kick off proceedings by exploring the economic drivers of a maintenance organisation. For those struggling to measure maintenances economic contribution, he will have suggestions and lessons from real life experiences. Delegates will learn why steering on value leads to continuous improvement and what can be learned from leading maintenance organisations around the world.

In a session moderated by Bill Parker, CEO, Institution of Diagnostic Engineers, and drawing on Brand new for this year is the complimentary Business Strategy Conference. Theres tremendous value to be had from listening to the experience of peers especially if they are some of the biggest brands in the UK today. Based on this idea, the Business Strategy Conference will feature experts from many of the UKs brightest companies. From a special theatre on the show floor, names such as Britvic, Pepsico , Alcon, Experian and Scottish & Southern Energy will explore how they are addressing the maintenance issues of the day. James Walker, Decksafe Solutions, AW Chesterton, Metool, SAACKE Combustion, Intertek, Keytracker, REBO BV, MOLYDAL Lubricants, Lubricus Grutzner and Ernst Schad are just some of the many names, from both the UK and overseas, making their MAINTEC debut. They will join MAINTEC veterans such as Schaeffler (UK), Flowcrete UK, R.Stahl, ERIKS, Idhammar Systems, SPM Instruments, For those looking for practical sessions, there will also be The Maintenance Exchange featuring a rich programme of 38 learnShops. Delivered by some of the shows most innovative exhibitors, these will provide visitors with unique insights into the very latest innovations, products and services to be found within the maintenance and asset management arena. Indeed there is so much to see and do that the Institution of Diagnostic Engineers (IDE) has decided to host a spring gathering during MAINTEC. This will also be attended by members of the Institution of Local Exhaust & Ventilation Engineers, another show supporter. IDE Chief Executive, Bill Parker, says: Wed urge all our members to put the dates These free learning opportunities will run alongside in their diary. PRUFTECHNIK and Prevost UK. There is much debate within the profession about which is better control maintenance or a reactive maintenance operation. Mark Thompson, Head of an exhibition packed full of exhibitors, many of whom, like CorDEX Instruments, are using the show to globally launch new products. case studies, John Davenport, Operations Director, Alcon and Paul Dennis, Technical Facilities Manager, Experian will explore successful maintenance strategies, how to choose the right one for your business and the merits of total productive maintenance versus a reliability-centred maintenance approach.


EMS Magazine | February 2013

EMS Magazine | February 2013


Maintec Preview
Wastewater Assets, Southern Water will explore the merits of each. Drawing on his own experience he will look at how you decide which one is the right strategy for your company. He will then explore the idea of whether there is a third way that involves a mix of asset management systems and reactive self monitoring devices. Many wonder whether formal standards The theme for day two is Innovation in Action with Steve Statham, Manager, Manufacturing Technology Centre starting the day by exploring the latest effective methodologies and highimpact technologies. As innovations go, social media has been transformational for many areas of business; Steve will outline its implications for maintenance professionals, specifically social medias role in providing feedback and alerts for building maintenance. He will also give examples of where innovation in asset management is helping to overcome those thorny maintenance issues of legacy systems & obsolescence. A panel discussion featuring David Smallbone, Head Asset Management, AMCL closes day two. In a lively session the cost of asset failure versus the cost of condition monitoring will be debated. Condition-based monitoring is a hot issue. Is an evolutionary or revolutionary approach to implementation best? Which assets and equipment should be included and what about all the data you are likely to gather? Any attendees struggling with these and other questions will get the chance to learn firsthand from Dr Sethuraman Muthuraman, Condition Monitoring Engineer, Scottish & Southern Energy. He will even have some suggestions People, processes and legacy sit at the heart of good maintenance management and day three focuses on these elements. Keynote speaker, Wayne Curry, Engineering Team Leader, Britvic will outline how the company manages the impact of new processes and KPI reports on maintenance staff. In a highly practical talk he will also cover the usability and access issues you face when rolling out new devices and equipment to a mobile work-force. This people focused day closes with Ian Rigby, Engineering Manager, Pepsico, who will look forward to 2017. Ian will predict what shape, dynamics and focus the maintenance team will have by then. Condition based maintenance offers many economic Managers of Energy from Waste (EfW) plants will be interested in the talk by Robin Buller, Director of Business Development at KRR ProStream. Using smart technology to maintain these specialist systems can result in more efficient outputs, explains Robin Buller. He will be focusing on three cleaning technologies, in particular, for boilers, bag house filters and heat exchangers. KRR ProStream specialises in power generation facilities and this talk will give delegates the opportunity to discuss specific efficiency issues with industry experts. really add value to an organisation. This day will be your chance to find out as in his talk Daniel Pairon, Global Head KPMG Asset Management will outline the core standards in asset management and how PAS 55 / ISO 5500x certification might actually empower your company. For instance John Roberts, Managing Director at Idhammar Systems, will give an insight into the OEE concept and how it is linked to return on investment. The concept is based on the availability of the plant for production and the performance of the plant. This is determined by the rate that units are produced and the quality of the saleable product. When these elements are considered together, and the current and desired efficiencies analysed, strategies to reduce energy usage can emerge. for those daunted by conditionbased monitoring, outlining the occasions when reactive or preventative measures may suffice.

The Maintenance Exchange

Complementing the Conference will be The Maintenance Exchange, featuring 38 free-toattend learnShops, designed to help plant and asset managers, engineers and maintenance professionals save money, improve efficiencies and enhance asset care.

benefits, as Stan Jackson, Managing Director from SPM Instrument UK will explain. The concept focuses on using staff more effectively on routine inspections to determine possible corrective maintenance. This is said to increase reliability and ensure maintenance work is planned.

Similarly, Roy Davis, Senior Consultant at MCP, will speak about how Operator Asset Care is implemented to complement maintenance excellence and the benefits to a business when asset care is carried out. He explains: The increased awareness and machinery-based


EMS Magazine | February 2013

EMS Magazine | February 2013


Maintec Preview
which is approximately 7.5 million kWh of annual gas savings.

First time exhibitor, SAACKE Combustion, recently helped Harveys Brewery improve the operation of its boiler plant. SAACKE recommended fitting a burner with a superior turndown, thus allowing the boiler to match the sites steam demand massively improving efficiency.

Those in the food or drink sector should also check out CRC Industries UKs new StopLight Food Safety Programme. Developed specifically for MRO chemicals, its a leap forward in the control of chemical product movements.

knowledge of production operators will ensure that any machinery failures or malfunctions are detected at an early stage, so that planned actions can be implemented.

downtime, while Ian Pledger, IAM Product Specialist from Schaeffler will discuss the implementation of an efficient asset management system using plant condition monitoring. Dr Trevor Holroyd, Technical Director at Parker Kitti Wake Holroyd, will speak

Among the vibration monitoring products from Hansford Sensors making their UK show debut will be the new HS-109 Triaxial accelerometer. This allows three axes to be monitored simultaneously, plus a new version of the companys spot facing tool, which has been re-engineered to extend its operating life even further.

