Vol 21 Issue 4 incorporating

July/August 2021
maintenance
&assetmanagement
Encouraging the pursuit of
excellence in Asset Management,
Engineering, Maintenance and journal
Manufacturing

MAINTENANCE & ENGINEERING

PLANT & MAINTENANCE

Five reasons why Point of Care Oil

Analysis makes sense now
Thermal imaging and industrial
maintenance best practices

MAINTENANCE & ASSET

MANAGEMENT JOURNAL
Continuous improvement leading to
energy consumption reduction

SITE, BUILDINGS, ENERGY

& WORKS MANAGEMENT

Preparing for Stage V compliance Why is Predictive

Scotland’s new non-destructive
testing training school
Maintenance so hard? p4
 
 
  

 
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 MAINTENANCE & ENGINEERING

July/August 2021
Vol 21 Issue 4 Contents
Editor 03 / COMMENT
Nick Barrett Editor Nick Barrett predicts a renewed focus on maintenance at fulfilment centres
nick@maintenanceandengineering.com
following a series of crashing robot related fires
Business Development Manager
Colin Campbell 04 / COVER STORY
colin@maintenanceandengineering.com Why is Predictive Maintenance so hard?
Commercial Director
Fawad Minhas
06 / NEWS
fawad@maintenanceandengineering.com Manufacturing to stage dramatic post-pandemic recovery
Account Manager
Kirsty Barrett
kirsty@maintenanceandengineering.com PLANT & MAINTENANCE
Production Manager
Andrew Pilcher 8 / ROUNDTABLE
andrew@maintenanceandengineering.com
Hovering around zero
Advertising Assistant
Alastair Lloyd 10 / CONDITION MONITORING
alastair@maintenanceandengineering.com Ongoing condition monitoring of large HV rotating machines delivers
Editorial Advisory Board financial and operational benefits
Graham Cooper, founder and principal consultant,
Systems Excellence 12 / OEE
Roy Davis, director, MPI (Manufacturing Measuring Maintenance Effectiveness
Productivity Improvements)
Prof. John Ahmet Erkoyuncu, 14 / LUBRICATION
Professor of Digital Engineering Five reasons why Point of Care Oil Analysis makes sense now
Head of the Centre for Digital Engineering and
Manufacturing, Cranfield University 16 / EXHIBITION
Dr Peter Geake Asset Performance 4.0 Conference and Exhibition goes Hybrid!
Steve Johnson, vice president digital, EPS, Petrofac
Dennis McCarthy, director, DAK Consulting 18 / PLANNED MAINTENANCE
John Saysell, director of technical training,
Extending the value of your maintenance software -
MCP Consulting Group
Georgia Smart, asset management leader, UKAEA Meter Based Maintenance and Virtual Stores
Printing 20 / PUMPS
Warners Midland plc
Maintenance reduced and H&S improved with new water mixers
Annual subscription
to all overseas destinations £99.00 22 / THERMAL IMAGING
Copyright Thermal imaging and industrial maintenance best practices
© Barrett Byrd Associates 2021

MAINTENANCE & ASSET MANAGEMENT

Barrett Byrd C
COON F ER
NFE RE NCE
ENCE 25 / Continuous improvement leading to energy
communication
Associates consumption reduction
Maintenance & Engineering
is published by IBE Conferences Ltd,
t/a Conference Communication, SITE, BUILDINGS, ENERGY & WORKS MANAGEMENT
a Barrett Byrd Associates company.

7 Linden Close,
30 / EMISSIONS MONITORING
Tunbridge Wells, Preparing for Stage V compliance
Kent
TN4 8HH 31 / STEAM
The evolution of steam and, what does ‘good’ steam look like?
Tel 01892 553143
E info@maintenanceandengineering.com 32 / TRAINING
W www.maintenanceandengineering.com Scotland’s new non-destructive testing training school

ISSN 1748 5290

FOCUS ON COMPRESSORS & COMPRESSED AIR

Audited Circulation
Jan-Dec 2020 34 / Pure and simple air quality with oil-free compressor
9,552 technology
35 / Variable Speed Drives: energy efficiency guaranteed
@MaintOnLine

Articles appearing in this magazine do not neccessarily

express the views of the Editor or the publishers. Every 38 / SPECIALIST SERVICES DIRECTORY
effort is made to ensure the accuracy of the information
published. No legal responsibility will be accepted by
the publishers for loss arising from articles/information
40 / INDEX OF ADVERTISERS
contained and published. All rights reserved. No part of
this publication may be reproduced or stored in a retrieval
system or transmitted in any form without the written
consent of the publishers.
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 COMMENT

It’s no joke...
Things usually run extremely well apparently, but a
similar fire destroyed Ocado’s automated warehouse at
Andover in 2019 and robot related incidents have been
reported at warehouses owned by fashion retailer Asos
in the UK and Germany. The latest fire was held in check
Nick Barrett, Editor better than the 2019 incident because of fire attenuation
nick@maintenanceandengineering.com measures that have reportedly been strengthened across
@MaintOnLine fulfilment centres since 2019. Little is being heard about
what improvements in robot operation might make

T
Ocado’s fulfilment
centre in Erith, Kent
Bankography / Shutterstock.com
hree robots bumped into each other in a
fulfilment centre – it might sound like the start
of a joke, but it isn’t – causing a £110 million fire
at what is held to be one of the UK’s most sophisticated
and largest automated warehouses. The fire at the Erith,
Kent, fulfilment centre operated in joint venture by Marks
& Spencer and Ocado, took 100 firefighters with five fire
engines some 14 hours to get under control. The incident
in July took the facility, that can process some 150,000
orders a week for home deliveries, out of action for the
best part of a week.
Ocado’s ‘Hive’ system is a highly impressive operation
normally, with over 1,000 robots whizzing around a
grid, stopping to pick up crates of food that are delivered
to areas where human packers assemble items for
delivery to people’s homes. Technology to replace human
involvement in the packing activities is being developed.
a difference, but doubtlessly software and hardware
specialists in the field are hard at work and artificial
intelligence modified algorithms will provide solutions.
All new technologies or new applications of
established technology suffer teething troubles and
the use of robots is no exception. But these incidents
can have an important knock on effect on investor
confidence. Venture capitalists and other investors
have poured millions of pounds and dollars into online
grocery delivery technology and they will be nervous, and
perhaps reluctant to make new funding commitments
until they are sure the crashing robots issue is resolved.
Expect a renewed focus on maintenance and other
technical support activities as fulfilment centre operators
and others using robots do all they can to ensure their
reputation does not get further tarnished.
The benefits of a benign outlook on a company’s
operations from the investment world has also been felt
at a diverse range of specialist engineering and other
technology companies of the sort that you read about
in every issue of M&E. Companies like Spirax Sarco,
Halma, Renishaw and Rotork typify the sort of specialist
engineers that have become stock market favourites
recently. Spirax Sarco’s share price for example is up
about 75% since the start of the Covid-19 pandemic,
despite having grown very strongly for three years prior
to that.
Companies recognised as technological leaders have

always enjoyed a premium over mainstream rivals, but

it has grown to around 50% from the traditional 10% to
20%. Stockmarket contrarians are already calling time on
the boom as share valuations are looking a bit stretched,
and against that background incidents calling into
question the safety of robotics could be enough to sway
sentiment.

…but here comes the punchline

A
strong manufacturing sector means a strong focus on
maintenance and asset management, hence the interest in
the above matters from this magazine. We will bring news of
improved robots and anything else that helps make manufacturing or
processing industries work better whenever we can.
These leading specialists may have been riding a wave of long structural
drivers in their key markets, but the outlook is now clouded by recent
news that China aims to develop 10,000 ‘little giants’ targeting the sort
of export markets that the above mentioned specialists have been so
successful in.
China wants to plug gaps that it sees in its advanced manufacturing
capabilities so will focus more on building homegrown ‘hidden
champions’ - small and medium-sized enterprises (SMEs) in niche
advanced manufacturing sectors. China aims to have these little giants up
and running by 2025, part of a new policy emphasis in the14th Five Year
Plan period of 2021-2025.
Along with that they aim to have 1,000 enterprises that will be
champions in single industries. Other leading companies will form groups
to cooperate to become globally competitive leaders in their fields.
Six government ministries have issued guidelines to underpin all of this,
in what sounds like a fairly robust industrial strategy, a comprehensive
blueprint for an industrial future and a roadmap of how to get there.
Which, as Make UK has pointed out, is the very thing that the UK is now
moving away from. It will be interesting to see which approach fares best.

ME / July/August 2021 / 3
 COVER STORY

Why is
Predictive
Maintenance
so hard?

Predictive maintenance (PdM) is a proactive approach to addressing machine failures before they become
a problem. By analyzing huge volumes of machine data, PdM allows maintenance staff to understand the
health of machines and optimize their activities accordingly to prevent unplanned downtime and eliminate
sudden failures. But, despite its obvious benefits, successful PdM deployments are often hard to achieve.
Alexander Hill Chief Global Strategist of Senseye looks at the rise of PdM, and why so many vendors - and
their customers - continue to get it wrong.

Predictive maintenance - then and now
Predictive maintenance has been around for a lot longer than
you might think. During the Second World War, scientist CH
Waddington observed that a plane’s rate of failure or repair tended
to be at its highest immediately after an inspection or maintenance
session.
Known as the “Waddington effect”, this phenomenon resulted
in the adjustment of maintenance processes to correspond with
a plane’s physical condition and the frequency of its use, with
adjusted inspection cycles based on analysis of the resulting data.
In short, it was the beginning of PdM.
A lot has changed since then, of course. The advent of the
Industrial IoT / Industry 4.0 has seen technological breakthroughs
occurring at a such a rate that they’re “disrupting almost every
industry in every country”.
These breakthroughs have led to significant improvements in
sensor, network, data acquisition, and storage technologies which,
along with the access to a wealth of computing power and data
made available by recent advances in AI technology, have seen PdM
become increasingly applicable to wider industry.
Today, just as it was almost 80 years ago, the key benefit of
PdM remains its capacity to inform decisions. Responsible for
overseeing many machines across one or more sites, maintenance
professionals are extremely busy people. By providing them with
a better understanding of the ongoing health of their machines, a
PdM solution can help them to make better use of the limited time
and resources available to them.
So, given its heritage and the clear advantages it offers,
why has it been so hard for so many to achieve success
in PdM?
others have applied conventional data science approaches to a
problem space that is far from conventional.
Without the necessary understanding of exactly what a PdM
system is, and just how it works, many new solutions won’t even
make it to the marketplace. As a result, few businesses will achieve
any real success at scale.
Ultimately, much of this lack of understanding - and subsequent
PdM success - comes down to three fundamental mistakes that
vendors and their customers will often make time and time again.
1. As we’ve seen, the concept of PdM is nothing new. Techniques
such as condition monitoring, maintenance credits, and
prognostics have been in existence for some time now. But a lack
of ability to scale these techniques beyond just critical machines
has meant their deployment has been largely limited to just
critical machines.
2. PdM is not, as some believe, a Big Data problem in which there
are millions of data points and labels on which to train models.
A factory environment is highly dynamic and noisy, with a
range of variables including machine maintenance, different
production speeds, and even behavior of different machine
operators. And, of course, every machine is unique. Despite this,
however, many organizations will still take a classic data science
approach to PdM.
3. It’s important to remember just how busy maintenance
professionals are. If a PdM system’s user experience doesn’t
reflect this, there’s a risk that it won’t engage with its target
users. All the valuable information and insight it generates will
be ignored, and an organization’s investment in the system itself
will be wasted.

