You are on page 1of 40

February 2013

|

Issue 10

Halifax Fan Ltd Reports Two Record Years
Page 12

4-6 16-17 30-35

Industry Latest News

Health & Safety

The Hazex/Maintec Show Preview

4-6 16-17 22-23 27 30-35 36

INDUSTRY LATEST NEWS

HEALTH & SAFETY

DUST AND FUME EXTRACTION

ATEX EQUIPMENT

THE HAZEX/MAINTEC SHOW PREVIEW

EXPLOSION PROOF PRODUCTS

Latest Industry News

ABB to highlight emissions technology and know-how at AQE 2013
ABB will be exhibiting its latest range of air and gas analysers at the Air Quality and Emissions (AQE) Show at the Telford International Centre (13-14th March 2013).
Stands 47 and 48 will feature a comprehensive selection of ABB equipment utilising a variety of measurement techniques, including laser, zirconia and FT-IR spectrometry. Products on the stands will include the LS25 laser gas analyser. Enabling in-situ monitoring in stacks, pipes, process chambers and other similar applications, the LS25 uses tuneable diode laser absorption spectroscopy (TDLAS) to measure concentrations of various gases including oxygen and ammonia in gas streams. Offering a very fast response time, the LS25 is especially suited to applications with fast changing conditions such as municipal waste incineration where the composition of gases may be subject to rapid changes. Other equipment on display will be ABB’s new Endura AZ10 zirconia oxygen and StackFlowMaster instruments. For more information, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. ‘AQE 2013’.

Finnish utility says Olkiluoto
3 nuclear plant faces further delays
Finnish utility Teollisuuden Voima Oyj (TVO) said that, based on recent progress reports from the ArevaSiemens consortium constructing the plant, “it is preparing for the possibility that the start of the regular electricity production of Olkiluoto 3 nuclear power plant unit may be postponed until 2016.” Last year it said that it would be delayed beyond 2014.

Rittal Introduce New TS 8 Updates
Based on customer requirements new cost saving innovations and improvements have been implemented into the manufacture of Rittal’s TS 8 enclosures. The following updates will start to take effect from December 2012 onwards. Tool free adjustment of the mounting plate depth; additional markings every 100mm in the vertical sections for positioning of rails; TS 8 punched pattern on the door frame for easier installation of equipment; simple mounting plate earthing from the front to negate the need to remove the rear panel or mounting plate and a low tack baying seal for easier re-adjustment where neccesary. All benefits have been introduced for quick and easy assembly of Rittal’s TS 8 enclosure, which can realise customer savings in both time and costs. For more information follow the link below: http://www.rittal.co.uk/information/TS8UpdateFlyerFINAL.pdf

Construction of Olkiluoto 3 started in May 2005, with completion originally scheduled for 2009. However, the project has suffered several setbacks. TVO announced in December 2011 that it anticipated the 1600 MWe Areva-designed EPR reactor would begin commercial operation in August 2014, some five years later than originally planned.

In July 2012, the company declared that the plant unit “will not be ready for regular electricity production in 2014.” Noting that Areva-Siemens are constructing the plant under a fixed-price turnkey contract and are therefore responsible for the time schedule of the project, it requested the

Eef Comment On Lofstedt Progress Report
Commenting on the report on the progress of the Lofstedt Report recommendations on health & safety, Terry Woolmer, EEF head of Health & Safety Policy, said:
“This report signifies welcome progress on restoring a proportionate and balanced approach to health & safety legislation. However, government must ensure that in the rush to clear the stock of regulations government doesn’t remove measures that business finds helpful. “Furthermore, having made welcome progress at home, the UK government must now lead efforts at EU level to ensure the forthcoming review of health & safety Directives ensures that we only see regulation from Brussels where there is clear evidence it is needed and, whose impact on business has been thoroughly assessed.”

supplier provide an updated schedule and completion date.

TVO’s senior vice president, Jouni Silvennoinen, said in a statement: “We have not yet received an adequate schedule update.” He added, “Additionally, the instrumentation and control (I&C) design has not proceeded as planned, and therefore the plant completion may be further delayed.”

HES December2013 HES February 2012 August 2012

4

5

HES February 2013

Latest Industry News

Coromill 316 Exchangeable-Head Milling System Is Now Available With Internal Coolant
The CoroMill 316 exchangeable-head milling system is a truly versatile system for milling operations. It can be applied for high feed face milling, slot milling, helical interpolation, shoulder milling, profile milling and chamfer milling of components in material groups from ISO P to ISO S.
From March 1st this high performance system is available with internal coolant holes. The machining of such materials as Heat Resistant Super Alloys, Titanium and Stainless Steels often requires the use of coolant for temperature control and chip evacuation during cutting. Re-cutting of chips and chip jamming often lead to poor surface quality, damage to the cutting edge and tool breakage. By offering an internal coolant solution, with precise positioning of coolant holes to optimize the effect of the coolant jet, CoroMill 316 is able to outperform existing solutions with external coolant, guaranteeing superior chip evacuation and a secure cutting process. The CoroMill® 316 system allows machine shops to quickly, easily and accurately switch between various operations such as cutter type, radius variation, teeth frequency, geometry and grade. CoroMill® 316 end mills are even suitable for five axis milling of flanks which often require tapered tools for stability at longer tool reach. For more information and a closer look at the CoroMill 316, visit www.sandvik.coromant.com/productnews

CoroMill 316 exchangeablehead milling system is now available with internal coolant

The CoroMill 316 exchangeable-head milling system is a truly versatile system for milling operations. It can be applied for high feed face milling, slot milling, helical interpolation, shoulder milling, profile milling and chamfer milling of components in material groups from ISO P to ISO S. From March 1st this high performance system is available with internal coolant holes.

Mine Explosion Kills Eighteen In Northern Russia
On February 11 the Russian Interior Ministry said nine people had died and eight more could be trapped under rubble at the Vorkutinskaya coal mine in the northern Komi region after a gas explosion. Later in the day, Interfax said the death toll had increased to 18, with 10 brought to the surface.
The blast, at a mine owned by a division of one of Russia’s largest steel producers, Severstal, was caused by a build-up of methane gas, the Ministry said in a statement. A total of 259 miners were working underground when the explosion took place and the majority have made it back to the surface, according to the Emergencies Ministry, with some accompanied out by rescue workers. Initial reports had said around two dozen miners were working in the shaft where the explosion took place. The mine, in the northern city of Vorkuta, is part of the coal mining division of the Russian steelmaking giant Severstal, whose mills it provides with hard coking coal concentrate. According to AFP it has been operational since 1973 and has an output of 1.8 million tonnes of coal a year, with total coal reserves estimated at 40 million tonnes. Methane gas explosions remain a frequent occurence in the coal mining industry in Russia, despite recent drives to improve safety. In 2010, 68 people were killed in twin methane blasts at Russia’s biggest underground coal mine, the Raspadskaya mine in the Kemerovo region of Siberia.