For those who have a health and safety agenda, Sira Test and Certification Ltd will hold a seminar on the worlds first international scheme for the certification of personnel associated with equipment, installations and servicing used by Ex industries, known as IECEx.

about the application of acoustic emission to detect ineffective lubrication in operating machinery.

Marketing Manager at Ernst Schad, Ram Greenshpon will explain how to keep your good old gearbox in service at a fair cost, whilst Reliability Maintenance Solutions will be speak about

Maintaining reliable RH measurements in harsh or corrosive environments is notoriously difficult as the conditions themselves degrade the sensors and equipment, often in short time-periods. Michell Instruments will be showing how its DT722 RH and temperature transmitter provide a solution to this problem.

Any uncertainty of hazards associated with static electricity will be clarified by Mike OBrien, Product Manager from Newson Gale. Sometimes thought to be witchcraft due to its invisible nature, static electricity can spark an explosion in combustible atmospheres, explains Mike OBrien. The highly dangerous charge can be built up by the movement of powder and liquids in a plant. Using a video to illustrate the dangers, he will be discussing practical measures on how to manage static electricity.

improving reliability by correcting the big four: balancing, shaft/belt alignment, looseness and resonance. Flowcrete will hold a seminar about how to get more from your floor.

Packed Show Floor of Innovating Exhibitors

Exhibitors sit at the heart of MAINTEC and this year is no exception. Many are using the show to launch new products or showcase their very latest work. For instance BEKO Technologies will be outlining how it has helped one of the largest car manufacturing plants in the UK replace its old dryers and thus reduce running costs significantly and improve air quality. The initial project was to replace just two dryers but projected energy savings provided a sound case to change all four existing dryers.

Attendees who work with fragile substances will not want to miss the talk by David Furley, Distribution Manager at CorDEX instruments. He will explain how to control the deployment of standard thermography equipment. Visitors will also be able to hear about web-based predictive maintenance systems, from Dr John Atkinson, Technical Director from C-Cubed.

Andy Parkinson, Business Development Manager from James Walker will speak about improving efficiency and costs by reducing maintenance

Thermal Energy International will show how a FLU-ACE Condensing Heat Recovery System which it implemented for Premier Foods saved the company 110,000 per year,


EMS Magazine | February 2013

EMS Magazine | February 2013


Maintec Preview
Steam system and flow control specialists Valveforce has created pneumatic control valves to handle a wide range of fluids such as thermal oil, steam, water, nitrogen and natural gases.

Dust extraction specialists, Dustcontrol UK, will showcase their latest centralised dust vacuum system - the DC 11 Module. By reducing noise to 65 dB(A), the DC 11 Module is easier to fit in a building where noise is a challenge. HAZEX Successfully launched last year, the HAZEX area brings the UKs top hazard prevention experts and innovations under one roof. For instance in a world first, CorDEX Instruments, the UK manufacturer of instrumentation and equipment for hazardous environments, is introducing its new TC 7000 T-Cards Direct is launching the latest upgrade to its new T-Cards Online at the show while Xetec will show its FlexMaint computerised maintenance management software. Newson Gale is showcasing its Bond-Rite static earthing clamps plus its Earth-Rite series of hazardous area static grounding systems. Also James Walker has successfully tested Supagraf Premier, a premium fugitive emissions valve packing, to ISO 15848-1 2006 Class A at 690bar. It will be showing visitors how this is the lowest rating of leakage definable under ISO 15848-1 and demonstrates a step change in performance for braided graphite fugitive emissions packing. DENIOS is running a live and explosive free lecture. Running for all three days this experimental lecture uses graphic demonstrations to explore the limitations of flammable materials in the workplace. Recently launched, Agility 4.1 from SoftSols is the latest version of its Agility Computerised Maintenance Management System and builds on the introduction of dashboards and key performance indicators in earlier releases. The winners of the first ever MAINTEC Maintenance Professional Awards will also be announced live from the show floor. There are two categories: Maintenance Professional of the Year and, in support of newer entrants to the industry, Maintenance Apprentice of the Year. For those focused on people development MCP Consulting and Training will show how an Operator Asset Care programme equips the very people operating production equipment to improve its reliability and performance. MGTS will explain its unique approach to technical training designed for both mature and new entrant employees across a wide range of engineering disciplines. MAINTEC is free to attend and preregistration is advised to avoid queues on the day. Register visit maintecuk. in this area R.STAHL is introducing IS1+ a key innovation for the companys already leading explosion-protected remote I/O system IS1. intrinsically safe thermal imaging camera at HAZEX.

MAINTEC will be the first opportunity to see Idhammar Systems new Maintenance Management System V11. This offers a number of new benefits including minimized downtime, improved maintenance planning, audit compliance and greater Ocip Energy will outline how a recent project to install new LED fittings at Fletcher Moorlands site is on target to save the company 70% of its lighting costs. control over budgets and stock.

There will be a unique demonstration of Schaeffler FAG WiPro s condition monitoring system for wind turbines. Via a live remote link to a wind farm based in Scotland, visitors will be able to see in real time how the main rotor bearings, gearbox and generators on five wind turbines are being monitored 24/7.

Fluke UK will show its Fluke CNX Wireless System. This is the first set of test tools that wirelessly connects multiple measurement modules and sends simultaneous readings to a master device up to 20 metres away, allowing users to troubleshoot problems quickly and efficiently.

And the Winner is

Hayley Groups brand new SmartVendTM eliminates the need for RFID tags, barcodes and the requirement to manually account for inventory. This automates data-collection and provides the user with real-time intelligence on inventory use.


EMS Magazine | February 2013

EMS Magazine | February 2013


CMMS Feature

Shire Systems: A New Look for Maintenance Management Software

Shire Systems has overhauled its range of uniquely easy-to-use PIRANA CMMS products at a price thats unrivalled.
Maintenance is an organisations greatest controllable cost and with cost-cutting uppermost in peoples minds it makes sense to get organised, and squeeze more out of your resources. and your team manage the maintenance operation. Users can see vital statistics at a glance. This encourages everyone to monitor the system on a regular basis, enabling transparency and driving productivity, enabling your team to accomplish more every day.