Three common mistakes Further reading

The truth is, many vendors have jumped
aboard the PdM bandwagon despite
having little appreciation of what is,
essentially, a very unique domain.
Some have simply tried to ‘super-
charge’ legacy monitoring tools, while
Download our white paper Why is Predictive Maintenance so hard? to
discover how Senseye can help you succeed at PdM with scale.
https://hubs.ly/H0RdHBm0
Senseye
+44 (0)845 838 8615 | Hello@senseye.io | www.senseye.io

4 / July/Aug 2021 / ME
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 PLANT & MAINTENANCE / NEWS

Resilient and agile manufacturing

rebounds from Covid damage
M
anufacturing will rebound to pre pandemic levels of months earlier than expected.
production by the end of 2022, predicts Make UK in its The survey, published jointly with business advisers BDO, says
latest annual Regional Manufacturing Outlook survey. the manufacturing industry across the UK has endured extreme
The four quarters surveyed were typified by two quarters of volatility, with the best and worst ever balance figures in the 30
struggle against the background of the Covid-19 pandemic, one year history of the survey being seen in the space of only five
quarter when there was a transition to recovery and a final quarter quarters. Most regions and nations in the UK report an increase in
that saw ‘explosive improvements in manufacturing performance’. their average business confidence compared to last year.
Analysis of manufacturing performance from the start of Q3 The survey reveals some ‘standout performances’ by regions
2020 shows the ‘brutal impact’ of the pandemic on the sector with even though there was only one positive quarter in the research
approximately £18bn output in value lost between 2019 and 2020.  period. The West Midlands has been the top performer at
However, Make UK has upgraded its manufacturing growth maintaining output levels on average in the second half of the
forecast for 2021 from +3.9% pandemic, posting a positive balance of 12%. The East Midlands
to +7.8%, so manufacturing posted the only double-digit balance figure for investment, and
should recover all lost output also improved its investment outlook the most of any region
by the end of 2022, six to nine compared to last year’s survey.
REGIONAL OUTLOOK***
In a joint foreword Make UK Chief Executive Stephen
Scotland
2020: 5.6 Phipson and BDO Head of Manufacturing Richard Austin praise
2021: 4.5
manufacturers for their response to the pandemic. They say:
“The industry remained switched on and kept the gears turning.
Automotive manufacturers switched production processes
REGIONAL OUTLOOK***
to produce PPE; chemical product manufacturers ramped up
North 2020: 6.0
Northern East
2021: 6.3 production of hand sanitisers and cleaning materials; and the
Ireland**
pharmaceuticals industry delivered an effective vaccine at a pace
REGIONAL OUTLOOK***
North
2020: 3.9* West REGIONAL OUTLOOK***

REGIONAL OUTLOOK*** Yorkshire 2020: 5.7 that’s never been achieved before. As difficult as the crisis has
previous two quarters & Humber
2020: 6.1 2021: 6.1
been it has shown how resilient and agile UK manufacturers are.”
2021: 6.2 REGIONAL OUTLOOK***

2020: 5.7 Make UK says the most recent indicators for 2021 show the
2021: 6.6
manufacturing sector has renewed optimism as the sector
REGIONAL OUTLOOK***

2020: 5.9 East

Midlands REGIONAL OUTLOOK***

2021: 6.4
2020: 6.1 bounces back with output rising to record levels, with heightened
West
REGIONAL OUTLOOK***
Midlands East of
England
2021: 5.7 levels of employment and investment intentions rising, partially
2020: 5.9
2021: 6.7 Wales boosted by the Government’s super-deduction scheme.
REGIONAL OUTLOOK*** However, when viewed over a twelve-month period the growth
REGIONAL OUTLOOK*** South East 2020: 6.3 achieved in early 2021 is not necessarily enough to recover losses
and London 2021: 6.4
2020: 6.2
South West incurred during the second half of 2020. Many regions on balance
2021: 6.0
still reported overall contractions, where on average the declines
in industry outweighed its gains within the measured period.
Some locations, like the East of England, South East & London,
Difference in Business Confidence Indicator*: compared to one year ago
KEY South West and Scotland, reported average balances that Make
n Positive relative change in confidence (upper quartile)
n UK says leave room for only cautious optimism. Only one region,
n the North West has produced average positive balances across
n Negative relative change in confidence (lower quartile)

* Business Confidence Indicator: Manufacturer’s confidence about their own business performance in the next twelve months
the board, whereas all other regions or nations have reported an
** Northern Ireland excluded from comparison due to missing data
*** Map coloured to show the relative change in average confidence between 2019q3/2020q2 and 2020q3/2021q2 overall contraction on at least one metric.

Exporters turn away from EU

T
he Make UK - BDO survey also reveals that uncertainty caused by leaving the EU was UK, said: “It’s clear that even before our final
Britain’s manufacturers were seeing their beginning to be felt even before the actual departure from the EU that political uncertainty
dependence on the EU as an export market departure and the signing of the trade deal at the was hitting exports to the bloc. While
decline even before the impact of full departure end of 2020. opportunities are opening up elsewhere the EU
and the agreement of a trade deal. The most recent quarterly trade data shows will remain our biggest trading partner through
The survey shows that in 2020 five English exports to the EU in Q1 were still 16% below sheer fact of geography. 
regions together with Wales saw their percentage Q1 2019 which Make UK says backs anecdotal Mr Phipson said it is vital that Government
of exports going to the EU fall, in two regions evidence that many companies were already works with business and the EU to smooth out
the share stayed the same and only the West choosing not to supply the EU or, that EU critical issues such as customs procedures.
Midlands and Scotland saw exports to the EU customers were turning away from UK based “Otherwise there is a risk that the drop in exports
increase. companies. to the bloc we have seen over the last couple of
Make UK says this shows that the political Stephen Phipson, Chief Executive of Make years will become structural and permanent.”

6 / July/August 2021 / ME
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 PLANT & MAINTENANCE / ROUNDTABLE
Hovering
around zero
Awareness of the government’s net zero target and how industry should
respond remains at a low level. The M&E Editorial Advisory Board discussed
how levels of engagement could be raised. David Fowler reports
T
he government has committed the UK
to cutting emissions by 78% from 1990
levels by 2035 on the way to net zero by
2050. The start of the 26th UN Climate Change
Conference, COP26, in Glasgow is less than
three months away.
The prospect of trying to reduce emissions
while they are still struggling with the
disruption of Covid-19 is daunting for many
firms, especially smaller manufacturers.
Recently Make UK highlighted examples of
companies that had achieved “incredible”
results, often in quite simple ways (M&E, May/
June). But, said chief operating officer Ben
Fletcher, the biggest challenge was to get across
the urgency of acting now.
‘I would say that for 90-95%
of SMEs energy efficiency
is not on their agenda, to
the extent that most didn’t
even know what they were
spending on electricity.’
Graham Cooper,
Systems Excellence
The M&E Editorial Advisory Board discussed
this question at its most recent meeting, in
particular focusing on levels of awareness of
the net zero target in the maintenance and
engineering community, as well as examples of
progress and best practice.
8 / July/August 2021 / ME
Graham Cooper, founder and principal
consultant of Systems Excellence, was formerly
operations director for an Agfa plant in
Leeds, and led a worldwide project to spread
sustainable practices. He said: “In Agfa, we
were highly aware of the net zero goal, but we
used to host best practice visits to our site of
SMEs, and I would say that for 90-95% of SMEs
energy efficiency is not on their agenda, to the
extent that most didn’t even know what they
were spending on electricity, let alone have a
target. They considered it a fixed cost. Bigger
companies generally will have more of a grip on
it, but I think for smaller companies, it doesn’t
appear on their radar.”
Georgia Smart, UK Atomic Energy Authority
asset management leader, said: “I think that
large organisations are certainly aware, but I
don’t think it’s trickled down to where it can
have an impact.” Companies’ boards might talk
about net zero, and produce glossy documents
on sustainability, but little was being done to
raise awareness among people on the front line.
John Saysell, MCP Consulting Group director
of technical training, referred to a list published
in February by Carbon Index of companies
which had set a target to achieve net zero by a
given date. But, apart from exceptions such as
AstraZeneca, Lucozade Ribena Suntory, Nestlé
and Spirax-Sarco, there were few examples on
the list of blue-chip manufacturing firms.
DAK Consulting director Dennis McCarthy
said that was his experience too, with a few
notable exceptions. He mentioned an engineer
at Arla Foods, “who was absolutely keen on the
amount of power a particular pump was using
and had done lots of experimentation in his
spare time”. And an associate had worked in
Brazil with organisations focused on driving
environmental improvement. “But I think
there’s potential there for engagement on the
front line that isn’t used,” he concluded.
In general positive examples of companies
making progress appeared thin on the ground.
Mr Cooper said: “There’s a passive
improvement going on because there’s more and
more renewables going into the grid, so if people
‘There is a direct correlation
between energy use and
OEE.’
Dennis McCarthy,
DAK Consulting
were tracking their CO2 emissions they would
see a downward trend without doing anything.
But there’s still a residual amount that needs
doing.” He added that one “excellent” example
was Crystal Doors in Rochdale, whose owner
and managing director Richard Hagan was “an
evangelist” for the environment. The company