The machining of such materials as Heat Resistant Super Alloys, Titanium and Stainless Steels often requires the use of coolant for temperature control and chip evacuation during cutting. Re-cutting of chips and chip jamming often lead to poor surface quality, damage to the cutting edge and tool breakage. By offering an internal coolant solution, with precise positioning of coolant holes to optimize the effect of the coolant jet, CoroMill 316 is able to outperform existing solutions with external coolant, guaranteeing superior chip evacuation and a secure cutting process. The CoroMill® 316 system allows machine shops to quickly, easily and accurately switch between various operations such as cutter type, radius variation, teeth frequency, geometry and grade. CoroMill® 316 end mills are even suitable for five axis milling of flanks which often require tapered tools for stability at longer tool reach.

For more information and a closer look at the CoroMill 316, visit www.sandvik.coromant.com/productnews

HES December2013 HES February 2012 August 2012

6

7

HES February 2013

HES December2013 HES February 2012 August 2012

8

Hazardous Area Enclosures

Hazardous Area Certified Enclosures - A Solution For Every Application
Pepperl+Fuchs the world’s leading manufacturer of intrinsically safe explosion protection and electronic sensors acquired UK based Walsall Ltd to increase expertise and capacity in the manufacture of mechanical explosion protection products for use in hazardous areas and harsh environments.
Walsall Ltd had over one hundred years of UK heritage dating back to the early days of Walsall Conduits PLC, which once dominated the world of electromechanical explosion protection. Today, Pepperl+Fuchs UK manufacturing is located in the companies new 60,000 sq ft facility in Wednesbury, just off the M6 J10. A complete range of mechanical explosion protection products and customised solutions are manufactured in the West Midlands for customers throughout the UK, examples of our portfolio are highlighted below:

Exd Customised Enclosure Solutions
Pepperl+Fuchs has a huge amount of knowledge and experience in creating customised Exd enclosure solutions to meet the specific project requirements of our customers. These bespoke solutions allow the hazardous area mounting of a wide range of industrial products which do not have “Ex” approval. Components such as PLC’s, intrinsic safety barriers, starters, and transformers can be mounted in an Exd enclosure which then allows them to be located in a zone 1 certified area. The enclosures are typically manufactured in cast iron, aluminium and stainless steel materials with a wide range of sizes and orientations available. Solutions can also be engineered to customer specific requirements using combinations of the product range. A typical example would be an ASM type Exd enclosure containing industrial equipment close coupled to an FXL type Exe enclosure via a line bush. The Exe enclosure is used to house control functions and terminals therefore allowing for easier installation. make provision for different methods or “types” of protection, two common methods plus a combination of both are as follows:

Increased Safety (Exe)
Increased safety (Exe) protection is based on the premise that an explosion will not occur if a spark cannot occur. Increased safety protection can only be used for equipment that does not include spark or heat producing components in normal service and where “increased safety” measures have been implemented to further reduce these risks. An Exe enclosure need only meet a rating of IP54 to prevent water ingress leading to electrical fault and sparking. A simple example would be a terminal junction box.

Enclosures & Terminal Junction Boxes
Pepperl+Fuchs mechanical explosion protection products are based around high quality enclosures in the increased safety, intrinsic safety and flameproof protection classes. The range provides several different options of enclosure dependant upon the project application and specification required, with a variety of sizes and materials available including stainless and mild steel, as well as glass reinforced polyester (GRP). All products are manufactured to the same exacting levels of quality which Pepperl+Fuchs has been associated with for over 65 years.

Flameproof (Exd)
Many types of industrial equipment such as PLC’s, contactors and MCB’s can be certified using the flameproof concept. The external enclosure of flameproof equipment is designed to withstand an internal explosion. The enclosure joints permit the products of combustion, and the resulting expansion of gases, to be relieved through the joints and not to permit that explosion to transmit through to the external atmosphere. In many instances a combination of both Flameproof and Increased safety in the same solution, rather than an Exd enclosure on its own, can provide reductions in cost, space and weight. Telephone: +44 (0)161 633 6431 Email: sales@gb.pepperl-fuchs.co.uk Group Website: www.pepperl-fuchs.co.uk

Certification
As a global supplier to a wide range of industries and applications, all Pepperl+Fuchs products are certified to a variety of international standards including the latest ATEX and IECEX guidelines. Our products are used in a variety of applications from oil platforms to pharmaceutical plants and everything else in between; therefore we ensure certification allows usage in gas and dust environments as well as a wide range of temperature extremes. The equipment product construction standards

Local Control
Using Pepperl+Fuchs manufactured enclosures, a comprehensive range of multi function local control stations and control panels are also available. Standard and customised local control stations in glass reinforced polyester and stainless steel enclosures are complemented by Exd IIC Local Control Stations utilising cast iron enclosures.

9

HES February 2013

Latest Product News

Detect Heat & Overheat Before There Is Fire Or Explosion
Detect Heat and Overheat (and Fire) and report/alarm from 60 – 385°C
in Engine-rooms, Wind generators, Power Plants, Ovens, Generators, Dryers, Trains, Gas turbines, Heating rooms, Factories, Inventories and many more. Reliable 2- or 4-wire N/O or N/C switches, FM approved, connect to your existing alarm system or take the comprehensive LICO HDL & Stand-Alone or intermitting Alarmpanel HDL to secure life and your values by “in advance monitoring”. LICO Hungaria Kft Raba u. 4 H-2030 Erd, Hungary Tel + 36 23 520 113 Fax + 36 23 520 115 email: office@lico.hu LICO Mecatronic S.R.L. Str.Bucinului Nr.2B / 19 RO-540526 Targu-Mures LICO Electronics GmbH Klederinger Str. 31 A-2320 Kledering Austria Tel + 43 1 706 43 00 Fax + 43 1 706 41 31 email: office@lico.at

Learn more by visiting: www.prevent-a-fire.eu or www.fenwal-direct.eu

Romania Tel. +40 365 807 497 Fax: +40 365 434 999 Email: office@lico.ro

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 Email: sales@cord-ex.com http://www.cordexinstruments.com/ Tel: +44 (0)1642 454373 LaserMETER 3000XP laser distance meter and the UT5000 intrinsically safe ultrasonic thickness gauge. The companys IW Series Intelligent IR Windows with locking mechanism and multiple identification system will also feature.

HES December2013 HES February 2012 August 2012

10

Industrial Fans

Halifax Fan Ltd Reports Two Record Years.
While the global economy is still struggling and major UK high street chains are failing, one Yorkshire based traditional engineering company reports two bumper years.
market was the Far East, particularly China, where power stations and petrochemical plants were being built widely and that to enter that market, we needed a local base. In 2006 we opened a modest manufacturing facility in Shenzhen, just over the border from Hong-Kong and this has grown to span three factory units totalling some 4,000 m2. Crucially, from the outset, we focussed on embedding our UK quality practices in the Chinese plant and invested in staff training to ensure that product quality and reliability is constant regardless of which plant our products are built in.”

The petrochemical and oil industries particularly demand fans built to the highest safety standards and Halifax has developed a particular expertise in this sector, even to the extent of in-house testing and certification to these standards. This has resulted in repeat orders such as the two year contract to supply 50 hazardous area fans per month to a US oil sector company and a single order for Halifax’s biggest ever fan worth almost $1m.