Its time to move to Pirana CMMS

Getting buy-in for a maintenance management system has always been a challenge for hardpressed managers but successful companies know how crucial it is to select the right CMMS. Shire CMMS is produced uniquely BY maintenance professionals FOR maintenance professionals. That is why Shire, who have 30 years experience, are the UK No 1 provider. Shire has constantly been the front runner in the usability stakes and so its browser based CMMS solution is also available as a hosted service. For a modest monthly fee, you get a fully functional Computerised Maintenance Management System whilst avoiding all those time-consuming IT hassles. If youre short on funds, lack IT skills, or just resent IT issues distracting you from core business, its the ideal solution. Shire hosts the system in a secure data centre, managing the whole service, so securing data preservation and disaster avoidance. You just need a PC, notebook, laptop or mobile with a web browser. Talk to Shire in the morning and you could be using your system later that day!

Key features
access worklists and update job information easily All CMMS providers boast features designed to entice. Shires pioneering systems offer unprecedented functionality for the price. Shire CMMS is not just easy to use but also facilitates powerful searching, is customisable, can be presented in different languages or terminology and offers a broad choice of security setup. All the key features are easy to locate. whilst on the move.

Take Control - Make Informed Business Decisions

Having a real-time view of your asset performance and full understanding of your resources is vital for maintenance management. Shire CMMS gives you essential control, with graphical KPI reports providing at-a-glance insight into performance across multiple locations, enabling you to make informed decisions.

Value for money

For added flexibility the Shire CMMS suite is available in independent modules. You can purchase the modules you need and add to them at a later date as necessary.

About Shire Systems

With over 10,000 customers, Shire Systems is an award-winning provider of business-to-business asset, materials and service management software systems. Established in 1982, Shire is one of the very first providers of PC-based business management software. Pirana offers a choice of setup and support that

Try before you buy

As experienced providers, Shire are confident in offering their CMMS solution on a trial basis. Shire can quickly set up a fully functional demonstration system. Just call or email!

Mobile Solutions
It is essential that all users are able to access your maintenance system wherever or whenever they like. Shire CMMS mobile solutions enable users to

is second to none: whether installed on your own server, or the stress-free fully hosted option, there is truly something for everyone. Why wait when a top class CMMS now costs so little?

Ease of Use is Paramount

Shire CMMS solutions offer the fast route to first class CMMS implementation. Being able to use the system straight out of the box and from a mobile device or laptop provides true flexibility. The uniquely intuitive interface is easy to navigate using recognisable icons, handy menus and searchable grids. Shire has gone to great lengths to make sure that its software is not cluttered with unnecessary features & gadgets. It does what it says on the tin! The interactive dashboard transforms the way you

Shire Systems will be demonstrating the Pirana CMMS suite of products at Maintec 2013 (Stand E11). Shire offers a FREE, no-obligation, fully functional demonstration system. +44 (0)23 8022 4111


EMS Magazine | February 2013

CMMS Feature

Building a Case for Maintenance Management Software

Implementing software to optimise the operational efficiency of the maintenance department makes sound financial sense. However, if funding approval is required, writing a business case can be a daunting prospect.
Software provider Service Works provides advice on how to structure a business case and the pertinent points to include.
Implementing maintenance management software or computerised maintenance management software (CMMS) enables organisations to work more efficiently, saving time and money. However, as with any major investment, convincing the finance director (FD) may be more difficult. A wellresearched business case will help persuade the board of the benefits CMMS software and its quick return on investment. But what should it include? system will enable the team to implement significant business improvements. Examples where improvements can be made are likely to include: Increased efficiency of the CMMS helpdesk Improved planned maintenance scheduling Optimised asset performance Rigorous contractor and SLA management Administrative savings Managed and auditable health and safety risk Improved stock control Improved facility bookings A ROI model should cover three elements. The first section requires entry of the costs payable to the chosen CMMS software provider for the initial installation of the system, the second covers the clients installation and ongoing running costs of For each of the improvements listed, include a brief remark about how CMMS software will support this. For example, centralisation of the Helpdesk team, supported by CMMS software to manage reactive maintenance requests, will remove reliance upon local maintenance staff in each geographic location and improve response times. End the section with a summary of tangible, longterm benefits that might be expected from a CMMS software solution. The business case should be around 10 pages. End with a clear summary statement that includes the business objectives; summarise the decision criteria; clearly state the results and findings; conclude with concise recommendations; and having CMMS software and the third section covers the savings expected from the implementation of CMMS software.

CMMS Software
The FD or budget holder may have little experience of CMMS software, so providing background may be helpful. The Maintenance Manager will have researched CMMS software providers and their product offerings before selecting the preferred supplier, and will have several reasons for doing so. Discuss the key areas that have been taken into consideration. These might include the functionality offered or cost and flexibility of pricing.

Return on Investment
Adding a return on investment calculation will help the case, as the budget holder is familiar with this business language. This calculation should demonstrate a positive cash flow and payback within two years of deployment, or less.

Begin by discussing how the maintenance department is an essential element in the effective running of the organisation. Talk briefly about the responsibilities of the department (i.e. helpdesk, reactive job and management). Discuss how the maintenance team plays a vital role in the realisation of the companys strategic objectives, such as generating cost savings, improved asset efficiency and enhanced environmental performance.


Optimising the Maintenance Departments Effectiveness

State that successfully carrying out all the tasks required of the maintenance team is dependent on streamlined processes, effective task management and visibility of enterprise-wide information; and that the introduction of a comprehensive CMMS

The Impact of No Action

As well as discussing the benefits of the software, presenting the consequences of staying with the status quo will be very convincing. Provide several bullet points about aspects of the maintenance team that are not presently optimised should be sufficient. For further emphasis the document might conclude that the benefits of introducing an integrated CMMS software application will be substantial, notably in the areas of cost reduction, operational efficiency and risk management.

formally outline the recommendation and how the organisation should proceed.

A copy of Service Works business plan template, Building a Business Case for CMMS Software, can be obtained by: Calling 0208 877 4080 or emailing

EMS Magazine | February 2013



EMS Magazine | February 2013

CMMS Feature

SoftSols And Agility Help To End The Age-Old Problem Of Wonky Wheels.
tracking, to support clients who require services

Leading retail products and services provider Symonds UK turned to Computerised Maintenance Management Systems specialists SoftSols to improve their existing performance still further.
The client
Symonds UK is a leading provider of products and services to the retail and industry sector in the UK, with an annual turnover of around 25m. Well established, with 20 years in the retail service industry, it offers solutions in maintenance, management, cleaning, logistics and storage for a range of clients, including the top five supermarket chains. Symonds seven days a week service response is backed up by a customer service help desk and a fleet of 100 service vehicles, all fitted with satellite With its head office in South Wales, Symonds employs more than 400 staff across the UK and Ireland, has national depots in Warwick, Abercarn, Cowdenbeath, Maldon and Tibshelf, and services around one and a half million assets in more than 16,000 customer sites.

from repair of customer trolleys to bakery cleaning.