GLF Media / Shutterstock.com
is on course to be carbon neutral by next year,
and it has won numerous awards for sustainable
manufacturing including a Queen’s Award for
Enterprise: Sustainable Development last year.
“We’ve got to make heroes of people like that, to
get other people to recognise it,” said Mr Cooper.
Mr McCarthy made the point that there is
“a direct correlation between energy use and
OEE”. At a plant in Belgium, GE had given the
maintenance manager responsibility for energy
costs, and by improving maintenance, energy
use had been reduced. BP in the North Sea
had found that “just by setting equipment up
correctly it used less power”.
Ms Smart said: “Part of it is to be able to
measure your what your energy use is so you can
demonstrate if you’re using a lot and then put
some targets against it.” But net zero needed to
become part of the business culture in the same
way as safety.
“We need to make it an energy culture,
where people know and feel engaged in the
whole thing. At the moment people see it as a
lofty ideal,” she said. Employees needed to be
given some sort of incentive or recognition for
bringing forward suggestions of how to save
energy.
Mr Saysell said that in electrical maintenance
more companies were expressing interest in
power factor and how they could reduce it in
order to cut overall electricity consumption, or
‘I think one aspect of net
zero is to stop looking at it
in terms of a money cost
and look at what is the cost
in environmental or energy
terms.’
Georgia Smart,
UK Atomic Energy Authority
the efficiency savings made possible by
changing from using a motor direct online and
adding an inverter, soft start or other more
efficient method of drive. Mr Cooper thought
there was a wider issue concerning electric
motors, which are estimated to account for 60
to 80% of industrial energy use. “People don’t
understand how much of it is waste. So many
motors out in the field now (a) are old and
inefficient but (b) they’re oversized.”
Traditionally a designer might calculate that
a 20kW motor was adequate for a particular
application, but might specify a 25kW item to
be on the safe side. The design might then be
reviewed by someone more senior, who might
increase it to 30kW.
“You end up with a twice-sized motor,
running at 50% load so it’ll be running at about
80% efficiency. If you right-sized that and put
in the latest IE4 high efficiency motor, you’d
probably pay back in energy savings in under 12
months,” he said.
Mr Saysell argued that benchmarking
tools used by industry to assess performance,
and standards such as ISO 55000 for asset
management, were all based on optimising
costs, such as the overall cost per tonne of
production or OEE. These had a bearing on
environmental impact but were not directly
related to it.
Ms Smart said that for the next update of
the standard, the committee was seeking to
address this point, “to recognise that it’s not just
money cost, and to talk about sustainability,
not just environmental sustainability but all
the UN sustainability goals.” It would be useful
to have environmental measures not related to
monetary cost.
“The argument is always that sustainability,
or whatever, makes good business sense, but
the truth is we run away with trying to turn
everything into a physical cost, and sometimes
that forces the cost of something else out.
“I think one aspect of net zero is to stop
looking at it in terms of a money cost and look
at what is the cost in environmental or energy
terms.” It would then be possible to consider the
two types of indicators side by side and come to
a more balanced assessment.
Mr Cooper said that the standard on energy
consumption, ISO 50001, is based on reducing
energy consumption, not cost. He had used the
standard as a vehicle to help replicate energy
saving measures from the Leeds plant in Agfa
plants worldwide. Senior management issued
a directive that all plants must be accredited
to the standard. “That enabled me to get the
local people on the ground interested in energy,
because from on high they had ‘you must
get 50001’, and the only way you get 50001
is knowing where all your energy goes.” He
suspected that the same standard might be used
by the government as a means to push more
companies towards net zero.
Mr McCarthy asked if there was a role for
training. “What should be done at the front line
level to raise awareness of what’s possible and
maybe focus specifically on the importance of
future environmental costs, rather than purely
the lowest cost in the short term? How difficult
would it be to tweak front line engineering
training to incorporate the idea of net zero as
being a desirable target?”
Mr Saysell said he could see two possibilities
for incorporating net zero – in reliability courses
alongside concepts such as mean time between
‘The idea of Net Zero has
got to be driven up from the
shop floor and down from
management.’
John Saysell,
MCP Consulting Group
failures, or in electrical courses where you might
be teaching technicians about power factor and
the use of inverters, over specification and so on.
“But with the maintenance technicians I’m
not sure how much influence they’d have on
specifying the equipment to start with. I don’t
know whether you’d be at too low a level with
the technicians – whether the training would
need to target the engineering managers and
more senior people, those doing the reliability
aspects.” He concluded: “I think it’s multifaceted
– it’s got to be driven up from the shop floor and
down from management.”
Summarising, Mr McCarthy said it seemed
that there was a lack of understanding or
awareness of the net zero goal – there may be
talk about it at senior level in larger companies,
but for smaller businesses, something
that needed to be done to raise awareness.
Recognising and publicising role models – for
example in industry magazines such as M&E –
would be one way to help achieve this.
There was a need to change attitudes
and develop a ‘sustainability culture’, and
incorporate the concepts in existing training
courses could play a role in this.
And there was a need for benchmarking
measures or diagnostics for measuring carbon
footprint and environmental effects which were
not based purely on monetary cost.
As Make UK pointed out, immediate action
is needed if the 2035 target is to be met. And, as
this discussion concluded, there remains much
to do.
ME / July/August 2021 / 9
 PLANT & MAINTENANCE / CONDITION MONITORING
Ongoing condition
monitoring of large
HV rotating machines
delivers financial and
operational benefits
Improving reliability whilst reducing maintenance
costs is the ultimate goal. Seoras Shaw, Product
Manager at Quartzteq, part of the Quartzelec
Group, explains why Lifeview® condition
monitoring is increasingly being adopted by
owners of large rotating machines to measure
parameters relating to insulation failure.
T
he global power chain is dependent on large high voltage
rotating electrical machines for mission-critical tasks which
when purchased new, cost hundreds of thousands of pounds.
Often expected to have ‘arduous’ lives, they are designed to deliver
many decades of reliable service across industry and infrastructure;
generating electricity, driving production lines, for utilities and
transport applications or mining and extraction and in hazardous
environments. The problem is that they start to deteriorate from day
one and if left untreated significant failures can occur.
All high voltage motors and generators are susceptible to
vibration, torque, thermal cycling, corrosion, and critically partial
discharge. Visual inspections and scheduled maintenance help
identify issues but are intrusive and with numerous large ‘aging’
motors in everyday use a more scientific approach is needed.  Quartzelec Group boasts over 100 years of experience in rotating
Quartzteq’s Lifeview® condition monitoring solution, ostensibly
developed around partial discharge analysis, is a flexible, modular,
and proven approach to evaluating the health of HV rotating
electrical assets. Offering both online and offline monitoring
options, assorted sensors and modules – to measure partial
discharge, tan delta, rotor flux or shaft voltage and current – can be
attached as part of an outage or permanently installed on rotating
assets to capture data and create a detailed analysis of the insulation
condition of each machine.   insulation issue, and when combined with an ongoing maintenance
Partial discharge
Damage
Partial Discharge is a localised high frequency discharge which
caused
by partial occurs when the electrical field of the equipment breaches the
discharge breakdown strength of the insulating material or gaseous insulation
voids and can excessively further
weaken and damage any insulating
material. It is difficult to identify
using traditional testing methods, the
damage is progressive, and it can result
in catastrophic failure if not detected
and effective action taken. Significant
stator earth damage often results in
weeks of downtime and major repair
expenditure anywhere between £400k
to millions.   a significant failure of a critical rotating machine that could have
 Following the development of
the partial discharge element of
the Lifeview® range, rotor flux and
shaft voltage/current measurement
10 / July/August 2021 / ME
capabilities were added to the online monitoring equipment range,
allowing users to determine bearing and rotor inter-turn insulation
condition during operation. 
Offline systems are typically used during regular maintenance
programmes and can detect issues during an outage, but constant
online monitoring is being increasingly implemented due to there
being no interruption to production.  
Data interpretation
With data being collected over time, careful analysis can determine
the exact insulation condition of a machine, with the most recent
data being compared to established baselines.  
 Professional interpretation of the data is also vital, and the
machine design and fault analysis from an OEM perspective. Reports
and recommendations from the experienced team of specialist
engineers help make informed maintenance decisions thus
preventing costly breakdowns whilst optimising machine lifespan.  
The financial return
The cost of implementing a Lifeview® condition monitoring solution
is minimal when comparing the potential costs of an undiagnosed
programme offers real value for money – particularly when data
analysis could prevent a critical failure, avert expensive repair bills
and potentially many months of lost productivity. Due to these
production saving benefits, insurance companies are increasingly
taking a real interest in the advantages that ongoing monitoring
delivers and where detailed machine performance data is available,
the reward can subsequently be significantly reduced premiums.
This means that the ‘payback time’ is often relatively short.  
The future
Around the globe owner/operators are increasingly discovering
the real benefits to be made by implementing online monitoring
alongside ancillary and critical plant maintenance. This achieves
an informed and cost-effective maintenance strategy that allows
them to focus on driving the business forward removing the risk of
serious implications to operators and business stakeholders.
www.quartzelec.com | t: 44 (0) 1788 512512
jody.townsend@quartzelec.com / seoras.shaw@quartzelec.com
 PLANT & MAINTENANCE / ADVERTORIAL
ROTRONIC ATEX Humidity/Moisture
& Temperature Sensors
Rotronic is a leading Swiss manufacturer
of precision Intrinsically Safe sensors and
measurement transmitters with selectable
analogue outputs, suitable for use
wherever there is a risk of explosion due
to dust or gas in the environment. They
were developed for the pharmaceutical,
biotechnology, grain & sugar, petrochemical,
and oil & gas industries.
C
onforming to the latest international standards,
the Intrinsically Safe (secondary side) HygroFlex5-EX
transmitters have two-channel 4-20 mA outputs. For many
installations there is no need for an Intrinsically Safe power supply,
dedicated clean earth or Zener barrier. Interchangeable probes
are available for all applications, including a screw-in probe for
pressure environments and a low dewpoint probe.
Significant features:
• Stainless steel probes certified for operation in Zone 0/20
• Standard and cable mount probes, screw-in probe for
applications at pressure
• HygroFlex5-EX measurement transmitter certified for Zone 1/21
• Intrinsically Safe secondary side
• Wall and duct mount transmitter versions available
• 2-wire power supply, two scalable analogue outputs
• Dewpoint, mixing ratio (g/kg) and other moisture values
available
• Robust aluminium transmitter housing; IP66 protection
• LC display option with trend indicators; keypad
• Service interface (USB) for configuration using Rotronic HW4
software
• Range of calibration accessories available.
.
A technical datasheet is available. Call Rotronic on 01293 571000 to
discuss your application or project.
www.rotronic.co.uk instruments@rotronic.co.uk
ME / July/August 2021 / 11
 PLANT & MAINTENANCE / OEE
Bankrx / Shutterstock.com

Measuring Maintenance Effectiveness

Using a case study of how a plant cut time spent by engineers Splitting the losses for each measure into internal and external
causes produces six loss categories.
on reactive maintenance from 80% to 10%, Dennis McCarthy of
DAK Consulting argues that the most important improvement
was transforming the engineer mindset from fixing
breakdowns faster to adding value.

E
ffectiveness is a measure of how well a process achieves
Maintenance effectiveness calculation and loss categories
its purpose, a measure of how often that process hits
that ‘right first time’ sweet spot. The gap between the Priority losses categories can then be targeted using the classic
Effectiveness achieved and 100% is a measure of the health of the Plan-Do-Study-Act cycle credited with transforming Japanese
process. manufacturing industry from third-rate to world-leading by driving
Although the most widely used measure of effectiveness is OEE progress towards ‘right first time’ outcomes.
(Overall Equipment Effectiveness), Effectiveness can be applied to The Effectiveness glide path for the food processor from Table 1
improve any process including Maintenance Management. is shown below. This illustrates how, as effectiveness improved
and around 40% of engineer time was released, it was redirected
So what? to improve the problem prevention score from 72% to 99%. The
Maintenance is most effective when engineers’ time is directed outcome of improved Maintenance Effectiveness included a
towards getting the most out of the asset. The table below reduced maintenance cost per tonne to almost 2⁄3 of previous levels.
Table 1 contains the results from a food processing and packaging
Causes of Maintenance Effectiveness Year 1 Year 2 Year 3 Year 4 Year 5
plant on their journey from over 80% of time spent on reactive
Effectiveness Planned as a % of Total 20% 48% 68% 91% 94%
Barrier maintenance to less than 10%.
PM Completion as planned 20% 70% 85% 88% 91%
Tactic Break out of Reactive Maintenance Process Asset Packaging Problem Prevention 72% 77% 92% 95% 99%
issues Asset Issues Maintenance Effectiveness 3% 26% 53% 76% 84%
Resolve technical weak points 21% 2% Maintenance cost per tonne index 100 89 89 79 68
Set standards to define normal deterioration 48% 31%
An important TPM concept underpinning the use of
Improve work instruction 5% 29%
Effectiveness is loss tree analysis. This provides a set of
Remove the causes of accelerated Wear 22% 27%
improvement glide paths that drive effectiveness up and cost down.
Remove the causes of human Error 3% 11%
100% 100% The table below summarises the loss tree steps for the case study.
The first order priority was to work on the causes of accelerated
As can be seen here, the biggest barriers to maintenance wear whilst locking in the gains by improving Maintenance
effectiveness relate to how well work routines are defined and Standards. This dealt with around 70% of recurring failures.
carried out. That is what effectiveness measures. In this case, As breakdowns became less common, the focus moved on
the biggest barrier to overcome was a lack of robust inspection to improving maintenance value added. The outcome was to
standards to trigger actions to restore component condition prior extend MTBI (Mean Time Between Intervention) which extended
to breakdown. component life (reducing maintenance material cost) and the risk
of human error. The most important improvement, however, was
Measuring Maintenance Effectiveness the transformation of Engineer mindset from fixing breakdowns
Effectiveness combines measures for resources used, faster to finding ways of adding more value. Priceless!
productivity and quality of output. In Overall Equipment
Effectiveness these are Availability, Performance and Quality. www.dakconsulting.co.uk

12 / July/August 2021 / ME
 LET’S
TALK
„… about your individual process solution and why
AERZEN Engineering is the key to it.“
Matt Kilgarriff, Special Products Manager +44 0208 502 8122 matt.kilgarriff@aerzen.co.uk

When it comes to your best solution, you should be as uncompromising as we are: It must be
precisely tailored to your requirements, absolutely reliable and highly efficient. With individual
assembly configurations and customised services, AERZEN has been serving demanding
process applications worldwide for over 150 years. Thanks to efficient compressors and blowers,
comprehensive engineering knowledge and pronounced consulting competence, AERZEN can
implement your individual customer requirements exactly. The unique AERZEN product expertise
ensures you an efficient process solution and sustainable plant availability.
www.aerzen.co.uk

LT_Processgas_210x148_UK.indd 3 02.01.2019 08:05:07

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 PLANT & MAINTENANCE / LUBRICATION

Five reasons why to interpret report complete with diagnostics and remedial action
recommendations.

Point of Care REASON #4 Better Analytics for Decision Making

It is a fact that freshly sampled oil provides better insight to the

Oil Analysis equipment health. Retests to corroborate or debunk a possible

problem can be performed quickly in-house at little extra cost.

makes sense now

Daniel Walsh, Director of Product Management and Technical
Sales Support at Spectro Scientific, outlines reasons why point
of care oil analysis testing is proving increasingly effective at
boosting reliability and generating cost savings.