All of this has required a continuous investment in computer based design and manufacturing technology, moving software and communications to the ‘cloud’ and extensive personnel training and most significantly, apprenticeships and graduate sponsorships to overcome the UK shortage of skilled engineers. Plans are in place for further growth globally so this one UK company that has ‘got on its bike’ and found success where other less bold companies have struggled to weather the recession. Halifax Fan Ltd, based in Brighouse enjoyed sales growth of 30% in 2000/11 and followed that up with a record 43% growth over the last twelve months. in China, Hong- Kong, Thailand and Sydney Australia. Managing Director Malcolm Staff, “Fan technology hasn’t changed much over many years but their application is essential in a great many Established in 1965 to serve the local textile industries, Halifax Fan designs and manufactures a wide range of industrial fans and has grown to be a global player with offices and factories industries. We saw the opportunity to strengthen our position simply by making our products more reliable and more efficient, reducing their total cost of ownership. It was also clear that the main growth t:+44 1484 475 123 W: www.halifax-fan.com e: sales@halifax-fan.com For more information on halifax fans, please contact:

HES December2013 HES February 2012 August 2012

12

Thermal Oil

Thermal Fluid Specialist Puts Food-Grade Oil On The Menu
Thermal oil specialist Global Heat Transfer is calling for the food and pharmaceutical industries to ensure they use compliant food-grade (FG) thermal fluids in heat transfer applications.
The company believes that, although the use of FG fluids is a regulatory requirement imposed by several bodies including the FDA and NSF, it is one that many manufacturers are entirely unaware of. transfer systems that require bulk temperatures up to 326°C (620°F), as are used in food processing plants, pharmaceutical operations If there is any possibility that an oil or lubricant could come into contact with food products, a certified FG fluid must be used to safeguard consumer health. Failure to use FG oil in a food application can result in the loss of the manufacturer’s top tier accreditation if the EFSIS (the European Food Safety Inspection Service, part of SAI Global Insurance Ltd.) learn that an inappropriate product is being used. Globaltherm™ FG thermal fluid from Global Heat Transfer is fully H1 certified by the US Food and Drug Administration (FDA). It also holds NSF (National Science Foundation) International HT1 approval. Non toxic, clear in appearance and odourless, FG oil is extremely important in the food processing industry as it is a regulatory requirement and a sound financial investment. FG oil is designed not to contaminate food so, should a minor spillage occur, there would be no need for products to be recalled. Furthermore, Globaltherm™ FG performs better than none FG products in FG applications as it maintains carbon in suspension rather than depositing it and therefore helps to reduce carbon build up. Made from a mixture of pure heat transfer hydrocracked base oils, Globaltherm™ FG thermal fluid has excellent thermal oxidation stability allowing operation at high temperatures for extended periods, which can be extended when the oil is maintained and monitored properly. It is nonhazardous, non-toxic and odourless, which means it requires no special handling and is not considered a controlled substance under United States OSHA (Occupational Safety and Health Administration), Canadian WHMIS (Workplace Hazardous Materials Global Heat Transfer’s FG oil is a high efficiency heat transfer fluid specifically developed for nonpressurised, indirectly heated, liquid phase heat Global Heat Transfer provides a complete solution Information System) or other work place regulations. For further information contact: Andrew Burns or Caroline Law, Global Heat Transfer Ltd., The Global Group of Companies, Cold Meece Estate, Cold Meece, Stone, Staffordshire, ST15 0SP Telephone: +44 (0) 1785 760555 Fax: +44 (0) 1785 760444 www: http://www.globalheattransfer.co.uk e-mail: carolinel@globalgroup.org Twitter: https://twitter.com/G_HeatTransfer for all thermal fluid related issues. It offers 24 hour delivery of premium quality thermal fluids and planned maintenance programmes as well as expert sampling and analysis services. The latter allow the end user to remain compliant with industry regulations and meet their insurance requirements. and other FG applications.

HES December2013 HES February 2012 August 2012

14

Health & Safety

Scott Safety Expands The Protégé Portable Gas Detection Portfolio With The Addition Of The ZM Protégé Single Gas Monitor
Scott Safety announces the introduction of the Protégé ZM Single Gas Monitor – a zero maintenance single gas monitor that is easy to use and delivers high performance in a small, ergonomically designed package.
The Protégé ZM is a zero maintenance solution, meaning no battery charging and no sensor calibration is necessary to operate the monitor. The monitor has a high performance battery which provides two years of operation. In typical conditions, calibration will not be necessary during the operational lifetime. Three single gas models are available including Oxygen, Carbon Monoxide and Hydrogen Sulphide. The Protégé ZM is small, lightweight, ergonomically designed and meets IP67 requirements for ingress protection. “We designed this monitor with ease of use and comfort in mind. The unique “Protégé profile” fits your hand nicely making the monitor comfortable to hold. It’s so lightweight and small, you will forget you’re wearing it while it protects you,” says Mel Gerst, Scott Safety’s Global Product Line Manager for Portable Gas Detection. “The monitor is very simple to use. Just turn it on for the first time, and it does the rest. Using the default settings from the factory there is no need to set up or program the monitor.” The Protégé ZM monitor is supported by a portfolio of accessories including a four-bay test station and IR Connect programmer. The test station supports bumping, calibrating, hibernating and programming of up to four monitors simultaneously, and is available in both portable and table-top versions. The IR Connect allows programming and hibernating of individual monitors. The Protégé ZM features plenty of customisable settings to meet your specific needs. For example, a Hibernate mode is available on the CO and H2S models. The Hibernate mode puts the monitor in a deep sleep for up to one year to extend the operating life beyond two years. Users can customise the alarm set points themselves or order monitors with custom alarm set points programmed by the factory. Users can also set up custom bump and calibration reminders if they desire. The monitor has the option to display continuous gas readings, life remaining or both. The monitor has a three point alarm (audible, visual, and tactile) and data logging capabilities. Mr. Gerst explained, “The Protégé ZM Single Gas Monitor adds to Scott Safety’s 80-year legacy of working with customers to bring innovative solutions to market. Our customers asked us for an easy to use single gas monitor that enabled them to focus on the task at hand instead of maintaining equipment. We are excited to expand the Protégé family of gas detection instruments with the introduction of the Protégé ZM.”

Scott Safety is a premier manufacturer of innovative respiratory and other personal protective equipment and safety devices and offers a broad range of globally certified gas detection solutions including singlegas, multi-gas and fixed gas detection systems. www.scottsafety.com