The business need

Symonds UK has worked with Maintenance Management System specialists SoftSols Group for a number of years. Previously benefitting from using the ImpactXP system, Symonds wanted a new browser-based CMMS solution to improve and integrate existing systems in job tracking, communication and offer a cradle to grave service for their customers assets.

Symonds UK also needed to be able to integrate different software packages for accounting and maintenance to reduce double entry of information and be able to track jobs more effectively. Their different customers all have distinct reporting needs according to the different businesses. Symonds UK had to find a solution that was robust enough to cope with the differing demands, yet flexible enough to be tailored. After extensive market analysis, they selected SoftSols maintenance management solution, Agility.

The solution
Agility is a comprehensive, browser-based maintenance management solution. Its flexible design meant that changes could be easily introduced to address Symonds specific asset management requirements. Symonds has many customers with multiple sites and the Agility system holds details of each site location and the fleet of trollies, roll cages and mechanical handling equipment at each one. Planned maintenance visits are automatically scheduled through the Agility system and reactive work requests can be entered by customer service staff or fed through from their remote offices, linking


EMS Magazine | February 2013

CMMS Feature
with their own accounts and operations systems. Symonds also implemented a custom upgrade to Agility a bar code hand held unit - to record details of every repair to every trolley or roll cage. Each asset has a unique bar code attached to it. Using the hand held unit, each asset is scanned prior to repair, with parts and time logged against the asset and a daily log displayed to fitters. That data is captured over a remote network and fed directly into Agility against the uniquely identified asset. Symonds implemented Mobile Expert for all mobile maintenance work in April 2011. This is being used to capture details of work completed, including custom data capture forms with configurable check list items and data fields. At the end of the job the engineers capture a signature from the customer and the work order is closed automatically through the Agility system. Agility is also a powerful performance tool. Reports and statistics can quickly be extracted to demonstrate the value to the business of improved maintenance rates and work scheduling.

The benefits
Mike Davies, from Symonds, said implementing Agility had made significant improvements across the company in a range of areas. Its allowed us much more flexibility, reduced our paperwork and made allocating jobs to our engineers much more efficient, he explained. We look after more than a million assets across 16,630 sites. Being able to accurately track the history of assets is crucial to our business. The simple Agility reporting system has allowed us to be able to adjust the reports as required for our maintenance work. Now, we can log maintenance time and parts against specific items with a scan of the items barcode, and all the information is held in Agility. The time saved with having all the information in one system and the ability to be able to track our own costs is priceless to us. We work with the top five supermarket retailers throughout the UK providing up to 100% of their trolley servicing and other contracts, and can provide around 300 reports, tailored to our customers needs. Agility has certainly helped us secure these and other contracts, helping to grow our own business.

Next steps We are planning to roll out Mobile Expert across other divisions of Symonds to reduce paperwork and processing, allow real-time job tracking and track stock. We are trialling milk cage tracking using barcodes with major dairy producers, and RFID (radio frequency identification) tagging on customer assets. Agility helps give us a clear and current insight into our performance and service to clients and improves our asset management enormously, added Mike.

SoftSols (EMEA) Ltd

Tel: +44 (0) 1924 200 344 Email:

EMS Magazine | February 2013


Training Feature

Calibration System Provider Aims To Assist Customers To Drive Process Improvements And Accelerate Return On Investment By Providing A Best Practice Training And Professional Development Experience.
Beamex is highly regarded for manufacturing and supplying high quality calibration instrumentation and software, designed to deliver cost savings whilst improving the efficiency and compliance to regulation of the customers calibration process.
Of course the formal training session is still requested by some customers but Beamex believes this path is best augmented, if not replaced, by additional Beamex Experience routes such as: Continuous best practise through customer support, enhancing our customers knowledge with valuable tips delivered under Service Level Agreements. Interactive webinars providing bite-sized learning experiences to suit todays busy professional with what they want, and when they want it. Open days that provide peer-to-peer networking opportunities providing a foundation for intra and inter-industry best practise. Seminars in core application knowledge, consultancy workshops tailored specifically to a particular customer to advise and change process whilst carrying users on that all important journey that brings change (for the better) to the business. These calibration solutions are purchased to achieve well articulated business goals and to satisfy core regulatory and best practise requirements. However, in many cases the solutions will add further value by introducing a change in a business process and having buy-in from all stakeholders to fully realise their potential. In the past in order to facilitate stakeholder buy-in it was deemed acceptable to provide rigid, standard training packages in stifled classroom environments to trainees who had no real self-reason to attend. The net result was rarely as successful as it could have been. Just like the modern day school or academy; the way in which students learn has changed for the better with an emphasis on the learning environment. Beamex strives to continuously enhance the Beamex Experience for their customers, tuning this environment to the lifecycle of the Beamex user. Using key principles such as the training cycle to better define student needs helps us: Better determine learning requirements, set out clearly defined and agreed learning objectives, design appropriate Beamex Experience learning material that can be delivered and sustainably supported, and improved with continual assessment and evaluation. For More information: Email: Web: The use of social media to provide interactive paths to information in a way that has become the norm in todays society. Beamex understands that one of the most important aspects in delivering Training and Support to our customers is having an internal environment that promotes teamwork, collaboration, and the shared goal To be the most desired partner in calibration, a goal many of customers tell us we have achieved.


EMS Magazine | February 2013

Training Feature

National Instruments Condition Monitoring & Predictive Maintenance Summit

Embedded condition monitoring of machinery and mechanical systems is essential in order to minimise unscheduled outages, optimise machine efficiency, reduce maintenance and repair costs, and support increased revenue growth through competitive advantage.
Hear from industry experts at NIs Condition Monitoring & Predictive Maintenance Summit in Newbury, Berkshire, on 10th April 2013. Topics include continuous online asset monitoring, prediction technologies (or prognostics), managing and processing large data sets, and using, calibrating and managing off-the-shelf measurement and monitoring systems built on flexible, industry-proven platforms. This free event brings together industry speakers, engineers and managers, for technology discussions, in-depth case studies, hands-on training and networking opportunities. Guest speakers include Dr Fatih Camci, a Senior Research Fellow from the IVHM Centre at Cranfield University, presenting a session entitled: Prognostics: A Pathway towards Next Generation Maintenance Management. For more information and to register, please call 01635 572498 or visit:

EMS Magazine | February 2013


Training Feature

BINDT Accreditation For Flir Infrared Training

Thermal imaging is now an industry standard method for condition monitoring and preventive maintenance. Its efficiency and application flexibility has driven its take-up across all industrial sectors and as a result camera costs have fallen thanks to manufacturing economies.
The technology is now eminently affordable and accessible to an increasingly wider engineering community and the need for dedicated training has become an increasingly important and natural by-product. Put simply, a Level I thermographer can use the equipment without knowing too much about its inner workings and perform uncomplicated measurements following existing routines. He or she will be able to detect obvious faults, recognize possible errors in measurement and carry out post processing and Technology leader, FLIR Systems, has always been a staunch proponent of expert training. It not only ensures that the user gets the best return on the camera investment but also that application standards are upheld. For this purpose, the company created its Infrared Training Centre (ITC), an independent organisation that provides courses that range from foundation through to professional level. In the Level I training course, the emphasis is very much on hands-on training. Theory is kept as simple as possible and use of formulas, minimised. Whilst the student will leave the course as a competent user of an infrared camera they would need to defer to a higher-qualified person to define inspection routines and guidelines. data collection. Level II thermographers to set up and run a successful condition monitoring programme. And as such, the instruction includes guidance on acquiring and developing the necessary personnel, resources and technologies.