I
n a recent reliability survey, between 60 to 70% of industrial
facilities employ oil analysis as an important component
of their reliability programs. Oil analysis gives a snapshot
of machinery health, preventing unnecessary oil changes REASON #5 Duplicate Success with Enterprise Tools
and predicting equipment failures before they happen. Most Shared software platforms, with the same point of care solutions
organizations draw oil analysis samples and ship them off-site to throughout multiple sites, increase efficiency within an enterprise.
be analyzed in a laboratory. The results are sent back anywhere Equipment reliability can be viewed at regional, national or
from days to weeks depending on location and industry. even global levels. Problem-solving knowledge from equipment
Point of care oil analysis (today’s on-site oil analysis) has grown maintainers also can be shared across the enterprise, so people at
rapidly in popularity as leading industrial companies in several each site can easily tap into others’ experiences and expertise.
sectors have invested in these tools and software solutions to bring
oil analysis in-house and are now reaping the benefits.
Here are five reasons why organizations across the world are
investing in point of care solutions:

REASON #1 Rapid Analysis

Point of care solutions provide the maintenance team with Lab
quality data right at the point of sampling and in no more than 15
minutes, rather than waiting for the results from the off-site lab.
Remedial actions can be performed during routine servicing, or
scheduled for later, thus increasing efficiency.

REASON #2 Lower Maintenance Costs

Point of care solutions have resulted in ROI payback in as little as
six months.
Changing to a condition-based oil change has immediate effects
like extending oil drains,
reducing or eliminating outside
laboratory testing and flags the
early onset of machinery failure
before it becomes critical.
Also, monitoring incoming oil
deliveries for cleanliness and
type reduces risk to equipment.

REASON #3 Simplicity
Breeds Confidence
Major advances in
instrumentation have resulted
in easy-to-operate instruments,
which means data can be
generated by the maintenance
team in the course of their daily
tasks. The new generation of
systems have software that not
only provides accurate data,
but also generates a single, easy
Summary
Oil analysis at various plant locations was once reserved for
those who could duplicate off-site laboratories. This model has
changed in the last few years. The new miniature, rugged, portable
instruments make this process simple and accurate without the
need for solvents and dangerous chemicals. Point of care oil
analysis is a proven and viable path forward for an organization
looking to reduce risk.
AMETEK Spectro Scientific
www.spectrosci.com | sales.spectrosci@ametek.com

14 / July/August 2021 / ME
 Your Global Automation Partner

Manual
or
Automatic
Data Collection
Which would you choose?
HOW DO YOU COLLECT YOUR OEE DATA?
Quality – Identify continuous Performance – Identify root causes for Availability - Tracking of process/
improvement opportunities non-optimal productivity machine availability

Manual Data Collection Automatic Data Collection

Past Present Future

Unreliable Accuracy and Inefficient Accurate and Efficient

Integrating wireless

sensors with

Industry 4.0 and IIOT

Turck Banner’s wireless part counting solutions enable our customers to deploy intelligent lean initiatives by providing
the means to accurately measure, analyse and optimise their OEE performance
Turck Banner Ltd. www.turckbanner.co.uk Tel: 01268 578888
Blenheim House, Blenheim Court, Wickford Essex. SS118YT For more information contact: enquiries@turckbanner.com
 PLANT & MAINTENANCE / EXHIBITION
Asset Performance 4.0
Conference and Exhibition
goes Hybrid!
From 26 to 28 October 2021 BEMAS, the Belgian Maintenance
Association, organizes the second edition of Asset Performance
4.0 Conference & Exhibition in Antwerp, Belgium. Last year’s
edition had to be transformed into a fully virtual event; this
year it will be a full hybrid event. Get ready for three inspiring
days, during which you can participate in workshops, attend
interesting presentations and discover all the newest
technologies at the exhibition!
What to expect?
● Three-day conference with in-depth expert presentations
● Deep insights & practical experience during the workshops
● Asset Performance Awards with keynote
● Exhibition with +50 exhibitors
● Extensive networking opportunities with peers and experts
● Choose to participate live in Antwerp or join all sessions online –
live or on demand
● Access to an extensive database with +150 recordings of the
Asset Performance 4.0 2020 conference sessions.
Asset Performance Awards 2021
BEMAS is excited to organise the Asset Performance Awards to highlight
achievements in maintenance and asset management. Asset owners and service
providers can participate in three categories:
☆ Asset Performance 4.0 Award
☆ Best Improvement in Maintenance and Asset Management
☆ Technical Team of the Year
Why participate?
☆ Show that you are proud of the achievements of your organisation and the
employees in your team.
☆ Increase the image of your technical department and/or your team and company.
☆ Finalists can present their case at the Asset Performance Conference.
You can still sign up for the 2021 edition via www.assetperformanceawards.eu
The winners of the Asset Performance Awards 2021 will be announced on
October 27.
Programme of this prestigious award night
(https://www.assetperformance.eu/vvgWrx)
5.30pm : Reception
6.30pm : Asset Performance Awards Night with keynote by Peter Hinssen
7.15pm : Announcement of the winners:
8.00pm : Walking dinner and networking at the exhibition floor
16 / July/August 2021 / ME
When?
26, 27 and 28 October 2021
Where?
Flanders Meeting & Convention Center Antwerp, Belgium & online
Who should attend the Conference & Exhibition?
Asset Performance 4.0 provides a comprehensive and attractive
agenda of learning opportunities for anyone with a keen interest in
increasing asset performance. The Asset Performance 4.0 initiative
offers essential insights on how to increase reliability, production
output and quality by using smart solutions and new technologies
without omitting the essential basics and best practices.
It addresses both technical and managerial practitioners
active in asset intensive industries across Europe and throughout
the world. The audience includes operations & maintenance
managers, plant managers, production managers, CTO’s, asset
managers, maintenance & reliability engineers, service managers,
quality managers and of course digitisation managers, Industry 4.0
program managers, AI & data engineers and IIoT specialists.
More info on www.assetperformance.eu/2021
or contact us at info@assetperformance.eu
Register now at very favourable Early Bird rates via
https://www.assetperformance.eu/YgvNbz
Hackathon
Lock failure prediction based on real-time
monitoring of PLC IO data and other parameters
Leading up to the Asset Performance 4.0 hybrid
conference and exhibition, BEMAS is organising a
hackathon. This year’s challenge is provided by ÆVO,
a maintenance and service organisation specialised
in infrastructure and energy transmission and
distribution.
One of their areas of expertise is the maintenance of
locks, and as a growing business they urgently need a
threefold solution for this type of maintenance work:
☆ Monitoring of the real time functioning of the lock
☆ Detection and identification of possible failures
☆ Remaining Useful Life Prediction
Is this challenge right up your street? Then participate
in this hackathon contest! Contestants get to present
their solution at the Asset Performance Conference
on October 28.
You can find more information and register for the
hackathon at https://bit.ly/AP40Hackathon2021
 ARI-Armaturen – your answer to all your valve needs

Introducing ENCOsys®
A COMPLETE SOLUTION FOR STEAM
TO WATER HEAT EXCHANGE

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 Reduced Heat Loss
 Improved Temperature Control
 Thermal Efficiency
 Operational Savings

ARI-Armaturen UK Ltd specialises in pipeline equipment for

steam systems, thermal oil and hot water and is a subsidiary
of a large German engineering company, reputed to have the
largest valve stock in Europe. Contact the UK sales office on 01684 275752
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ARI-Ad-UK-ENCOsys-182-129.indd 1 23.06.2021 14:21:36

 PLANT & MAINTENANCE / PLANNED MAINTENANCE
Extending the value of
your maintenance software
Meter Based Maintenance
and Virtual Stores
Computerised Maintenance Software Systems (CMMS) have
been around for over 40 years, having evolved from a need
to reduce equipment failure rates. Adrian Whyte, Operations
Director of asset and maintenance management software
specialist PEMAC, explains how the efficacy of each deployment
and its benefits can vary.
M
ost CMMS projects focus on getting the preventative
maintenance element up and running first. Identifying
the equipment to be maintained, the intervals and
the key value-added tasks that need to be performed to reduce
equipment failures. The biggest mistake here is assuming that
time-based maintenance is the correct approach. It is clearly the
easiest method to use, but its efficacy is questionable, especially
when you factor back in the varying demands put on equipment.
Usage based maintenance is a much more effective strategy.
Connecting a meter to your routine maintenance check allows
the equipment usage to trigger a maintenance check, saving
resource time, expensive spares, and productive capacity. Proving
this,however, is a challenge.
One way to start this evaluation is to capture the unplanned
work generated in the system and start generating a metric such
as Mean Time Between Failure (MTBF) for the asset. By comparing
this figure to the current maintenance interval against a machine,
overmaintained and undermaintained interventions can be
identified. It’s essentially a very simple way to create a feedback
loop or learning outcome in your system.
Once this is done, engineering can then decide how to capture
those meter readings from the equipment. It can be done
manually as part of a visual inspection
route and captured on your maintenance
app. Alternatively the meter data can be
captured remotely through an interface.
These interfaces have become much more
commonplace and are often mentioned in
conjunction with Industry 4.0 or the Internet
of Things (IOT) initiatives. In software terms,
if your CMMS includes an Application
Program Interface (API) or more correctly a
Published API, these interfaces become easier
18 / July/August 2021 / ME
and hence cheaper. It’s a very small step then to start integrating
critical and non-critical alarms into the CMMS, providing real-time
data on machine performance and reducing the gap between
reporting a problem and engineering reacting.
Over carrying of engineering spares is another common
problem. This occurs most often when equipment failures are
not fully captured in the CMMS. Without usage data for spare
parts, it is nearly impossible to calculate demand and hence the
appropriate stock levels. The alternative approach is to then carry
large quantities of every conceivable spare but this is inefficient
and expensive.
To maintain control of the spare part holding, the first step
is to ensure that all unplanned work is recorded on the CMMS.
When a spare part is issued to the asset, engineering can then
calculate demand, getting a better understanding of the total cost
of ownership (TCO) for the asset and reset reorder levels. This is
the first step, but you are still left with an expensive problem, an
investment trade off, carrying the spare and incurring the cost
now versus taking a chance that you can get the spare quickly if
required. Various strategies have been tried to help reduce lead
times from consignment stock through to spares hubs.
One innovation is to use 3D scanning technology to create a
virtual store, scanning certain spare parts and then making spares
locally.
One of our clients started scanning shafts using a 3D scanner
and then linking the scanned image to the appropriate spare in our
PEMAC Assets system. When the spare is required, the drawing
is issued to a local company via PEMAC. The turnaround time
was lowered and the costs were on average a third of the Original
Equipment Manufacturer (OEM) cost. In the first year the company
achieved a return on investment of 850%.” To extend the benefit
further the company started specifying the material to be used.
This doubled the life of the spare, extending the maintenance
interval and reducing costs further.
Software is one of those rare products. After you buy it, it
continues to change. That change comes from interacting with
people and organisations, solving problems and learning. It’s
that shared learning that you really buy when you make your
investment and then realising it becomes your key challenge.
07480 181 787 | sales@pemac.com
 It’s not new –
but sometimes
there’s no need to
reinvent the wheel.

The Chopper Pump.