HES December2013 HES February 2012 August 2012

16

Health & Safety Page Header

Are Your Safeguards As Safe As You Think?
There are machines in the UK fitted with multiple guards which are monitored in one circuit by series connected safety switches; does this sound like one of your machines? Can any of these guards be opened simultaneously? Then read on!
Historically the practise of series-wired safety switches has arisen because it saved money on cabling and safety relays, and because dual channel wiring of the switches met Category 3 of the withdrawn standard EN 954. Category 3 lives on in the replacement standard EN ISO 13849-1 which requires that for Category 3 to apply at least 60% of faults have to be detected in a diagnosis mechanism (DC = low). The ability of a system to detect 60% of dangerous faults can be impacted by a phenomenon known as “fault masking” which can dramatically reduce the Diagnostic Coverage and consequently the Performance Level. If more than one guard can be opened with a frequency of greater than once an hour, or there are more than 4 of them in series, the statistical chance of a fault occurring and being masked is high with the result that Diagnostic Coverage is reduced to less than 60%. According to EN ISO 13849-1 this is equivalent to no DC, and uder these circumstances, the best achievable PL is PL c, or Category 1 in old terms. If your original risk assessment required Category 3 your system is no longer compliant. Possible cures for fault masking include: 1. changing the wiring of existing series-connected switches to individually wired switches (which may be costly in terms of wiring and the need for extra safety relays or extra inputs on safety controllers) 1 Three safety gates are connected in series to an evaluation device. Initially all the safety gates are closed and the relay’s outputs are “on”, i.e. the machine can be operated. 2 On the left-hand safety gate, a short circuit occurs in the line to the switch with the N/C contact. At first the fault is not detected (because a demand has not yet been placed upon the safety function) and the machine can continue operating (because the guard is still closed). 3 The left-hand safety gate is then opened, an event which the left switch signals to the relay. During feasibility comparison of the two switches the safety relay discovers an inconsistency and switches to a fault condition, i.e. once the safety gate is closed the machine cannot be restarted (but in this case the safety gate is left open). 4 Now the right-hand safety gate is also opened. Via these signals the relay once again detects a normal condition. The fault condition is reset, the safety gates can once again be closed from left to right and the machine is ready to start up again. This example illustrates an undetected fault in the safety circuit, which has built up as a result of the clearing of the fault by the simultaneous opening of two gates. An additional, subsequent fault could cause the whole interlocked guard system to fail to danger. In the current standard EN ISO 13849-1, the maximum diagnostic coverage (DC) that the switch can achieve is restricted, depending on the masking probability. In practice, a single switch pair that is evaluated by a safety relay can achieve 3. Replacement of volt-free contact based switches with RFID-coded, selfmonitoring switches (such as Pilz PSENcode switches, PSENslock solenoid interlocks. PSENini inductive sensors or PSENsgate gate access devices) which can be wired in series and maintain 99% Diagnostic Coverage individually, with PL e integrity E-stops in series? It is worthy of note that series connection of Emergency stop devices is unlikely to incur a loss of Diagnostic Coverage, because it’s unlikely that any two E-stops will be actuated simultaneously or as frequently as once an hour. Therefore it is reasonable to wire such devices in series. Conclusion: Designers of safety guards and associated circuits on new machines, and those responsible for existent machines in use should review whatever safety guard circuits they have where safety switches are connected in series. There are solutions, as outlined above. For a more detailed version of this article, please visit the Machinery Safety Alliance website - www.machinery-safety-alliance.co.uk. Alternatively, please email marketing@pilz.co.uk, telephone 01536 460766 or visit www.pilz.co.uk. 2. the zoning of guard monitoring switches into distributed I/O systems (such as Pilz Decentralised Periphery PDP67 systems) a DC = 99%. In the current draft of EN ISO 14119 (which will soon replace the current interlocking standard EN 1088), the maximum DC for a group of interlinked switches is dependent upon the number of switches connected in series and their frequency of operation. As you can see in the proposed table below, masking restricts the maximum achievable DC and PL.

17

HES February 2013

Flow Meters

GE’s PanaFlow HT is World’s First SIL-Rated Ultrasonic Flow Meter
HT means that refinery operators can now enjoy

Allows Users to Benefit from Ultrasonic Technology in Safety-Critical Applications

the comprehensive benefits of ultrasonic flow metering in pipelines from 3 in to 16 in (80 to 400 mm) diameter as standard, with special meters available up to 36 in (900 mm). Typical applications include vacuum distillation units, delayed coker units, visbreakers, crude distillation units and fluidic catalytic cracking units.

About GE Oil & Gas

GE Oil & Gas is a world leader in advanced technologies and services with 37,000 employees in more than 100 countries supporting customers across the industry—from extraction to transportation to end use. Making the environment, health and safety, quality and integrity our highest Billerica, MA, USA, 4 February 2013. PanaFlow HT from GE Measurement & Control is the first ultrasonic flow meter for liquids, which has been engineered to meet Safety Integrity Level (SIL) accreditation to allow its operation in a Safety Instrumented System (SIF). This has involved extensive third party testing and certification of every component of the flow meter, from transducers to meter body. As a result, the benefits of ultrasonic flow meters can now be enjoyed in a wide range of safety-critical applications throughout the oil and gas sector, while greatly mitigating risks to personnel, plant, process and the environment. Ultrasonic flow meters already enjoy wide application throughout the oil and gas industry, providing reliable and accurate flow measurement. They have no obstructions which might clog or restrict material flow, they operate without a pressure drop and have no moving parts so that they feature minimum drift, requiring no periodic “Third party SIL accreditation specifies the safety integrity requirements needed by a product for it to be o part of a Safety Instrumented System,” explains Thomas Michalowski, global product manager at GE. “Such a system will control a safety-critical function. For example, a flow meter can measure the flow into a vacuum distillation unit and then act to activate a valve if the flow is too low, acting as process monitor.” To date, safety-critical flow metering in refineries has been carried out typically by wedge meters and orifice plates, with SIL-certified pressure transmitters. The introduction of the PanaFlow calibration. Furthermore, ultrasonic flow meters can measure flow in both directions while, with patented Bundle Waveguide Technology (BWT) transducers, the PanaFlow HT can operate at high and low extremes of temperature. Measurement & Control T +44 1925 604095 M +44 7720557346 F +44 1925604096 GE Oil & Gas The new PanaFlow HT is the first ultrasonic flow meter to meet SIL accreditation and is also ATEX and ICEX certified for operation from -200°C to +600°C, which greatly extends the application of ultrasonic flow metering throughout the refineries sector. priorities is The Way We Work. Our technologies and services include: surface and subsea drilling and production, monitoring and diagnostics, measurement and controls, large-scale LNG, pipeline compression and inspection, well site and industrial power generation, technologies for the refining and petrochemical industries, and modular CNG and LNG units for transportation sectors. Through our customized service solutions, training programs and technologies, GE Oil & Gas partners with customers to maximize their efficiency, productivity and equipment reliability; develop their next generation workforce; and fully benefit from the megatrends of natural gas, the growth of subsea and hard-to-reach reserves and the revolution in asset health management.

19

HES February 2013

Atex Equipment

Rugged ATEX Computers and Battery Packs
safety requirements. Our batteries are used in