BINDT Accreditation
All FLIR certification courses are already highly regarded for their quality and depth but now this has been independently verified. FLIR Level I and Level II thermography courses have been validated by the British Institute of Non-Destructive Testing (BINDT) against its minimum requirements for structured training of condition monitoring practitioners.

These courses have been continuously developed over time by ITC experts. They are based on the collective experience of ITC worldwide to determine what thermographers need to know. And these learning objectives are part of the ISO compliant quality control system of FLIR Systems in both Sweden and the United States.

Greater depth
In the Level II course, this knowledge base is expanded. The training course includes more theory and goes deeper into the physical laws that the infrared camera uses to generate an image and measure temperature. It also explores the causes, anomalies and patterns that are commonly encountered in thermal imaging. BINDT is world renowned. Its aim is to promote and advance the science and practice of non-destructive testing, condition monitoring, diagnostic engineering and all other materials and quality testing disciplines. FLIR has worked closely with this organisation for many years with the aim of creating a quality standard in infrared training.

All students who complete a Level I, Level II or Level III training course are eligible for ITC certification which is valid for five years. To be re-certified for an additional five years, the student must demonstrate continuing education in, or professional contribution to, the field of thermography.

The student uses more formulas and is expected to be able to perform simple calculations. Steady state and transient mechanisms are examined in more detail and the course work involves more laboratory experiments. As a result the certified Level II thermographer is qualified to perform and direct infrared thermography according to established and recognised procedures.

We are delighted that our courses have been ratified by such an important industry body, concluded Jon Willis FLIR Systems ITC Manager. This achievement also gives industry the assurance that the training we provide is in compliance with ISO18436 requirements for the training and qualification of personnel. Contact details:

Level I to III qualification

So what do these various qualifications mean? A Level I thermographer is certified to perform industrial thermographic measurements and fundamental infrared thermography, including basic image post-processing according to established and recognized procedures. This includes the use of measurement tools, emissivity adjustments and span & scale adjustments.

For any professional thermographer, Level III certification is the gold standard. It signifies wide experience and a standard of knowledge that meets internationally recognised criteria.

FLIR Systems, 2 Kings Hill Avenue, Kings Hill, West Malling, Kent. ME19 4AQ Tel: +44(0)1732 220011 ITC email contacts: |

The goal of this course is to enable pre-qualified

Websites: |


EMS Magazine | February 2013

Training Feature

The Importance Of Efficient Hydraulic Hose Training

When the efficient operation and maintenance of plant and equipment, as well as the health & safety of the workforce is at stake, only the best hydraulic hose training and service provision is acceptable, writes Ian Morris, director, the British Fluid Power Association.
Fluid power plays an important part in the production, maintenance and operation of a wide range of plant and equipment within a wide range of industrial sectors; from engineering and manufacturing, offshore and agriculture to construction and off-highway. One of the most critical of all components within the fluid power armoury is the hydraulic hose. And despite its simple appearance, the hose has to be able to operate at very high pressures and also needs to be capable of handling extremely high temperatures and shock loads. When a business is largely reliant on hydraulic machinery to undertake its mission-critical tasks, the last thing it needs is for this equipment to cease functioning to the best of its ability, or to fail to operate entirely in some instances. Therefore, the process of fighting fires after the equipment has broken down is something to avoid at all costs, and is a perfect example of the importance of ensuring hose and fittings are compatible, of a high quality and regularly maintained. Sourcing the right grade of hose is also extremely important from a health & safety perspective; a high-pressure hydraulic oil injection injury is a very serious occurrence and something to be avoided at all costs. With these points in mind, any hose fitter or maintenance engineer tasked with fitting and testing equipment for new build or maintenance projects should ensure that the right grade of hose is coupled with the right coupling in the most safe and competent manner. In general, hydraulic hoses are highly effective in their daily tasks; it is only when something goes wrong that serious problems can occur; such as costly downtime, environmental contamination and even physical injury. It is for these reasons that the British Fluid Power Association (BFPA) and British Fluid Power Distributors Association (BFPDA) have established their hose training courses: The Foundation Course in Working Safely with Hydraulic Hose and Connectors and The Hose Assembly Skills Training Programme. The first is a one-day course titled Foundation Course in Working Safely with Hydraulic Hose and Connectors. This course sets out to explain clearly how individuals can work more safely with hose and related equipment. The second is a practical, workshop-based course titled The BFPA Hose Assembly Skills Training Programme. This course takes this basic level of knowledge and trains to a fully assessed level of ability in hose assembly techniques. When the efficiency of your plant and equipment, as well as the health & safety of the workforce or general public is at stake, only the best product, training and service provision is acceptable.


EMS Magazine | February 2013

Training Feature
Denso Builds A Brand New Training Centre
Anti-corrosion and sealing specialist Winn & Coales (Denso) Ltd have just finished building and furnishing a new training centre in their London head office and factory premises.
The area comprises a highly customised workshop, primarily designed for the application and demonstration of the companys coating and sealing products but which also includes the facility to film the demonstrations. These features are all contained within a controlled environment which is safe for visitors/ spectators and can be used all year round, in any weather. Denso are confident that the creation of this new centre will enable them to fully demonstrate the virtues of their products and systems to customers as well as being a perfect venue to hold regular training sessions for the many applicators / contractors who need to keep abreast of the latestdevelopments in this highly specialised field. Winn & Coales (Denso) Ltd | Tel: 020 8670 7511 e-mail: | web: Caption: Training session at the new Denso Training Centre

Diagnose Problems Early

Before They Even Become An Issue.
Deterioration in machinery health and performance is usually associated with misalignment or imbalance, corrosion and wear, fouling, sediment build-up or poorly lubricated parts.
Detecting these underlying problems early allows you to correct issues before they affect your process, optimising the performance of your plant. With this combination of best-in-class technologies and services helps increase equipment effectiveness, reliability and performance by allowing you to be proactive in your maintenance. With this level of solution you have a comprehensive view of every machine, allowing you to diagnose problems early before they even become an issue. From portable vibration analysis through to continuous online machinery predictive and protection monitoring, RMS can be your single source for optimizing your mechanical assets. Reliability Maintenance Solutions Ltd Web