Leaders in temperature measurement – Invented by Landia in 1950.
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Sheffield tel: +44 (0)1909 569446 www.landia.co.uk
 PLANT & MAINTENANCE / PUMPS
Landia Jet Mix at Glatfelter.
Much easier to maintain than
the previous system.
Maintenance reduced and H&S
improved with new water mixers
Compared to pumps, mixers often seem to be the poor relation
– with some thinking that any mixer will do. Paul Davies, Key
Account Manager at Landia, reports on how one company has
benefitted from making a careful choice.
N
o matter how careful you are, working at height, especially
outdoors in winter or in strong winds, is not brilliant.
For the maintenance team at Glatfelter, a leading global
supplier of engineered materials, this, following regular failures of
a mixing system for an open-topped tank, meant it was time for an
upgrade.
Hayes GFS, who are experts in the installation and  11kW Jet Mix system is described as a “resounding success”; so
refurbishment of glass-fused-to-steel tanks, suggested that
Glatfelter try an externally-mounted mixer from Landia.
Manufacturers of quality key products for industries such as
food & beverage, electrical, building and medical, Glatfelter’s
open-topped 1000m³ above-ground (7m) glass-lined steel tank
(used for pH correction) was fitted with an internal propeller
mixer that for repair and servicing was only accessible via vertical
ladders, and then use of a cumbersome mechanical winch –
although the problems were manyfold.
Failures with the mixer had become all too frequent, so on top
of the arduous and very awkward process of having to retrieve it,
there was also the downtime of having to wait for it to be repaired,
and sometimes replaced altogether with a brand-new unit. This
had become a costly, ongoing exercise that was no longer viable.
A new mixing system would have to be much easier to manage,
and also be able to deliver on performance in a very aggressive
application with pH levels from three, right up to 13. The old
internal mixer also couldn’t prevent crust building up in the centre
of the tank – and when the vessel was drained down, Glatfelter
discovered that the mixer had been scouring the bottom of the
unit. The reinforcing bars could be seen, which wasn’t good at all,
so it was time for a replacement tank.
Having the mixer on the outside of the tank is always going
20 / July/August 2021 / ME
to provide benefits, but to be perfectly honest, Glatfelter were a
little sceptical about how any mixer could deal with the range of
different fibres used in their manufacturing process, where the
dewatering rate can vary significantly. The old internal mixer
couldn’t stop some fibres from settling in the middle of the tank,
which with significant effluent volumes being handled, led to a
small mountain building up in the centre.
The mixer became completely blocked and the crust was so
thick it wouldn’t disperse, so several times over the years, Glatfelter
had to drain everything down and pay for contractors with cranes
to come in and dig it all out.
Four years on, we are proud to say that the installation of our
much so that Glatfelter decided to invest in three more Landia
mixers. Two further JetMix systems now serve a 1500m³ vessel,
with another JetMix installed in a 500m³ unit. Both containers
work as balancing tanks before the wastewater goes on to other
treatment processes at the Gloucestershire plant, including two
DAF systems.
For each tank, the pump outlets are horizontal, allowing mixing
to continue, even if tank levels are low. JetMix, which is mounted
through the side of the tank wall, makes it well-suited for mixing
liquids with a high viscosity, such as drained or digested sludge.
The optimal motor cooling function also makes it an ideal choice
for liquids with high temperatures.
All of the health and safety issues caused by the old mixing
system have been removed, including working in confined
spaces. And even though there are very high pH levels, the first
Landia mixer is still in very good condition four years on from
its installation. And despite all the variables in the wastewater,
the mixers, which run almost 24/7, have received excellent
performance reports, with our in-house service team now visiting
the Glatfelter facility every six months to carry out preventative
maintenance.
t: 01948 661 200 | pd@landia.co.uk | www.landia.co.uk
 Maintenance and Engineering - Advert 1 Feb21.pdf 1 10/02/2021 18:42:45

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Dual Pumps 182x129 Jul-Aug.indd 1 15/07/2021 17:03:23

 PLANT & MAINTENANCE / THERMAL IMAGING
Thermal imaging and industrial
maintenance best practices
Fluke Corporation industrial imaging field application engineer
Alexander Bardakov considers best practices for using
thermal imaging in industrial maintenance.
M
onitoring equipment performance with thermal imaging
cameras can reduce the likelihood of unplanned
downtime, reduce reactive maintenance fees and
equipment repair costs, and extend the lifespan of machine assets.
A change in heat pattern is often an early symptom of equipment
damage or malfunction and thermal imaging is an important tool in
preventive maintenance programs.
Asset maintenance and troubleshooting
Thermal cameras are very useful for both troubleshooting problems
as well as for condition monitoring, for long-term preventive
maintenance. They can also be used for assessment of mechanical
equipment such as motors, drives and conveyors, but are commonly
used for electrical inspection.
Thermal inspection methods
There are three typical methods for infrared inspection: baseline,
thermal trending, and comparative.
Baseline thermography requires the technician to scan the
equipment when it first commissioned and uses this image as a
reference point to look for temperature anomalies in current scans.
Once a baseline has been set, thermal trending inspections
can be used to compare how temperature is distributed in the
same components over time, helping to plan future maintenance
schedules.
Comparative thermography involves scanning similar equipment
working under similar conditions and compare the results. Once
you have three or more pieces of equipment operating under similar
conditions it is relatively easy to pick up an anomaly.
Electrical panels
When conducting routine maintenance
of electrical panels, the primary job for
the maintenance technician is a visual
inspection. Under-sized conductors, loose
connections or excessive current flow
cause heating. Signs of scorching or discoloration of the panel cover,
components or component connections having changed colour
due to heating are a good indicator of a problem in the circuitry.
22 / July/August 2021 / ME
Thermal imaging
Following a visual inspection,
the next step would be to capture
thermal images of all electrical
panels and other high-load
connection points such drives,
disconnects, controls, and so on.
Where higher temperatures are discovered, follow that circuit, and
examine associated branches and loads.
A good rule of thumb when making a comparison of increased
temperature on a thermal image, is anything five degrees or more
above ambient temperature may indicate an electrical fault. This is
a rule of thumb used to indicate candidates for further investigation
and experience is often the best guide.
Ideally, electrical device checks should be made when they are
fully warmed up and at steady state conditions with at least 40% of
the typical load. That way, measurements can be properly evaluated
and compared to normal operating conditions. Where possible
check panels and other connections with the covers removed to
improve the assessment as thermal cameras read only the surface
temperature.
Check current and voltage
When a thermal image shows an entire conductor is warmer than
other components in a circuit, the conductor could be undersized or
overloaded. The next step in diagnosing the problem is to measure
the current and voltage using appropriate tools to assess the load
and compare with the conductor rating.
To measure the electrical current use a clamp meter and a
multimeter with a clamp to check the voltage. On the voltage side,
check the protection switchgear for voltage drops. In general, the
voltage drop should be within 10% of the nameplate rating.
From these measurements an assessment can be made as to the
cause of heating. If the component is not over-loaded this could
indicate a lose connection. A raised temperature at a connection
could indicate it is loose, causing an increased resistance.
Useful tools
Thermal imagers are making maintenance tasks easier by including
features like asset tagging. The thermal imager is equipped with a
digital camera for scanning QR codes or bar codes on cabinets for
filing and storing thermal images and making notes of tests and
results. It is useful to have an easy way to identify which thermal
image applies to which cabinet, particularly when they all look so
similar.
To find out more about thermal imaging for electrical systems
follow https://www.fluke.com/en-gb/learn/blog/thermal-
imaging/electrical-systems
 When OVER

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 PLANT & MAINTENANCE /
COMPANY NEWS & PRODUCT REVIEW ABSTRACTS
email kirsty@maintenanceandengineering.com to feature here

Humidity Solutions Fluke Reliability’s eMaint CMMS

50:50:50 offer software added to RS Components’
maintenance solutions
2021 marks the 50th anniversary of
the production of the Vapac brand of Fluke Reliability,
humidifiers in the UK. provider of simplified
Originally produced by the Eaton connected reliability
Williams Group in Edenbridge Kent, the solutions, has
Vapac product line was purchased by today announced
Nortek Global HVAC in 2015 and is now a partnership with
manufactured in the West Midlands. RS Components
The Vapac brand has been the dominant (RS) to provide eMaint computerised maintenance
electrode boiler humidifier for the past 50 years with technical changes made when required but the basic management system (CMMS) award winning
functional unit staying true to its original design providing a stable and reliable product with continuity of software to customers of RS. eMaint was one of the
spares and consumables. first providers of CMMS to offer a completely web-
Humidity Solutions are the exclusive distributor for Vapac in the UK and Ireland, and are marking this based SaaS model to help predict failures, eliminate
important anniversary with a unique 50:50:50 offer: 50% discount off list price for the first 50 unit orders downtime, and improve reliability. By adding eMaint,
received after 25th June 2021 to celebrate the 50 years of humidifiying. RS aims to provide a world-class CMMS solution
John Barker of Humidity Solutions commented: ‘The move to buy British is strong after Brexit and Covid, that helps its customers better manage work orders,
so the security of knowing that the product you are purchasing is home produced and supported by a UK predictive maintenance schedules, and parts inventory
company providing Units, spares and technical support is reassuring and a secure, risk free choice.’ for industries such as manufacturing, facilities, services,
www.humiditysolutions.co.uk fleet, energy, packaging, government and education.
www.emaint.com | www.fluke.com

CBM service for robots
A Condition-Based Maintenance (CBM)
service from ABB enables robot users to
create a preventive maintenance schedule for
individual or robot fleets based on real-time
data, to optimise productivity and minimise
downtime.
Using real-time data on robot operations
helps identify any potential issues that
could affect performance, including duty,
speed, acceleration, and gearbox wear.
These variables are compared against other
robots in ABB’s worldwide robot database to
calculate the likelihood and timeframe of a
potential fault or failure. ABB’s CBM tool can
advise whether remedial action is required,
involving either repair or replacement of
affected parts. By identifying which parts
are likely to fail and when, spare parts can
be purchased and prepared without having
to hold them in stock, helping users to plan
their budgets and ensure that resources
are available to carry out the work when
required.
To help customers decide which preventive
measures to take, a report is provided for the
robot, including its serial number, summary
table, data analysis, individual maintenance
recommendations, conclusions, and rating of
the system. Using this data, the customer can
design an appropriate maintenance schedule
– with help from ABB if required.
www.abb.com/robotics | t: 01925 741517
ABB PixelPaint wins
prestigious Innovation and
Entrepreneurship Award
ABB’s PixelPaint robotic non-overspray
technology for the automotive industry
has won this year’s IEEE/IFR Innovation and
Entrepreneurship Award for Outstanding
Achievements in Commercializing Innovative
Robot and Automation Technology.
Launched in 2020, PixelPaint uses inkjet head
technology to directly apply high resolution
two-tone or individualized designs to a car body
in a single pass, enabling manufacturers to easily
meet the rising demand for customized paint jobs
while eliminating wasteful overspray.
“We are delighted that our PixelPaint solution
has been recognized for its innovative,
sustainable technology that helps our customers
respond to consumer requests for more
personalized design. With PixelPaint, 100 percent
of the paint can now be applied in half the time
compared to the previous method used for
custom paint jobs, with a much better finish
quality,” said Joerg Reger, Managing Director
of ABB Robotics Auto OEM Business Line. “For
our customers, this provides the triple bonus
of saving millions of dollars per year through
reduced paint consumption, improved efficiency
and improved environmental performance
through reduced VOC and CO2 emissions, while
meeting their customer needs.”  the climate challenge, we are moving forward,
ABB Robotics Global Media Relations
Nick O’Donnell
t: +44 7704 294085
e: nicholas.odonnell@gb.abb.com
Total is transforming and
becoming TotalEnergies
Paris, May 28, 2021– At the Ordinary and
Extraordinary Shareholders’ Meeting,
shareholders approved today, almost
unanimously, the resolution to change the
company’s name from Total to TotalEnergies,
thereby anchoring its strategic transformation
into a broad energy company in its identity. In
tandem with this name change, TotalEnergies is
adopting a new visual identity.
“Energy is life. We all need it and it’s a source
of progress. So today, to contribute to the
sustainable development of the planet facing
together, towards new energies. Energy is
reinventing itself, and this energy journey is
ours. Our ambition is to be a world-class player
in the energy transition. That is why Total is
transforming and becoming TotalEnergies,”
declared Patrick Pouyanné, Chairman and Chief
Executive Officer of TotalEnergies.
This new name and new visual identity embody
the course TotalEnergies has resolutely charted
for itself: that of a broad energy company
committed to producing and providing energies
that are ever more affordable, reliable and clean.
t: 01977 238 200
e: ms.marketing@totalenergies.com
w: www.services.totalenergies.uk

24 / July/August 2021 / ME
Vol 36 no 4
maintenance
&assetmanagement
July/August
2021

journal

ME / July/August 2021 / 25
 maintenance
&assetmanagement

Continuous improvement leading to

energy consumption reduction
ABSTRACT
The Agfa Graphics Ltd plant in Leeds ran two continuous process lines (24 hrs × 7 days)
electrochemically treating aluminium to produce substrate for lithographic printing plates. These
aluminium reels were typically 1,000 mm wide × 0.275 mm thick, weighing 6 tonnes (Fig 1).