Steatite, through its divisions Steatite Rugged Systems & Steatite Batteries has a long history of supplying equipment intended for use in potentially explosive atmospheres.
Steatite supplies Rugged Mobile Computers and high-temperature lithium battery packs into the Oil & Gas sector, which when required to be used in potentially explosive atmospheres, have to meet certain testing standards including; V100-Ex 2, which is the only ATEX certified laptop to come as standard with intrinsically an safe serial port, providing a means of wired connection to instrumentation and other field devices within Zone 2 hazardous areas. The V100 Ex 2 also includes Bluetooth and WiFi and is also the only zone 2 • ATEX (ATmosphères EXplosibles) Directive 94/9/EC • • UL1604 Certification Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) hazardous area approved laptop to come with GPS and intrinsically safe 3G option. Steatite Batteries has a long history of specializing in lithium battery packs for use in harsh and hazardous environments. By working with the world leading cell suppliers we are able to design One such mobile computing solution is the Getac battery packs designed to meet with ATEX and

downhole, subsea, environmental measurement and monitoring devices. Following the acquisition of RZ Pressure in 2008, Steatite has continued to grow and establish itself as the premier European supplier of battery power solutions for the energy market. Steatite designs and builds battery packs to perform in some of the world’s harshest and most dangerous environments and is regarded by service companies and equipment manufacturers as the largest proven supplier of battery packs for the EMEA region, offering safe and reliable solutions with dependable design and assembly. Steatite provides lithium cells and battery packs that deliver dependable power on demand, extremely high reliability and peak performance. Major oil services companies and OEM’s rely on Steatite to recommend the right battery and portable power solution. • Battery packs for Down Hole drilling, Exploration and Critical Monitoring • • Custom Engineered Battery Packs High temperature lithium battery packs up to 200° C • Wide range of battery packs that are UN approved for transportation • Worldwide channel partner for Electrochem cells Steatite offers a wide range of products to suit a diverse range of portable and fixed industrial applications. The latest products aimed at explosive atmospheric environments will be showcased at Ocean Business 2013 (9th-11th April, Southampton) and Offshore Europe 2013 (3rd – 6th September , Aberdeen).

Steatite Limited Ravensbank Business Park, Acanthus Road, Redditch, Worcestershire B98 9EX Email: sales@steatite.co.uk Tel: +44(0)1527 512400 Fax: +44(0)1527 512419 Web: www.steatite.co.uk

21

HES February 2013

Fume Extraction

Fume Extraction System Shortlisted For Bauma Innovation Award
Volvo Construction Equipment’s extractor for bituminous fumes has been shortlisted for a bauma Innovation Award. The innovative design improves the operator environment on the company’s ABG pavers by substantially reducing fumes without significantly increasing fuel consumption, noise or affecting visibility into the auger channel.
Volvo Construction Equipment’s (Volvo CE’s) revolutionary extractor for bituminous fumes is one of three finalists in the machinery component category of the bauma Innovation Awards. The system, which is available as an option on Volvo CE’s C-Series ABG pavers, introduces a new way of removing fumes from the operator’s working environment. The innovative feature improves the working conditions of the operator – who sits directly above the auger channel. By delivering 83% efficiency, the system exceeds the National Institute for Occupational Safety and Health (NIOSH) guidelines which state that 80% of fumes should be captured. Volvo’s results have been independently certified by an environmental institute. Volvo’s design is located at the back of the machine and features a very short distance between the intake and the fan – eliminating the need for additional piping and funnelling in the auger channel. This increases efficiency, prevents any loss of power and ensures that there is no effect on the operator’s visibility into the auger channel. Because extra power is not needed, smaller fans are used. These can be installed horizontally instead of vertically which offers a smaller, more compact architecture. This also helps to maintain visibility into the auger channel which is vital to ensure consistent material flow and good quality, smooth paving. it does when the machine is working in max power mode. working environment is significantly cleaner than was previously the case.”

As well as increased efficiency and visibility, another benefit of the Volvo design is reduced noise. The difference in sound between the system being on or off is insignificant – just 0.3 decibels. This means that there is no risk of the system distracting the operator or causing fatigue.

Paving the way
Although there is currently no legislation insisting pavers meet the NIOSH 80% guideline, the Volvo system has been designed to meet demands from customers and operators in certain markets. Due to the modular design of the Volvo system, it can be retrofitted to machines already in the field.

Behind the breakthrough Innovative and efficient
“The pioneering system works by using a fume intake, with a fan located directly behind it, on both the left and right hand side of the auger channel,” explains Anders P. Larsson, executive vice president of Volvo CE’s Technology function. “The fan captures and transports the fumes via two tubes to the top of the paver where they are then released. This means that the air in the operator’s During the majority of operating conditions, Volvo’s ABG pavers run on smart power which lowers the engine rpm and considerably reduces fuel consumption. The new fume extraction system continues this environmentally friendly and fuel efficient approach and works just as efficiently when the machine is operated in smart power mode as

“We are thrilled to be a finalist in these prestigious awards which honor forward-looking developments and outstanding innovations,” says Anders. “This nomination is a credit to our hard working employees who are helping Volvo CE to deliver world class innovations. Achievements like this are only possible thanks to great teamwork. With more than 180 years of innovation behind us, we are proud of the company’s pioneering spirit and will continue the Volvo tradition of being innovative leaders in the construction industry.”

HES December2013 HES February 2012 August 2012

22

Hazardous Area Equipment

Portable Hand Lamp For Zone 1 And 2 Hazardous Areas
Cooper Crouse-Hindshas launched a new explosion protected hand lamp certified for use in ATEX Zone 1 and Zone 2 hazardous areas.
The new HE 9 Basic Ex-Hand Lamp is well suited for inspection, maintenance, control, and repair work that needs to be carried out in potentially explosive atmospheres, including industrial chemicals, petrochemicals, and pharmaceutical plants, as well as in other potentially explosive atmospheres such as rescue services, sewerage, and water treatment plants. The HE 9 Basic hand lamp is certified to the European ATEX Directive 94/9/EC for use in explosive gas atmospheres in Zones 1 and 2, in The HE 9 Basic hand lamp is the successor to our existing HE 8 range of hand lamps, which have been used in hazardous areas for many years, said Klaus Weyer, product line Manager at COOPER Crouse-Hinds GmbH. The HE 9 Basic replaces all accordance with the latest IECEx standards. The lamp uses environmentally friendly, rechargeable, high-tech Lithium-ion batteries (3.75V / 4.8 Ah), which provide up to five hours battery life. These lightweight, high energy density batteries make Visit www.crouse-hinds.com. For information on Eaton visit: www.Eaton.com. three previous HE 8 hand lamps, but is technically similar to the HE 8 EURO PLUS hand lamp. We are currently planning to introduce an HE 9 Premium version that incorporates LED technology and an emergency lighting function. handling easier, but also eliminate memory effects, which ensures a reliable power supply to the lamp. A protective circuit and electronics guarantee protection against deep discharge and overcharging of the Li-lo batteries. The HE 9 can be recharged by using a separate, compact, plug-in charger unit.

Intrinsically Safe (Ex I) Direct Acting Solenoid Valves For Use In Harsh Environments
ASCO Numatics has introduced two intrinsically safe solenoid valves with Ex ia IIC T6 certification.
The solenoid operators are designed for use on the 327 range of direct operated solenoid valves and are available in epoxy coated aluminium or stainless steel. The solenoids are certified to ATEX, Category 1G/2D and Equipment Protection Level (EPL) Ga/Db. Both operators are IECEx approved and certified to IEC 61508 Functional Safety (SIL 3 capable). The 327 series solenoid valves feature a brass, stainless steel or aluminium (NAMUR) body. These The polarity insensitive solenoid operators have a power consumption of only 0.5W at 24V DC and feature a newly developed electronic booster coil and stainless steel core for optimum performance. Available with either an epoxy coated aluminium or The solenoid valves are suitable for use in ambient valves have a large flow rate (Kv 0.45 m³/h), operate from 0 to 10 bar and require no minimum operating pressure. Web: www.asconumatics.eu For more information please visit: 316L stainless steel enclosure rated to IP66 and IP67. The operator can be rotated 360° and locked into position to select the best position for cable entry. Electrical connection is via a cable gland (M20x1.5) or cable connection 1/2” NPT and easy access screw terminals. temperatures from -40°C to 60°C, and are rated to ll 1/2G Ex ia IIC T6 Ga / II 2D Ex tb lllC T85°C IP66/67 Db, Certification: ATEX and IECEx EN 60079-0, EN 60079-11, 60079-31, EN 61241-0 and EN 61241-11.