LOK Link adaptor Connects Modular Safety Interlocks to Enhance Machine Safety
Fortress Interlocks has introduced a new LOK Link adaptor that connects its modular mGard interlocks directly to its new amGard Pro range of LOK and Stop safety gate switch interlocks.
The ability to link the two enhances Fortress mechanical mGard range by adding a safety switch and direct solenoid control option to the mechanical module. This means there are several possible configurations that LOK Link provides that will enhance safety in a variety of heavy duty, industrial applications. LOK Link can connect stainless steel mGard heads to explosion proof locks, facilitate electrical indication of bolt position, connect a head for small radius doors and join mechanical interlocks with monitored exchange boxes and solenoid controlled exchange boxes and bolt locks. Trapped key interlocking is a proven method of safeguarding operators and machinery. By trapping and releasing keys in a pre-determined order, safe working environments can be achieved and only then will access be granted. Fortress mGard range of robust mechanical trapped key products is a completely modular system where individual modules can simply be added or removed depending on the application. The new amGard Pro range builds on the modular, robust design of the existing amGard range but with added features that delivers new control functionality. amGard Pro is designed for heavy duty environments and the LOK Link adaptor provides customers with new configurations to suit their applications. For more information about LOK Link, please visit the company website at or call +44 (0)1902 349 000.

EMS Magazine | February 2013


Seals & Lubrication Feature

Unique Lubrication System Extends Chain Life

It was Leonardo da Vinci who said that simplicity is the ultimate sophistication and, with Interlubes unique chain lubrication system, it seems that the simple ideas really are the best.
The revolutionary Rotalube system significantly extends chain life and reduces maintenance costs which is paramount in todays competitive global market place. Rotalube has a unique porting system that meters lubricant through precision ejectors incorporated within the sprocket assembly. Although simple in principle, the science is complex. The interaction from the chain rotates the sprocket applicator and With applications as diverse as theme park rides, car manufacturing plants and bakery ovens, Rotalube is a precise method of lubricating chain - a patented invention that delivers the right amount of lubricant to the exact point of the chain that enables lubricant to penetrate into the bearing areas. when the ports align within the sprocket body the pressure within the system over comes the back pressure of the ejector nozzles, this results in lubricant delivered onto the link plates of the chain precisely and reliably. From then on the science of capillary action takes over and results in a perfectly lubricated chain that crucially - extends chain life. Comparable drip feed, manual application, brush application and spit/spray systems while better than no lubrication - have varying degrees of success and can struggle to hit the right spot, especially when chain speeds fluctuate. Rotalube is available as standard in four sizes , Rotalubes simple yet precise technology is not affected by speed fluctuation - it simply delivers the right amount of lubricant to the right place every time, lubricating more accurately, efficiently, reliably and reducing lubricant consumption. Interlube has developed a new low cost ACR Designed by people who know chain and concept proven at University of Lancaster, the calibre and pedigree of the engineering team that has taken this product from concept to creation is unequalled pump specifically to operate with standard Rotalube applicators. The 24V DC ACR pump has fully adjustable run and dwell settings and is pre programmed to open and shut a solenoid valve that will allow air to mix with the metered oil output from the pump. 5/8, , & 1 the modular design extends the product offering from simplex to duplex & triplex. Bespoke solutions using Rotalube technology for other sizes are available on request. The Rotalube is a controlled applicator that does not suffer from excessive wear, and maintains accurate lubrication whatever the condition of chain. recently designed and installed two such systems One an oil lubrication system that feeds six Rotalube applicators mounted inside an oven, first cleaning the chains with a constant air supply before the lubrication unit delivers a set amount of oil to each feed.

The second, a Rotalube for chains on a chocolate moulding line. The Rotalube had an additional row of centre nozzles that ensured lubricant was applied to the roller and therefore coating the guides that supports the chains. This application will not only improve the life of the chains but has already shown an 81.5% reduction in cleaning time. Interlubes high quality and reliable products help to keep trucks, buses, trailers, cranes, quarries and heavy-duty production lines moving reliably 24 hours a day, seven days a week. Interlube Systems Ltd has been manufacturing lubrication equipment in the UK since 1922. The company was the subject of a management buyout in 2000 and the US distribution business was bought from Invensys in 2002. MSP Distributors Limited and Filtakleen Manufacturing were acquired in 2007. The company is a world leader in lubrication solutions and, with facilities in Plymouth (UK), Asia, Dayton Ohio (USA), China and Brazil, it offers a global service to its growing customer base.

The system can be used throughout the food, automobile, steel, fiberglass and cement industries. Typical applications that can benefit include food processing machines, industrial dryers, tissue converting factories, waste paper conveyors, truck manufacturing plants, escalators and elevators.

Keith Horner Tel 01752 676000

Interlube offers full technical advice on design and installation for bespoke systems. The company


EMS Magazine | February 2013

EMS Magazine | February 2013


Seals & Lubrication Feature

Using Low Cost Seals Can Be A Long Term False Economy

Production processes utilising hazardous chemicals such as acids and amines, very often at elevated temperatures of 150C or more, occur in a wide range of manufacturing industries including oil and gas, chemical, pharmaceutical and semiconductor.
The combination of corrosive fluids and high temperatures can be particularly destructive for any sealing elements used in valves, pumps and other equipment forming part of a production process and associated pipework. Interruptions to production processes through leaks and breakdowns resulting from seal failures can prove to be very costly, as well as having potential ramifications of causing environmental damage and jeopardising workforce safety. The DuPont Kalrez Spectrum 6380 perfluoroelastomer sealing parts are a non-black product specifically developed for chemical processes involving hot, aggressive amines. In O-ring seals in this material are available from stock in a wide range of both British Standard Imperial and metric sizes from the UK authorised distributor Dichtomatik Ltd. These Kalrez products are unique to DuPont and are only available through recognised and authorised distributors. This ensures addition, this product has an excellent overall chemical resistance and mechanical properties making it suitable for applications involving both static and dynamic sealing requirements. This cream coloured product is a prime choice for sealing operations with harsh aggressive chemicals, and it can withstand a maximum continuous service temperature of 225C, with short-term excursions to higher temperatures also being permissible. that the raw material and all the production and manufacturing processes involved are controlled by DuPont within their own facilities, giving them an extensive bank of knowledge and expertise of the chemistry and raw materials required to maintain product performance for a wide range of difficult and problematic sealing applications. Further information is available from: Dichtomatik Ltd, Telephone: 01332 524401 Fax: 01332 524425 E-mail:

Fragol Releases New Food Grade Lubricants Line Fragol Gmbh+Co. Kg Has Introduced A Comprehensive Portfolio Of High Quality H1 Lubricants.
The products on offer range from compressor and vacuum pump lubricants through hydraulic fluids, gear oils, greases and on to a brand new state of the art chain oil for extreme temperatures.
FRAGOL uses a wide range of available XH1 registered base oils to create products with a performance meeting the highest user demands. All FRAGOL Food Grades are produced in an ISO 21469 facility, registered H1 and are Halal and Kosher certified. FRAGOL intends to introduce lubricants based on new technology base fluids within the year making it one of the most innovative and extensive product portfolios on the market. Visit:


EMS Magazine | February 2013

Seals & Lubrication Feature

Lubricus Modern Lubrication Technology
The Lubricus is a compact lubrication unit for oils and greases.
The lubrication system operates either autonomously with a battery pack or via an external power supply (24VDC). Lubricus is available with 1-4 outlets, to ensure the right medium is available to choose from for every application. The lubrication unit is therefore very flexible and is not only suitable for applications with one lubricating point, but also for multiple lubricating points. Thanks to its compact dimensions the lubricating system can also be very easily retrofitted. Lubricus operates reliably within a temperature range from -20 C to +70 C and pumps the lubricant with a pressure of up to 70 bars. With a capacity of 400cm3, sufficient lubricant is available to reliably supply several lubricating points, even for lengthy periods. Gruetzner GmbH Kohlenhofstr. 60, D 90443 Nuernberg |

ATS Electro-Lube (UK) Ltd Have Added Another Product To Their Well Proven Range Of Self Contained Automatic Lubricators.
The new Jack-Luber is a fully self-contained battery powered lubricator available with either a 125cc or 250cc replaceable grease cartridge.
Grease cartridges can be supplied filled with the specific brand & type of grease type required for the application & can be changed in seconds by the user. As the Jack-Luber is a motor-driven lubricator, it can generate up to 250psi operating pressure, meaning that it can be used with long feed lines or in cases where there is high back pressure at the bearing. Jack-Luber Model 125 & Replacement Cartridge This new addition fills the gap in the ATS ElectroLube product range, fitting between the low pressure (50 psi) Electro-Luber Gas Series and the The Jack-Luber is suitable for indoor or outdoor use and is not affected by changes in temperature. In addition, the Jack-Luber is certified intrinsically safe for use in hazardous areas. The innovative new Jack-Luber incorporates a Jackscrew mechanism which reduces wear & therefore prolongs the operational life of the unit. Once activated, the Jack-Luber runs intermittently to supply grease on the optimum Little and Often principle. Integral switches allow users to set the required feed rate, allowing up to 2 years operation between cartridge/battery change. higher pressure (900 psi) Ultimate-Luber Motor Drive Series.

Detailed information, including demonstration videos for the entire ATS Electro-Lube product range can be found at their new website:

EMS Magazine | February 2013


Seals & Lubrication Feature

Water Mist Generator For Shock Wave Attenuation

Water mist generator designed for protecting people from unauthorized explosions in underground structures, oil platforms and methane explosion in coal mines.
The new generator activates at the command received from a blast detection wireless system. The activated generator produces a tailored water mist with droplet sizes in the range of 25-400 micron that are discharged along selected sections of a tunnel. Above: Water mist generator for vertical dispersal.

The time of activation from the moment of blast is 11 ms, the mist discharge speed is 60-80 m/s, the volume of discharged water mist is 90-100 liters per activated station, and the shock overpressures are decreased by a factor between 1.9 and 2.3. Above: Water mist generator for horizontal dispersal 1 - absorber control block 2 - high pressure camera 3 - water container 4 - nozzles

Center for Infrastructure Protection and Physical Security (CIPPS), University of Florida, 365 Weil Hall, PO Box 116580, Gainesville, FL 326116580, USA (

G. Tsulukidze Mining Institute, 7, Mindeli St., 0186 Tbilisi, Georgia (


EMS Magazine | February 2013

Seals & Lubrication Feature

Sololube Precise Electromechanical Single-Point Lubrication
Sololube is a reliable, easy-to-operate Lubricator with an electromechanical drive.
Its precise delivery system makes Sololube equally suitable for the automatic lubrication of roller and friction bearings, gear racks, open transmissions or chains. Sololube has a robust, very precise drive motor, supplied with voltage by a high-capacity 6V Li battery. The lubricant cartridge - optionally with 150 cm3 or 250cm3 content - is simply screwed to the drive unit. With a delivery pressure of 7.5 bars, the Sololube works automatically, independently of temperature, for up to a year. The performance of the Sololube is monitored with a clearly visible LED. The filling level of the lubricant cartridge is moreover clearly visible at all times through the transparent housing. Gruetzner GmbH Kohlenhofstr. 60, D 90443 Nuernberg | Klber Lubrication customers include producers of components, modules, machines and systems as well as companies using this equipment in their production or process activities. Klber Lubrication manufactures over 2,000 different speciality lubricants, many of them developed and manufactured to specific customer requirements. With highly competent customer consulting and wide-ranging

Innovative Tribological Solutions Are Our Passion

Speciality lubricants are the Klber Lubrication business. Klber Lubrication offer their customers expert tribological solutions by supplying tailormade speciality lubricants directly to customers in almost all branches of industry and regional markets.

Tribology/TechLube (TTL) has originated, specified and produced the highest quality, synthetic and specialty, Food Grade (FG) rated lubricants for over 30 years
Recently, TTL gained added respect in this strictly monitored field by passing a meticulous manufacturing audit by one of the largest and foremost pharmaceutical companies, worldwide.
FG lubes, formulated for the pharmaceutical industry, range from popular multipurpose greases and oils to OEM approved temperature/ pressure lubricants used in complex, high speed tablet presses. Food processing, beverage and many other essential companies utilize these proven, cost saving, FG products in all types of applications, on a daily basis; PTFE fortified bearing greases, long life gear and compressor oils, water resistant greases, and much, much more. Please visit for a comprehensive overview of TTLs highly effective capabilities!

services, our employees have established a reputation for Klber Lubrication as a partner of excellence to all industries and trades. With more than 40 years experience as a leading speciality lubricants supplier, Klber Lubrication GB is looking to continue this. Said Peter Webster, Klber Lubrication GB Managing Director 2012 has been a great year. Celebrating our 40th Anniversary, expansion of our internal staff team and our sales force; sets us up for continuing to move forward; were looking forward to a great 2013. Going into 2013 During 2013, Klber Lubrication are looking forward to further expanding the Klberbio range of biodegradable lubricants. Already delivering great benefits, the Klberbio LR9 range of hydraulic oils are proving of great benefit across many hydraulic applications; including in the environmentally sensitive areas of docks and harbours. Add to this Klberbio LG39-700 our biodegradable lubricant for open drives. White in colour, highly adhesive for long lubricant life and with great low temperature performance, this biodegradable lubricant is also proving its worth as a wire rope lubricant providing excellent long-term lubrication & protection. So, whether in automotive or cement, wood & paper or food & pharmaceuticals, Klber Lubrication continues to be your global specialist. Klber Lubrication GB Ltd Bradford Road, Northowram, Halifax, HX3 7BN Tel: 01422 205115 | Fax: 01422 206073 |