Graham Cooper
Founder and principal consultant,
Systems Excellence
graham@systems-excellence.co.uk
With a worldwide network of plants and a slowly declining sales volume due to technology shifts in
the market, there was intense internal competition between the companies’ factories worldwide,
because product loading was biased towards the most efficient plants. The Leeds plant adopted the
strategy of focusing on reduced consumption to reduce manufacturing costs. Particularly noteworthy
successes were achieved with gas, electricity, water, and acid consumption reduction and a move
from 6,000 tonnes of general waste to landfill to zero tonnes. Collectively, this type of work won the
IMechE MX awards for sustainable manufacturing in 2007 and 2011.

This article will focus on the way energy consumption was characterised and then reduced using
classic continuous improvement (CI) techniques (Demings PDCA or the more modern Six Sigma
DMAIC processes). This approach was followed because there was already a strong culture of CI in
the plant and because capital was severely restricted given the business environment. The specifics
of what was done in the Leeds plant may not be directly transferrable to other businesses, but the
processes followed should be illuminating to others.

Understanding the split of gas

consumption
At the start of the project in late 2005 there
was an objective to reduce gas consumption,
but the only data available was the annual gas
consumption of around 9,500 MWh. Quotes
were obtained to fit sub gas meters at various
points in the site to understand how and where
the gas was consumed. However, because it
was not known whether consumption could
be reduced, the capital costs quoted to install
meters with hard-wired connections to the site
systems were considered much too high, with
uncertain payback.
The team came up with an imaginative
solution to the problem, which was to get the
security guard on his nightly rounds to read the
single main incoming gas meter and enter the
results in a spreadsheet on the site server.
The chart (Fig 2) shows the resulting picture Figure 1
over a two-year period. The peaks are the
winter months, and the troughs are the summer The data obtained was very variable from day zero production from a line.
months. to day. This noise was inspected and correlated The results were: Line 1 consumed around
with what was happening at the time of the 11,700 kWh/day when in full production; line 2
reading: for example the drop to zero in the consumed around 7,300 kWh/day when in full
middle of the chart is a summer shutdown of production, and the balance was space heating
one line followed by the other. By knowing ranging from 17,500 kWh/day in winter down
when one line or the other was down for to close to zero in the summer.
extended maintenance, overhaul, breakdown The consumption on both production lines
or product change, the basic split of the gas was from a gas boiler heating a pumped
consumption was identified by comparing days circulating pressurised hot water system to heat
Figure 2 with full production from a line and days with process baths via plate heat exchangers. The

26 / July/August 2021 / ME
 maintenance
&assetmanagement

major consumer of heat on both lines was the Figure 3

final wash system, where a continuous flow of
deionised water was heated up from ambient
(circa 12°C) to 50°C to wash the aluminium
“photographically” clean. This was a one-pass
system requiring continuous high heat input.
Other ways of heating this flow were
investigated but none was as efficient (cheap)
as the existing system.

A parallel project provides inspiration

Many improvement projects were under way
in the factory at the time, including one to
increase the capacity of the production lines.
One capacity bottleneck was removal of heat
from the electrochemical cells on the lines. In Figure 4
these cells high currents were passed through
acid solutions to the aluminium to transform the
aluminium surface. One of these processes was
the anodising process. DC current heated up the
sulphuric acid in the cells via Ohmic heating, in
which the heating is proportional to the current
squared multiplied by the resistance in the
cell (i²r). Several thousand amps were passing
through four cells on the larger of the two lines.
The heat was removed from the acid via plate
heat exchangers, with coolant being pumped
through being sent to an evaporative cooling
tower for cooling before being pumped back.
In order to investigate the cooling capacity
constraint (during summer months with higher
temperatures and humidity making the cooling
tower less effective) the team had constructed a
view of the whole cooling system on the process
control system (Fig 3). getting the process back within temperature Next steps for gas reduction
The important figure on this screenshot is specification. Once new the line 1 system was fully proven,
highlighted in the green box. At this moment the These problems were resolved by fitting a repeat project was carried out on line 2 in
cooling tower is removing 2.015 MW of heat. automatic valves controlled by the main control summer 2008, and this successfully reduced line
The link was made that on the same line we system to shut off the cooling when the anodic 2’s consumption from around 7,300 kWh/day to
needed to find a heat source, for the final wash system was not creating heat. 2,300 kWh/day.
system in order to reduce gas consumption, and It is worth noting that the production team The cooling tower was still required at the
a heat sink, to take load away from the cooling quite reasonably wanted to ditch the new end of these projects. All of the heat from the
tower for the electrochemical systems. system when the first problems with low anodic systems was not removed by the wash
In spring 2007 a solution was designed, anodic temperature were encountered because water and none of the heat from the other
costed and fitted that took the hot acid from the significant waste was being caused. It was electrochemical systems (graining) was removed.
anoidising process through one side of a new important that the plant manager could see However, the cooling tower then had some extra
plate heat exchanger and the cold deionised the end state and insisted that the system was capacity due to this work and coped better on
water for the wash process through the other fully adopted following the modifications. hot, humid days.
side (Fig 4). With both projects done, the space heating
The new scheme dramatically reduced was the main remaining consumer of gas. Gas
the gas consumption on line 1 from around was being consumed in three areas. The first
11,700 kWh/day to around 3,500 kWh/day. was the offices, where a few small gas boilers
The cost of the installation (shown in Fig 5) fed a hot water system going to radiators to
was £26,000; in the first 12 months £65,000 provide heating. The second was around the
worth of gas was saved. warehouse/storage areas of the factory where
However, the implementation had some there were seven gas burning air heaters. Finally
problems. Insufficient thought had been given to in the production area was a heating ventilating
non-standard operating conditions. It was found & air conditioning (HVAC) unit, which produced
that when the anodic power was reduced or temperature-controlled very clean air to the
turned off, the waste heat recovery continued to production lines.
cool the anodic acid, creating start-up problems Figure 5 The following was done to subdivide and

ME / July/August 2021 / 27
 maintenance
&assetmanagement

understand the heating consumption. First,
the offices were only heated on Monday to
Friday. The gas consumption for heating at the
weekend was compared with midweek, and
the office consumption was inferred from the
difference (around 7% of the space heating gas).
The gas space heaters in the warehouse
had a fan motor and a burner assembly and
were either fully on or fully off, controlled by
thermostat. The site electrician suggested fitting
a £10 run timer to each fan motor (see Fig 6).
Figure 6
The fan motor only came on when the burner
was on, and the capacity of the burner was fixed
and known. Therefore, by knowing how long
the fan had been running in a day the gas the
space heater had consumed could readily be
calculated.
Each of the seven space heaters’ run
timers were added to the security guard’s
daily walkaround and the results placed in a
spreadsheet. In this way the gas used to heat the
warehouse was found to be around 29% of the
total space heating gas.
Knowing the office and warehouse
consumption allowed the production area
consumption to be estimated, at around 64%
of the space heating. This was the area that was
looked into further. 
hottest two or three months of the year, would
have the coolant from the HVAC cooling coil
diverted to it which would be heated by the
cooling tower return water.
In Fig 7 (below), HX is the new heat
exchanger. Water returns to the cooling tower
at around 28°C from the process line and is fed
to the cooling coil circuit for the HVAC system
via HX.
The HVAC cooling coil then instead becomes
a pre-heating coil for air for the production area
with liquid at 26°C within it.
Because the cooling coil had a very large
surface area it became a very efficient pre-heater,
and the gas heated heating coil only came into
use when the external air went below 5°C.
Fig 8 shows the smoothed monthly gas
consumption from Jan 2006 to December 2011,
clearly showing the impact of the line 1 project
in May 2007, the line 2 project in July 2008, and
the HVAC project in September 2010.
Electricity consumption reduction
Encouraged by the early successes with gas
reduction it was decided to investigate what
might be possible for electricity reduction, with
the project commencing in 2010. Work had
been done prior to this project, replacing old
lights with more modern efficient ones, with
sensors to turn lights off when nobody was
present. However, although significant energy
was saved, on a site level this was not significant.
What had never been done before was to
look at the electrochemical process lines where
most of the electrical energy was consumed.
For the decades before this project, this usage
was considered fundamental to the product and
thought to offer no opportunities.
Being a large consumer (at the time the plant
consumed 28,000 MWh of electricity annually
at a cost of just over £2,000,000), the team had
access to half hourly meter readings from the
supplier.
Note that sites which consume more than
100,000 kWh of electricity per annum will have
a half hourly meter.
This data had never been examined before.
Fig 9 is an example from June 2010 for the
Leeds site.
At this time there were two distinct product
types being produced which had different
specifications for surface roughness and anodic
weight. This required different current flows
in the electrochemical processes. Each of
these products also had a variety of gauges of
aluminium ranging from 0.15mm to 0.4mm.
The thinner gauges had to run more slowly
because of the limited current carrying capacity
Figure 7

Figure 8
Reduction of production area space
heating gas consumption
The HVAC system consisted of air being drawn
through filters, across a large cooling coil and
across a smaller heating coil. The cooling coil
was fed by a chiller, but was inactive most of the
year because Leeds rarely gets warm enough
to require it (the air temperature specification
for the production area was a maximum of
25°C). The heating coil was fed by a gas boiler
providing circulating hot water. The heating coil
was used most of the year.
Beneficially for the project, the HVAC unit was
situated adjacent to the cooling tower referred
to earlier. The proximity allowed the installation
of another heat exchanger which, in all but the

28 / July/August 2021 / ME

Figure 9
of the aluminium cross-section. The final variable
was web width, which varied from 700mm to
1500mm. All these factors combined resulted in
the required power varying substantially up and
down as in the graph.
Looking at three months’ of data of
consumption data, the team went back to the
production records and worked out how many
square metres of aluminium was processed
on each machine in each half hourly period
and which product was being produced. The
team also noted whenever one of the two lines
was completely stopped. It was thus possible
to understand how much electricity the site
consumed with no machines running, how
much was consumed by running a machine but
not producing, and how much was consumed
per m² of aluminium on each product on
each machine. These factors were configured
as a model and compared with the actual
consumption (Fig 10).
Figure 10
The next step was to install current
transformers (CT devices with Wi-Fi output)
to the various transformers on the site and
to collect that data into the process control
system. In this way the instantaneous current
being consumed could be compared with the
predicted current via the model and displayed to
the operators.
On the screenshot in Fig 11 the actual power
is shown in red and the predicted power in
green. The model was refined by looking at this
on a daily basis until it was extremely accurate.
When the line speed, the web width or the
product was changed significantly, the applied
current in each cell of the graining and anodic
processes had to be set to get the specified
surface roughness and anodic weight. The
operators would confirm that the settings were
correct via this application without having to
wait for the confirmatory destructive tests in
QC.
With an extremely accurate model it was
possible to simulate how much power would be
consumed in a month if the lines ran at 100%
efficiency. This was done, with the surprising
result emerging that only 75% of the electricity
being consumed was going into good product.
25% was what was termed “non-productive
energy” (NPE) and was used when the lines
stopped and started, or idled waiting for quality
control results.
Identifying this huge amount of waste
resulted in a programme to review and update
all standard procedures related to stopping and
starting the lines to minimise the NPE. It soon
became apparent that turning off all power
when the line stopped was difficult for the
operators. When a line stopped, they had to
scroll through dozens of process control screens
searching out pumps and fans to switch off and
then do the reverse to start back up again.
A new control screen was configured that
listed every electric motor on each line (Fig 12).
If a motor is running it is shown in green; if
it is stopped it is shown in red. This screenshot
shows the line in a stopped state. The operator
can stop and start motors from the screen,
making shutdown and startup extremely quick.
With the review and change of many
long-established procedures over time and the
provision of the operator screen shown above,
the NPE was driven down, as shown in Fig 13.
maintenance
&assetmanagement
Figure 11
Figure 12
This improvement represents almost
£500,000 reduction in electricity consumption
with no significant capex at all.
Figure 9
Conclusion
Simply by understanding electricity consumption
in detail and then acting on that understanding,
a reduction of almost £500,000 reduction in
electricity costs was realised.
For a total capex of just over £100,000
the gas consumption for the Leeds plant was
reduced from 9,500 MWh at a cost of £240,000
to 3,500 MWh at a cost of £88,000 (using a
cost of £0.025 per kWh from the period).
This demonstrates that it is possible to be
inventive in splitting down gross consumption
into subsets without huge cost, which will make
it possible to focus on the largest consumers
first.
Think about the energy flows in your plant
holistically, as you may be able to re-use
otherwise wasted heat to reduce primary energy
consumption.
ME / July/August 2021 / 29
 SITE, BUILDINGS, ENERGY & WORKS MANAGEMENT / EMISSIONS MONITORING

Preparing for Stage V compliance

Keith Brown, Technical Manager at DiPerk Power Solutions,
explores some of the challenges when producing Stage
V-compliant machinery, and how businesses can streamline
their journey to compliance.
engine rated 19-56 kVA will typically utilise a DOC and a DPF, but
once the rating exceeds 56 kVA, SCR will also be needed to reduce
NOx levels to Stage V requirements.
OEMs may need to redesign the engine and aftertreatment
housing to accommodate aftertreatment devices. These can be
mounted on or off engine, but this added space claim volume may
require the manufacturer to modify an enclosure so it can be fitted
correctly with the required air flow and clearances.