HES December2013 HES February 2012 August 2012

24

Atex Valves

Burkert Supplies Atex Devices For Fuelmatic System
Burkert Fluid Control Systems is providing a complete package of Atex-rated valves, flow sensors, level switches, positioner systems and conductivity and flowmeters for Green Fuels’ Fuelmatic system.
Designed to produce up to 20,000 litres per day of high-quality biodiesel, the fully automated Fuelmatic is skid mounted to facilitate shipping and installation. In addition to finding a company with the required products, Green Fuels also required the supplier to UK-based Green Fuels designs and manufactures a range of low-cost processing equipment that produces biodiesel for small-scale, domestic usage, right up to commercial production levels. Burkert offers a range of Atex products and The advanced technology integrated into Green Fuels’ systems enables customers to produce their own high-quality biodiesel inexpensively and safely for use as a sustainable road transport fuel. The fully automated Fuelmatic is controlled by a PLC that interfaces with Burkert’s 8640 pneumatic The Fuelmatic system is suitable for the mediumscale commercial production of biodiesel. valve islands. These units are built to specific requirements and save space by providing for the actuation of up to 24 valves on compact modular backplanes. The Type 8640 provides users with a combination of pilot-valve input/output (I/O) modules and fieldbus communications for the control of process valves. can provide consultancy, system design and manufacture and installations and testing. provide technical support to assist in the integration of the Atex equipment into the redesigned Fuelmatic. However, all the products had to be Atex-approved EeX lA devices, powered via safety barriers.

We offer global experience you can rely on. Bürkert is an adaptable organisation with flexible processes. We are continually committed to achieving success, both for our customers and ourselves. Consistent and continuous investment in research & development and in staff training enables us to offer our customers the very best in technology and services. For any request or goal you might have for your fluid process control, Bürkert can be relied upon; working together with you, we’ll find the best solution, both from a technical and an economical point of view. As Bürkert has grown, sales activities abroad have expanded, supported by an increasing number of subsidiaries in key industrialised countries. Our global presence enables us to focus on the most topical problems in specific markets, whilst offering our customers the most efficient solutions in their country.

Designed to produce up to 20,000 litres a day, the Fuelmatic offers key advantages in that, as a skidmounted unit, it can be transported to the source of the feedstock material from which biodiesel is produced.

This is said to compare favourably with larger fixed biodiesel plants, where feedstock has to be transported to a central location - a process that is costly and, in view of the emissions from the many trucks required to transport the feedstock, nonecological.

On the redesigned Fuelmatic, the 8640 system provides the actuation of Burkert pneumatic angle seat, globe and diaphragm valves, all with Type 1062 electric feedback switches, and the Type 2712 modulating globe valve with an Atex electropneumatic positioner.

In its redesign of the Fuelmatic, Green Fuels stipulated working with a single source for the supply of all valves, sensors, flowmeters and positioners.

Completing the package are Atex-approved flow and displacement sensors, a vibrating level switch, positive displacement flowmeters and a conductivity transmitter.

25

HES February 2013

Atex Equipment

NORD DRIVESYSTEMS’ UK Geared Motor Same Day Assembly Service Expanded For ATEX Gas And Dust Up To 18.5 kW
NORD DRIVESYSTEMS has expanded its fast assembly service for ATEX geared motors to include Gas Zone 1 & 2 and Dust Zone 21 & 22 for nominal motor power ratings up to 18.5 kW. Consolidating NORD as one of the leading ATEX drive suppliers in the UK, the geared motors are available with a wide selection of options for standard delivery within 3-days or, for very urgent requirements, a same day assembly and despatch service.
The 94/9/EC compliant range options include temperature class to T4 (135ºC) and both nonconductive and conductive dusts. The ATEX classification 2G/Zone 1 geared motors available from the UK assembly service suit IEC frame ATEX rated motors in both standard and IE2 high efficiency classes, for frame sizes 80 through 180. Geared units include a broad selection of foot and B14 or B5 face mount versions with a wide choice of motor mounting positions. With torque output from 32 to 3200 Nm, options include synthetic and food grade oils, Viton seals and backstops. Motor options include a wide choice of voltages, thermistors, IP66 sealing, encoders and auxiliary fans. NORD SK 200E decentralized frequency inverters are also suitable in ATEX classification 3D/Zone 22 in IP55 & IP66 enclosures, available with output ratings up to 22 kW. Web: http://www.nord.com For technical information, please contact Andrew Stephenson at: NORD GEAR LTD. (U.K.) 11 Barton Lane Abingdon Science Park, Abingdon OX14 3NB Oxfordshire United Kingdom Tel: +44 (0)1235-534404 E: Andrew.Stephenson@nord.com NORD also supplies a complete programme of geared motors for more demanding ATEX Category 2D and 3G/Zone 2 applications that are available with quick turnaround from its German manufacturing facilities. Covering EX d & de pressurised encapsulation, EX e increased safety and EX n non sparking motors, a wide range of options are available including pressure resistant encapsulated motors, motor brakes, special voltages, reinforced gear unit bearings, and many more. Users interested in the complete NORD ATEX range can download or request the G1001 catalogue for gas atmospheres or the G1022 catalogue for dust atmospheres from www.nord. com or email info@nord-uk.com. In addition to the fast turnaround service for Category 2 ATEX geared motors, NORD DRIVESYSTEMS also offers a rapid assembly service across its full range of NORDBLOC.1 and UNICASE geared motors from its Abingdon facility including helical bevel and helical worm designs spanning output torque from 90 Nm to 3200 Nm.

27

HES February 2013

Wind Turbines

Manufacturer Gears Up For Record-Breaking Turbine
the existing gearboxes in wind turbines and found

Offshore wind turbines have been getting bigger and better since the first wind farm was installed in Denmark in 1991. Nowadays, the general rule is the bigger the wind turbine the more energy it can produce, reports Sam Shead.

some alarming statistics. ‘Offshore wind turbines are designed to survive for more than 25 years. But we found that there was a very high rate of interventions related to gearbox issues between six and 10 years,’ said Farquhar.

“Our estimates tell us that the market for gearbox repair was $150m last year. By 2020 that will grow to $2bn” Farquhar went on to establish a business unit of David Brown that specifically looked at postwarranty inspection work, which helped the firm to identify a lot of common gearbox failure issues.

‘We saw that because of the very variable and poorly understood loads that the winds drive into these gearboxes, there are a lot of misalignment effects in the forces going through the gearboxes and therefore a lot of bearing failures and gear tooth failures,’ he explained.