EMS Magazine | February 2013


Pumps & Valves Feature

No Power? No Problem For Rechargeable Drum Pump Motor

The ability to transfer fluids safely and cleanly from drums and barrels even when an electrical or air supply to power a pump is not available, would, in certain applications be a distinct advantage. Thanks to the introduction of a new rechargeable drum pump motor this is now possible.
The S6 12-Volt Lithium Ion Cordless Rechargeable Drum Pump Motor developed by Finish Thompson fits all EF pump tubes, is versatile, economical, extremely portable and available from pumping specialists MICHAEL SMITH ENGINEERS. The cordless design makes it easy to transfer fluids virtually anywhere, with maximum fade-free performance, equivalent to a corded AC powered motor. The latest Lithium ion batteries have a much higher energy density compared to nickel cadmium (NiCd) or nickel metal hydride (NiMH) batteries so the pumps can operate effectively for up to 50 minutes between charges. Also, Lithium ion batteries have no memory effect which means they can be recharged at any state of their discharge. The unit has a solid-state electronic control circuit that monitors all aspects of the motor and battery pack to ensure reliable operation and long-life, while dual cooling fans help to improve the performance and life of the battery pack. Multiple charging options include 115 or 230 volt AC and for mobile applications an automobile or commercial vehicle 12 volt port option will suffice. For permanent charging locations, a moulded wall hanger is available which stores the charger unit internally. The rechargeable motor can be used with any of the Finish Thompson EF Series tube sets polypropylene, pure polypropylene/PVDF and stainless steel while the 2-speed motor ensures smooth and precise dispensing. On the low speed setting, the pump / motor will run for approximately 50 minutes between charges and the high speed setting, it will run for around 20 minutes. Further details are available from: Michael Smith Engineers Ltd, Oaks Road, Woking, Surrey, GU21 6PH, UK. Tel: FREEPHONE 0800 316 7891 Fax: 01483 723110 The S6 Rechargeable Drum Pump Motor will be an ideal option for transferring fluids from drums, barrels and carboys where a power supply is not available, is too distant from the point of pumping, or where fluids need transferring in remote, isolated locations.


EMS Magazine | February 2013

Pumps & Valves Feature

Portable Valve Actuator from Netherlocks Takes the Strain Out of Manual Valve Operation
Power Wrench is ergonomically designed for safe operation and employee comfort
The Netherlocks Power Wrench portable pneumatic valve actuator facilitates operation of manual valves for process industry employees while contributing to safe working conditions. It is capable of opening and closing any size, type or number of manually operated valves, making it a cost effective alternative to multiple actuators. The Power Wrench connects to valves by a bolt-on universal drive plate, allowing a single Power Wrench to operate multiple valves: plates can be installed on all necessary valves, then the operator can simply and quickly attach and use the Power Wrench as and when needed. The drive plates do not interfere with normal manual operation. Air-powered (4-7 bar), it is also safe for use in applications where explosive and/ or flammable liquids or gasses are present. The integrated safety lever and variable throttle valve configuration enforces two-handed operation of the Power Wrench, making sure the operator has full control over the device at all times. The device weighs only 10.2kg and can effect up to 515Nm of torque, meaning even the toughest manual valves can now be turned quickly and easily without unnecessary strain on the operator. An instructional video on the Netherlocks Power Wrench can be viewed at:

SFC Launches New Regulator Packs to Ensure Safe Operation of Valves

EasiDrive is a valve operating system that actuates hardto-operate valves in power plants, chemical processing facilities and oil refineries.
It is ideal for use wherever there are manually operated valves with high operating torques, hundreds of hand-wheel turns to open/close or are just difficult to operate. To ensure the correct amount of torque is set to the EasiDrive system, Smith Flow Control (SFC) has now introduced a series of Filter Regulator Lube (FRL) packs. FRL packs manage the output available to drive the valve, preventing human error that can result in improper use of the system. Mike Fynes, Sales & Marketing Director at Smith Flow Control, comments, This product has been designed to address the issues associated with applying incorrect torque at sites and will ensure the safe operation of the valve. The new packs have been adapted to include storage for the pneumatic gun- this makes it easy to carry the equipment and assemble the system on site. For more information, please visit

Self-Diagnostic Valve Position Monitor

The Type 3738 electronic valve position monitor from SAMSON CONTROLS can be used on on/off valves across a wide range of applications and enables valve position monitors to be configured at the push of a button.
This robust, innovative device is a contactless, magneto resistive sensor system that works with a NAMUR signal in compliance with IEC 60947-5-6 and is powered by a two-wire supply. As a result, the valve position monitor can replace existing solenoid valves and limit switches without the time consuming process of changing wiring or signal levels. At the same time, it includes functions like self-tuning and diagnostics, which opens up a wide range of opportunities for control and asset management. The supply air for the actuator is routed through bores at the bottom of the housing, making additional tubing unnecessary. This makes it suitable for integrated attachment, which facilitates mounting and guarantees exceptional ruggedness. The contactless position sensor makes adjustments as well as moving levers redundant. Further details and literature is available from: John Middleton, Samson Controls, Redhill, Surrey, RH1 5JQ, UK |

Free-flow with Valveforces new Ball Segment Valves

Steam system and flow control specialists Valveforce have launched a new range of high capacity Ball Segment Valves that benefit from a free-flow design that minimises clogging.
Suitable for numerous control applications, the superior properties of this range help provide excellent tightness in closed positions. Compared to other valve designs, these Valveforce Ball Segment Valves allow use of smaller and far more economical valve sizes, offering significant capital cost and ongoing energy savings. The ball segment and shaft are also manufactured in one piece to give a backlash-free torque transmission and even at high dfferential pressures, segmented bars and specially designed trims mean very low noise. In combination with Valveforces pneumatic actuators and positioners the overall result is a highly flexible unit with a very wide control range.

Valveforce will be at Maintec on Stand A1

Web: Email: Tel: 44(0)121 7111 908 Address: Valveforce, Unit 1, Radway Road, Shirley, Solihull B90 4NR, United Kingdom


EMS Magazine | February 2013

Buyers Guide

EMS Magazine | February 2013


Buyers Guide


EMS Magazine | February 2013

Buyers Guide

EMS Magazine | February 2013


Buyers Guide


EMS Magazine | February 2013