Getting started with Stage V

Stage V has introduced various new design considerations for
OEMs. The first step to Stage V compliance is obtaining a model
of the equipment’s engine and the necessary aftertreatment
device(s) from the engine supplier. Using a CAD model,
manufacturers can identify the space constraints caused
by the integration of additional hardware. At this stage, the
manufacturer can also establish if there are any clashes with the
existing design caused by the electricals, exhaust or any other
engine interface.
Engines with SCR technology may require a more powerful
electronic control module (ECM) to drive the aftertreatment’s
monitoring and controlling devices. SCR uses AdBlue to reduce
NOx emissions — converting NOx into nitrogen and water

T
A technician he introduction of Stage V emissions legislation was vapour. The ECM controls the AdBlue pump, which primes
carrying designed to tighten restrictions on non-road engines and the AdBlue dosing system and purges it back into the tank
out engine equipment, lowering limits on particulate matter (PM) when the engine is turned off. Electrical power to the ECM is
maintenance
emissions for equipment ranging from 0 to 560 Kw (engines maintained until the process is complete, otherwise it can lead
up to 19 Kw have used in-cylinder technology to meet their to crystallisation of the AdBlue within the system. OEMs can
emissions limits). Stage V was introduced for engine ratings solve this issue by installing a permanent battery connection
below 56 Kw and above 130 Kw in 2019 and for 56 Kw in 2020 — to the ECM — this requirement will be outlined in the engine
130 Kw engine ratings also became subject to this legislation. manufacturer’s installation documentation.
OEMs were given until June 2021 to place transition engines Larger engines fitted with an SCR system use NOx sensors to
— engines built before the Stage V introduction — onto the measure the difference in NOx levels between the engine outlet
market. and SCR outlet. Some engines are designed for NOx sensors to
The move from Stage IV to Stage V poses a real challenge be easily incorporated, although the manufacturer may need to
because OEMs must now select an engine fitted with a diesel find an off-engine location to house the electronic NOx sensor
particulate filter (DPF) as well as a diesel oxidation catalyst (DOC) controllers.
and a selective catalytic reduction (SCR) cannister (>56 Kw). This By engaging with the engine supplier early on, OEMs can
addition has in many instances increased the overall footprint get a clear understanding of their machine’s design limitations
of the engine assembly. Although manufacturers were granted and how their engine choice will affect emissions. A registered
1204J-E44TTA
extra time to prepare, many are still looking for guidance on dealer will already have several years of experience working
Stage V
compliant redesigning their equipment, so they can continue to sell their with different Stage V technologies and can also recommend the
engine products in the European market. correct engine rating and emissions technology best suited to the
application. Such collaboration will be key for helping industrial
Adapting to equipment OEMs as they prepare on their Stage V journey.
aftertreatment
The key to Stage V compliance t: 0800 0730 424 | engines@diperk.co.uk | www.diperk.com
is integrating the engine and
aftertreatment technology
to equipment, be it a pump,
genset, or combine harvester.
In the electric power market,
manufacturers of constant
speed mobile generators will
now have aftertreatment
Stage V
devices including selective 1204J
catalytic reduction (SCR), diesel particulate filters (DPFs) and electric
NOx reduction systems (NRS). The choice of aftertreatment power
combination is determined by the engine’s power rating: an engine

30 / July/August 2021 / ME
 SITE, BUILDINGS, ENERGY & WORKS MANAGEMENT / STEAM
The evolution of steam and,
what does ‘good’ steam look like?
Steam is an incredible heat transfer medium, an integral,
clean and essential part of modern technology in use across
food, textile, chemical, medical, power, heating and transport
indutries. Steam Quality Specialist Michael Hyde of Spirax
Sarco argues that maintaining the quality of your steam
systems is a good starting point to achieve net zero or other
carbon reduction targets.
D
id you know that every kilogram of steam contains
around 2200 KJ of condensable energy? That’s 26 times
more usable energy than a kilogram of water in a typical
heating system based on flow and return temperatures with a
delta of 20°C!
Steam is easy to distribute and when its work is done, it is
simply water – reassuring to know in our environmentally
conscious world.
A sustainable and clean energy source
Steam is a reliable and more importantly, sustainable energy
source. An efficient steam system targets the demands of your
industrial processes, including improvement requirements for
energy-saving, environmental performance, safety or regulatory
compliance.
So, what does a ‘good’ steam system mean?
For your plant to operate effectively, steam should be delivered:
◆ in the correct quantity
◆ at the correct pressure and temperature
◆ clean, dry, and free from air and other non-condensable gases
(NCGs)
Why is steam quality important?
Good quality steam will help you to get the best out of your
applications and processes. Heating water, cooking food, drying
garments, curing tyres, delivering power, or any application where
steam is applied, will require steam to perform efficiently and
effectively.
For steam to perform at its optimum level, the steam must be
dry with a minimal amount of entrained moisture and free from
NCG’s. As mentioned earlier, the steam must also be delivered at
the optimum pressure and temperature.
Good quality steam ensures correct process control, short
warm-up times, and maximum productivity. Using good quality
steam also minimises the amount of steam used. Less steam used
equates to lower running costs and reduced CO2 emissions. This
can also affect the longevity and reliability of the plant. Again, in
an increasingly, environmentally conscious world, reducing our
footprint on the earth couldn’t be more crucial.
Steam - creating a strong foundation for your
success
While steam is a very forgiving medium, you need to start with
a strong platform for your success. Steam doesn’t function at its
best without every level of the process being in check before it
comes into play. You’ll need to have a well-designed system and
the correct skills to maintain. Your system needs to be efficiently
managed to ensure your productivity and sustainability targets
are achieved.
On the topic of sustainability, let’s take the example
of Heinz…
Yes, the beans. To help achieve their sustainability targets, Heinz
reduced their carbon emissions by 200 tonnes per year. How?
Simply, by improving the management of their steam system.
But their success doesn’t stop there, Heinz predict to slice more
than 4% of its energy consumption in the next three years after
introducing a steam trap management plan, with the help of a
team of steam experts.
So, what can we take away from this? Steam is simply water
– clean and environmentally friendly when managed correctly.
Regular maintenance of your steam systems could help you to
make big sustainability improvements and do your bit to help our
planet.
If you have net zero or carbon reduction targets, then
maintaining the quality of your steam and steam systems is a
fantastic place to start.
e: hello@uk.spiraxsarco.com
w: www.spiraxsarco.com/global/en-GB/contact-us
t: +44 1242 521361
ME / July/August 2021 / 31
 SITE, BUILDINGS, ENERGY & WORKS MANAGEMENT / TRAINING
Scotland’s new non-destructive
testing training school
Non-destructive training in central Scotland was threatened
when Covid-19 caused closure of courses at Fife College after
30 years of operation. Thanks to IMechE’s intervention a new
facility has now opened its doors.
I
MechE Fife NDT has now opened, offering a full range of
non-destructive testing (NDT) training courses, including
Magnetic Particle Inspection, Radiographic Interpretation,
Weld Inspection, Liquid Penetrant, Visual and Ultrasonic testing.
Based in Dunfermline, it is also the first training school in
Scotland to offer the advanced courses of Phased Array, Ultrasonic
Testing and Time of Flight Diffraction.
NDT training in Scotland has been threatened when Covid-19
caused the NDT school at Fife College to close its doors in 2020
after more than 30 years in operation. Scotland was left with no
NDT training school in the central belt of the country where there
is significant manufacturing, marine and defence industries that
depend on skilled, certified NDT technicians.
IMechE Argyll Ruane, based in Sheffield, had supported Fife
College for many years by providing NDT examination services
for their PCN courses as an authorised qualifying body (AQB)
with the British Institute of Non-destructive Testing (BINDT).
IMechE Argyll Ruane convinced its parent, the Institution of
Mechanical Engineers (IMechE), to step in to save the jobs of the
training staff and commit to establishing a new training school.
After determining the optimum location for the new training
centre, IMechE Fife NDT Ltd was incorporated and established in
32 / July/Aug 2021 / ME
a modern building to the south of Dunfermline. There are a range
of hotels nearby and the training school is easily accessible from
the M90 motorway or from Rosyth railway station. The facility
has extensive car parking and has been fully refurbished with
modern classrooms and a comfortable student breakout area
where free student lunches are provided. Most importantly, the
training centre has excellent equipment and an extensive range
of training and exam samples.
IMechE Fife NDT is headed by Training Manager, Peter
McPherson, who has been training NDT technicians for over 20
years. Peter is supported by Graeme Innes who has a full lifetime’s
experience in NDT, including 7 years as a trainer at Fife College,
and Stewart Gray who has 6 years’ training experience in a variety
of methods. IMechE Fife NDT is fully supported by IMechE Argyll
Ruane and teaches using IMechE Argyll Ruane’s best-in-class
training material that is used around the world by numerous
affiliated training schools.
Ultrasonic Phased Array and Time of Flight Diffraction (TOFD)
are challenging NDT inspection techniques that are frequently
used in Scottish industries as varied as oil & gas, defence and
aerospace. IMechE Fife NDT offers regular scheduled courses in
these methods using the latest equipment and representative
training samples.
Additionally, the training school offers training at Level 3, the
highest and most difficult to achieve certification level. This is
provided by specialist tutors and Level 3 consultants from IMechE
Argyll Ruane who are now happy to deliver training in Scotland.
Also offered, is a full range of Level 3 consultancy services, from
procedure writing to employer-based training and examinations
under ASNT SNT-TC-1A and EN4179 certification schemes.
Peter McPherson said, “These are difficult times, but I am
delighted that the Institution of Mechanical Engineers supported
us, and myself and my colleagues invite Scottish NDT Technicians
to experience our expanded services and first-class facilities in
Dunfermline”.
Chris Kirby, IMechE Argyll Ruane General Manager, said,
“This has been a major investment in the current climate,
but the IMechE felt it was important to support the Scottish
NDT sector. Our new colleagues have worked hard to create
an excellent training centre and continue to offer the friendly
and efficient service that Fife College was known for, with the
benefit of now being able to provide a significantly expanded
service that includes advanced methods and Level 3 training and
consultancy”.
Make a booking at FifeNDT@imeche.org
or call +44 1383 669004.
w: FifeNDT.imeche.org
 C

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THE BEST KEPT SECRET IN THERMAL FLUID TECHNOLOGY

DID YOU KNOW?

Frequently referred to as just a steam boiler manufacturer, Fulton also
specialises in thermal fluid solutions and, as such, considers all options
when responding to a customer’s process heating requirements.