The costs of repetitive gearbox failures are enough to plunge wind-energy companies into spiralling financial difficulties. ‘One manufacturer quoted to me the cost of an insurance claim for one written-off With this in mind, South Korean company Samsung Heavy Industries (SHI) is developing a 7MW offshore wind turbine that promises to be the most powerful of its kind when it’s demonstrated towards the end of 2012. The firm plans to test the new generation of wind turbines at Fife Energy Park off the east coast of Scotland before taking orders to build them at its European facility in Methil, Scotland. Farquhar explained that David Brown works in an environment where in the design and production of In order to help SHI achieve its goal, David Brown, a company that is perhaps best known for having its initials on the back of several Aston Martin models, will be delivering an innovative new gear system that will be able to generate three to five per cent more energy than existing gearboxes. But how exactly did David Brown end up in the wind-energy market? Scottish entrepreneur, Jim McCull, bought the 152-year-old Huddersfieldbased gears company back from the US after it had This increase in energy output could be key to energy companies that are deciding which gearbox to go with in an age when government is desperately trying to bring down offshore wind’s cost of energy from £150 per megawatt hour to David Brown began assessing the performance of a 10-year-spell at Textron. The £368m sale went through in November 2008 and the company is now targeting new and developing markets. a gearbox, the cost or consequence of failure, in relation to a wind turbine, is extremely high. Ian Farquhar, managing director of wind energy at David Brown, said: ‘We’ve probably got in David Brown the most comprehensive gear-making capability in the world.’ £100 per megawatt hour by 2020. gearbox can be up to $500,000,’ said Farquhar. ‘Our estimates tell us that the global market for gearbox repair was maybe $150m last year. We believe that by 2020 that market will have grown beyond $2bn.’

David Brown spotted the gap in the market for more reliable gearboxes and launched a service and repair business to mend broken gearboxes. This enabled it to gain additional valuable experience on the trends and failure modes of existing equipment, which it used to provide a series of upgrades to existing turbines, for companies such as Vesta, one of the world’s oldest and largest wind-turbine companies.

But as you may have guessed by now, in addition to repairing gearboxes it is also manufacturing customised gearboxes for new customers, such as Samsung Heavy Industries. ‘Having seen all of these different design models, common failure

HES December2013 HES February 2012 August 2012

28

Wind Turbines

modes, and having an understanding for some of the challenges that exist offshore, we can design a specific application for a customer,’ said Farquhar. ‘We’re very much like the Saville Row of gearboxes in that we will design something specific to the customer.’ Building a gearbox for the world’s most powerful wind turbines Farquhar explained that one of the key criteria for wind turbine gearboxes is that they are as light as possible.

revolving about a central or ‘sun’ gear. The planet gears will be mounted onto a movable arm or carrier and provide a link to the outer annulus gear, which will have a diameter of approximately 3m. David Brown claims the system will offer a combination of high power density, efficiency and structural integrity.

£100m assembly facility in Scotland for 500 people. David Brown has an agreement with Samsung that it will set up an assembly facility in the same location if Samsung goes ahead with this plan.

On a more immediate note, David Brown is planning to expand its Yorkshire facilities in order to meet the demands of the new partnership with SHI.

“Our motivation is not purely about maximising the selling price. We’re taking a whole-life cost view” Two new buildings that are being built in Mirfield will include a gearbox research and innovation

Heavy gearboxes require stronger tower structures and present greater transportation and erection issues. Approximately 20 per cent of the mass of a wind turbine is associated with the gearbox, the largest single contributor after the blades.

The gearbox will initially cost somewhere between £500,000 and £900,000 but the company hopes to reduce this over time.

centre, as well as a gear-manufacturing centre of excellence. Farquhar said this one project could increase the current size of the company by three to four times.

Farquhar said: ‘Our motivation is not necessarily purely about maximising the initial selling price. David Brown is seeking to draw on its gear history to solve a relatively contemporary issue. The company is looking to make a significant difference to the wind energy market and its new gearboxes could help to reduce the price of wind energy, making this renewable source a far more attractive

The compact, low-weight gearbox that has been designed for SHI will still weigh between 50-90 tonnes but Farquhar claimed it is 10 to 15 per cent lighter than any competitor product on the market.

We’re taking a whole-life cost view. The way in which we’re working with our customers means we are all motivated to try and make continuous improvements.’

The gearbox is a multi-stage epicyclic (planetary) unit, which means it has several outer gears

Samsung has elected and signed a memorandum with Methil and Fife Council to potentially set up a

option.

29

HES February 2013

Hazex/Maintec Show Preview

MAINTEC 2013 – PACKED WITH LAUNCHES & LEARNING
MAINTEC, the leading exhibition for the UK’s 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.
in their diary.” So let’s take a closer look at what’s on offer at MAINTEC 2013.

says: “We’d urge all our members to put the dates

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 maintenance’s 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, Brand new for this year is the complimentary Business Strategy Conference. There’s 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 UK’s 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, 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 show’s 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, ERIKS, Idhammar Systems, SPM Instruments, PRUFTECHNIK and Prevost UK. These free learning opportunities will run alongside an exhibition packed full of exhibitors, many of whom, like CorDEX Instruments, are using the show to globally launch new products. Institution of Diagnostic Engineers, and drawing on case studies, John Davenport, Operations Director, Alcon and Paul Dennis, Technical Facilities Manager, Experian will explore successful maintenance strategies, how to choose the right one for your business and the merits of total productive maintenance versus a reliability-centred maintenance approach.

There is much debate within the profession about

HES December2013 HES February 2012 August 2012

30

Hazex/Maintec Show Preview

which is better – control maintenance or a reactive maintenance operation. Mark Thompson, Head of Wastewater Assets, Southern Water will explore the merits of each. Drawing on his own experience he will look at how you decide which one is the right strategy for your company. He will then explore the idea of whether there is a third way – that involves a mix of asset management systems and reactive self monitoring devices.

Dr Sethuraman Muthuraman, Condition Monitoring Engineer, Scottish & Southern Energy. He will even have some suggestions for those daunted by condition-based monitoring, outlining the occasions

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 media’s 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.

when reactive or preventative measures may suffice. and asset managers, engineers and maintenance professionals save money, improve efficiencies and enhance asset care.

Many wonder whether formal standards really add value to an organisation. This day will be your chance to find out as in his talk Daniel Pairon, Global Head KPMG Asset Management will outline the core standards in asset management and how PAS 55 / ISO 5500x certification might actually empower your company.

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

A panel discussion featuring David Smallbone, Head Asset Management, AMCL closes day two.

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

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

In a lively session the cost of asset failure versus the cost of condition monitoring will be debated.

‘People, processes and legacy’ sit at the heart of good maintenance management and day three focuses on these elements. Keynote speaker, Wayne Curry, Engineering Team Leader, Britvic will outline how the company manages the impact of new processes and KPI reports on maintenance staff. In a highly practical talk he will also cover the usability and access issues you face when rolling out new devices and equipment to a mobile work-force. This people focused day closes with Ian Rigby, Engineering Manager, Pepsico, who will look forward to 2017. Ian will predict what shape, dynamics and focus the maintenance team will have by then.

analysed, strategies to reduce energy usage can emerge.

Managers of Energy from Waste (EfW) plants will be interested in the talk by Robin Buller, Director of Business Development at KRR ProStream. “Using smart technology to maintain these specialist systems can result in more efficient outputs,” explains Robin Buller. He will be focusing on three cleaning technologies, in particular, for boilers, bag house filters and heat exchangers. KRR ProStream specialises in power generation facilities and this talk will give delegates the opportunity to discuss specific efficiency issues with industry experts.

Condition based maintenance offers many economic benefits, as Stan Jackson, Managing

The Maintenance Exchange
Complementing the Conference will be The Maintenance Exchange, featuring 38 free-to-attend learnShops, designed to help plant

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

HES December2013 HES February 2012 August 2012

32

Hazex/Maintec Show Preview

savings provided a sound case to change all four existing dryers.

Thermal Energy International will show how a FLUACE Condensing Heat Recovery System which it implemented for Premier Foods saved the company £110,000 per year, which is approximately 7.5 million kWh of annual gas savings.

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

Those in the food or drink sector should also check out CRC Industries UK’s new StopLight™ Food is implemented to complement maintenance excellence and the benefits to a business when asset care is carried out. He explains: “The increased awareness and machinery-based knowledge of production operators will ensure that any machinery failures or malfunctions are detected at an early stage, so that planned actions can be implemented.” Andy Parkinson, Business Development Manager from James Walker will speak about improving efficiency and costs by reducing maintenance downtime, while Ian Pledger, IAM Product Specialist from Schaeffler will discuss the implementation of an efficient asset management system using plant condition monitoring. Dr Trevor Holroyd, Technical For those who have a health and safety agenda, Sira Test and Certification Ltd will hold a seminar on the world’s first international scheme for the certification of personnel associated with equipment, installations and servicing used by Ex industries, known as IECEx. Marketing Manager at Ernst Schad, Ram Greenshpon will explain how to keep your good old gearbox in service at a fair cost, whilst Reliability Any uncertainty of hazards associated with static electricity will be clarified by Mike O’Brien, 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 O’Brien. “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. Maintenance Solutions will be speak about improving reliability by correcting the ‘big four’: balancing, shaft/belt alignment, looseness and resonance. Flowcrete will hold a seminar about how to get more from your floor. Director at Parker Kitti Wake Holroyd, will speak about the application of acoustic emission to detect ineffective lubrication in operating machinery. Maintaining reliable RH measurements in harsh or corrosive environments is notoriously difficult as the 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 company’s spot facing tool, which has been re-engineered to extend its operating life even further. from C-Cubed. Safety Programme. Developed specifically for MRO chemicals, it’s a leap forward in the control of chemical product movements.

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

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

HES December2013 HES February 2012 August 2012

34

Hazex/Maintec Show Preview

troubleshoot problems quickly and efficiently.

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

Dust extraction specialists, Dustcontrol UK, will showcase their latest centralised dust vacuum system - the DC 11 Module. By reducing noise to 65 dB(A), the DC 11 Module is easier to fit in a building where noise is a challenge. wide range of engineering disciplines.

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 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. 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 Ocip Energy will outline how a recent project to install new LED fittings at Fletcher Moorland’s site is on target to save the company 70% of its lighting costs. James Walker has successfully tested Supagraf® Premier, a premium fugitive emissions valve packing, to ISO 15848-1 2006 Class A at 690bar. 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. Recently launched, Agility 4.1 from SoftSols is the latest version of its Agility Computerised Maintenance Management System and builds 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 Hayley Group’s 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. on the introduction of dashboards and key performance indicators in earlier releases. 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. management software. Newson Gale is showcasing its Bond-Rite® static earthing clamps plus its Earth-Rite series of hazardous area static grounding systems. Also in this area R.STAHL is introducing IS1+ a key innovation for the company’s already leading explosion-protected remote I/O system IS1. maintenance planning, audit compliance and greater control over budgets and stock. HAZEX Successfully launched last year, the HAZEX area brings the UK’s top hazard prevention experts and innovations under one roof. For instance in a world first, CorDEX Instruments, the UK manufacturer of instrumentation and equipment for hazardous environments, is introducing its new TC 7000 intrinsically safe thermal imaging camera at HAZEX.

And the Winner is…
The winners of the first ever MAINTEC Maintenance Professional Awards will also be announced live from the show floor. There are two categories: ‘Maintenance Professional of the Year’ and, in support of newer entrants to the industry, ‘Maintenance Apprentice of the Year.’

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 MAINTEC is free to attend and preregistration is advised to avoid queues on the day. Register visit www.easyfairs.com/ maintecuk.

35

HES February 2013

Signals & Alarms

PATLITE Explosion-Proof Products
values the signal towers because they are highly

PATLITE presents a new series of signaling devices, which have been especially designed for rough environments and explosive atmospheres.
Besides explosion-proof and maintenance-free LED signal towers of the EDLM and EDWM series, which achieve ATEX guideline 94/9 EC and are suitable for zone 1 and 2, Patlite also offers visual, audible and hybrid products which are suitable for zone 2 and 22. food industries. The terminal block of the EDLM and EDWM models is found at the back and provides easy access to the signal tower. The signal towers are suited for flush mount, wall mount and horizontal mount. The EDLM type comes with patented prism facet LED modules in the colours red, yellow and green. The EDWM type is available with 5 LED modules in red, yellow, green, blue and transparent. The Japanese Tokuyama group is planning to install a fair quantity of EDWM signal towers at its polycrystalline silicon production plant in Malaysia. “Besides providing safety for our co-workers and machines, the explosion-proof LED signal towers model EDWM-502 helps us to improve quality control and productivity”, explains a company spokesman from Tokuyama. The company

dependable, maintenance-free and offer a long lasting serving life.

Energy-efficient LED lights
The series AR-070 and AR-078 are signal towers with up to five LED modules and a diameter of 40 or 60 mm. The signal lights are resistant against gas or dust explosions and are approved for zone 2 and 22. The energy-efficient LED modules with a PATLITE patented prism cut provide full and brilliant illumination. Vertical and horizontal cut lenses in combination with a double-reflection system enhance the diffusion of the LED illumination. The LED modules – available in the colours transparent, yellow, red, blue and green - as well as the main body are made of strong synthetic materials. They withstand even high pressure and heat as well as damage caused by acid or bases. The signal towers reach IP65 protection. That allows installation even in damp or dusty environments. The AR-078 and AR-070 series signal towers can be either flush or wall mounted and are available with one to five LED modules. They can also be ordered with a flashing/non-flashing function and / or two super-loud alarm sounds with an 85dB (at 1 m) output. The type with alarm sound reaches protection IP54.

Safely encased
The innovative, explosion-proof signal towers EDLM (3 coloured LED modules) and EDWM (5 coloured LED modules) come with a high-strength main body made of aluminium alloy. Thanks to their pressure- and flame-proof housing they reach protection IP66. They have been designed for use in potentially explosive atmospheres in environments such as (petro-) chemical industries, handling with combustible dusts, production of gas and even in

Large product spectrum
Explosion-proof products that are suitable for Zone 2 and 22 also include the hybrid type LKEHFE/ EXN and LKEHFV/EXN, the signal horns EWH24/ EXN and PVW04JF/EXN as well as the LED working lights of the CLA series and the bar lights CLF2024/ EXN and CLT3024/EXN. All explosion-proof PATLITE signaling devices comply with the standard CE/ATEX/NEC certificates.

Learn more at www.patlite.com.

HES December2013 HES February 2012 August 2012

36

Buyers Guide

Buyers Guide

HES February 2013

38