With industry-leading efficiencies greater than 87% LHV and 80% HHV,
our range of compact thermal fluid heaters feature a four-pass,
high-efficiency design with heat outputs to 3500kW and standard
operating temperatures up to 345°C. And like many Fulton heat transfer
systems, thermal heater solutions can also be skid-mounted and
delivered to site ready for installation connection to existing pipework.

To find out more about its range of thermal fluid heater solutions
visit www.fulton.co.uk, email sales@fulton.co.uk
or call +44 (0)117 972 3322.

Improving life through heat transfer solutions

FBW201 - FT-C Advertisement - ME.indd 1 30/06/2021 15:53

 F¥CUS / COMPRESSORS
Pure and
simple air
quality with
oil-free
compressor
technology
David Bruchof, Product Manager for oil-free
screw compressors at CompAir, part of Ingersoll
Rand Inc., details some of the key considerations
for operators looking for consistent, high
compressed air quality and outlines how oil-free
compressor technologies can help improve site
efficiencies.
W
hen it comes to compressed air, quality matters.
Avoiding process contamination, which can lead to
potential product rework or production downtime
is a necessity. There are a number of rigorous standards in place
governing compressed air performance to ensure processes
remain free from contaminants – or that they are reduced to
acceptable levels – while minimising unscheduled downtime and
the associated costs.
These regulations include ISO 8573, a group of international
standards stipulating compressed air purity and quality. ISO
8573 consists of nine separate parts, with part one identifying
contamination levels that can be tolerated within a single
cubic metre of compressed air. Specifically, part one identifies
permitted particle count, pressure dewpoint and amount of oil
allowed within this sample.
The other eight parts detail testing methods for a range of
contaminants, including solid particles, oil vapour, organic
solvents, microbiological contaminants, liquid water and gaseous
contaminants, alongside humidity levels and aerosol content.
They also ensure that air quality test results are comparable
within a given tolerance of measurement.
Many operators are now applying additional measures to
guarantee high-quality compressed
air, adopting the principles of the
Hazard Analysis Critical Control Point
(HACCP). This ensures facilities are
complying with hygiene legislation
and either eliminating any potential
hazards or reducing them to an
acceptable level.
In some cases, high-quality air
is achieved by using oil-lubricated
compressors, which rely on filtration
to protect products and equipment
34 / July/August 2021 / ME
from contamination. However, to guarantee air purity, many
businesses are switching to oil-free compressors.
Why choose oil-free?
Oil-free systems use a range of technologies that remove the need
for lubricating oil. This eliminates the risk of contamination and
ensures guaranteed air purity.
There are many benefits to oil-free technology, which can help
energy managers make valuable cost savings while improving
operational efficiencies too. Whole life costs are reduced, with
businesses able to save on the cost of oil replacement. Unlike oil-
lubricated systems that require oil change intervals throughout
their service life, there is also no need to purchase equipment
that would clean and separate oil from air, such as oil separators,
filtration equipment and condensate treatment.
The latest oil-free solutions take advantage of innovative
technologies to help improve site efficiencies, too. CompAir’s
Ultima compressor, for examples, uses its efficient U-Drive
concept to maximise compressed air production.
Traditional two-stage compressors use a single motor and
mechanical gearbox design to drive the low and high-pressure
air-ends. In contrast, Ultima replaces the gearbox and single motor
with two high-efficiency, permanent magnetic motors, allowing for
performance optimisation throughout the complete volume range.
This technology offers energy efficiency savings of up to 13 per
cent when compared with other traditional, two-stage oil-free
compressors. The motors are powered by two separate inverters,
so they can be individually driven at different speeds depending
on demand. An intelligent digital gearbox design then monitors
and continuously adjusts the speeds of each aired, ensuring
maximum efficiency and pressure ratios at all times. Most
importantly, the compressed air it delivers is 100 per cent oil-free.
In conclusion
Oil-free technologies can provide additional assurance to
operators keen to mitigate risk – delivering clean, oil-free air that
can help reduce the likelihood of downtime and product spoilage,
while being mindful of the environmental concerns around waste
oil disposal.
To find out more about oil-free compressor technology, visit
https://www.compair.com/en-gb/oil-free-compressors
e: david.bruchof@gardnerdenver.com
 F¥CUS / COMPRESSORS
Variable Speed Drives:
energy efficiency
guaranteed
Oliver Kent, Product Marketing Manager - Industrial Air and Oil
Free Air at Atlas Copco explains that advances in technology
mean more air can be delivered from units with smaller
footprints, smart connectivity, and less energy cost.
T
ypically, a fifth of UK industry’s electricity bill is attributed
to the production of compressed air, but it is a sobering
fact that a substantial portion of the generated power
dedicated to its production is energy wasted.
That is why over 25 years ago, compressor technology leader
Atlas Copco addressed the problem and was the first to introduce
VFD/VSD technology in its screw compressors, which is
recognised as the greatest energy saving innovation in the history
of compressed air developments.
It is a fact that most operators who decide to purchase a
variable speed drive compressor do so primarily because of
the prospect of low total cost of ownership. Even though the
compressor’s initial price tag is likely to be higher than that
of equivalent, fixed-speed models − because of its greater
sophistication and advanced components – VSD compressors are
actually less expensive to own and operate over their lifetime.
That is because they consume far less energy and because the cost
of that energy makes up the bulk of a compressor’s total cost of
ownership.
The benefits of VSD+ technology
Now, in the form of the latest advanced solutions, compressors
with high-tech VSD+ specifications are not only capable of
achieving outstanding savings of up to 50% of their energy
requirement, but they offer the attributes of total functional
reliability and the essential benefit of smart control and
monitoring communication technology, such as the OPC UA
common language that allows equipment items to ‘speak’ with
each other.
Where these advanced compressors come into their own is
The GA 160 when air demand fluctuates significantly between jobs, varies
VSD with by shift on weekends or seasonally, and when manufacturing
Optimizer 4.0 processes require tight tolerances for operating pressure. But
is ready for of the three primary benefits that VSD+ technology brings to
Industry 4.0
and designed compressor users − energy efficiency, reliability, and connectivity
for smart – it is guaranteed energy efficiency that is the key to affordable air
factories with up to 50% achievable savings, and lower cost of ownership.
Stating the obvious, plant
operators can only enjoy
improved energy efficiency if the
compressor keeps on running
reliably. That is why market-
leading compressors are built
to function unfailingly even
in the toughest conditions.
Specifically, that means a
capability of operating at ambient
temperatures of up to 46° C and
Plant room with the GA90VSD+FF rotary screw compressor,
Optimizer 4.0 central controller, FX dryer and AirNet pipework.
making certain that the electrical cubicle of the inverter, a crucial
piece of technology for the efficiency of the compressor, can
withstand temperatures of up to 55°C.
The net results of all these dependable features are smooth
operation, productivity gains, increased uptime, and lower
maintenance costs. An additional benefit of this increased
efficiency is that it also lowers emission levels and allows for a
more sustainable production. As a result, a VSD+ compressor
does not just improve a company’s bottom line, it also helps to
protect the environment.
The principal game-changing innovation of Atlas Copco’s
VSD+ design is in the close-coupled IP66-rated drive train − the
combination of a high-efficiency motor and technically advanced,
asymmetric compression element. The IP55 motor was designed
in-house with special attention to cooling requirements and
efficiency.
With no coupling or gears between the motor and screw
element the compressors are exceptionally quiet, 73dB (A) in
operation and extremely energy-efficient in performance. The
vertical aspect drive train of the VSD+ machines is a closed
circuit in which both the motor and the element are cooled with
oil, thus contributing additional energy savings. Added to this
is an impressive 6% increase in free air delivery for improved
efficiency and performance, plus a reduction in the compressors’
total lifecycle costs in the order of 37%.
Overall, this new technology in the form of the latest
revolutionary, compact and smart VSD+ compressors brings
unprecedented levels of industry-leading performance and
savings to medium and large-scale operations − attributes
that can be summed up as more air, smaller footprint, smart
connectivity, and less energy cost.
www.atlascopco.co.uk/compressors
compressorsGB.web@atlascopco.com
ME / July/August 2021 / 35
 SITE, BUILDINGS, ENERGY & WORKS MANAGEMENT /
COMPANY NEWS & PRODUCT REVIEW ABSTRACTS
email kirsty@maintenanceandengineering.com to feature here

More Hart doors for Erwin Hymer 

Hart Doors has recently completed a contract for Erwin Hymer’s Consett,
Co Durham, plant where a range of Hart’s industrial doors from roller shutters
to Speedor Storms, Speedor Minis and a combination of a Speedor Storm and
roller shutter were installed.
Gordon Kipling, Hart’s Northern Sales Manager comments that Hart has been
involved with Eldiss caravans for many years prior to its acquisition by Erwin
Hymer, one of Europe’s largest manufacturers of motor homes and caravans.
“We are fortunate that they are going through a huge refurbishment,
reorganisation and rebuild project and have chosen Hart to be a part of it,” says
Mr Kipling. “The Storms were recently installed in a temporary warehouse and
we have also installed a range of Hart’s doors in other parts of the plant.”
Mr Kipling adds: “This is a great demonstration of how Hart Doors and its
excellent and reliable high-quality products work hand in hand with customers
to provide a solution to issues they may face.
“We offer design, manufacture, installation and service of a range of doors.
Our customers return to us time after time as we understand that one size
does not fit all.”
www.hartdoors.com  
t: +44 ( 0 ) 191 214 0404 A Speedor Storm at Erwin Hymer

Succeed with preventive behaviours,” says Svanäng. “When your company
adopts a kaizen mindset where employees are given
maintenance by engaging the opportunity to influence their workplace, it will
machine operators lead to more motivated employees.”
Tork®, an Essity brand, is launching a new guide to Recent research shows that 89% of machine
‘kaizen’ that aims to help businesses implement a operators believe that continuing to improve
culture of continuous improvement. preventive maintenance routines is important and
Equipped to Improve™ - A guide to improving 87% agree that preventive maintenance reduces
productivity, is available to download here and lost production time.*
contains concrete tips on how to implement a “We want to help companies improve preventive
continuous maintenance routines by contributing with smart
improvement and innovative products that can improve efficiency,
culture. In because we know small changes can have a
developing the significant impact,” says Jenny Turner, Marketing
guide, Tork worked Director for Industry for Essity’s professional hygiene
with kaizen expert, business.
Jonas Svanäng The Tork Performance® system therefore includes
“The goal of a wide collection of professional wiping cleaning
kaizen is to products to help optimise autonomous cleaning
establish a culture routines in industrial environments.
of continuous Visit www.tork.co.uk/equippedtoimprove to
improvement download the free guide.
by changing *Source: Tork machine operator research, Psyma (July 2019)
Thorite –
Nitrogen system
installations at
the University of
Liverpool
Thorite has successfully
completed installation of
a series of compressor
systems and Nitrogen generators for brand new
laboratories at The University of Liverpool.
The university is leading pioneering research
into coronaviruses and antimicrobial resistance to
antibiotics from their new Centre of Excellence for
Infectious Diseases & Research building. The research
laboratories required multiple nitrogen outlets which
are used in liquid chromatography, mass spectrometry
and a range of analytical instruments.
Thorite’s installation is is exceptionally energy efficient
and is based on a Parker NITROSource system which
consists of three, N2-80PALY nitrogen generators in a
two on-duty, one standby configuration.
t: 0800 092 1273 | e: capital@thorite.co.uk
w: thorite.co.uk.

New from world leading welding Knee and elbow protection

inverter manufacturer JASIC:
the TIG 200 Amp AC/DC machines Gotec Trading has a comprehensive
range of knee and
The JASIC TIG 202 Analogue Pulse AC/DC and JASIC TIG 202
elbow protection
Digital Pulse AC/DC are technologically advanced single-phase
to suit every
inverter power sources suitable for medium production work.
application.
The 202 Analogue has an innovative and user-friendly
• Ergonomic
analogue control panel allowing full control of the welding
parameters. design
The 202 Digital has an innovative and user-friendly digital • Comfortable
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The excellent technical characteristics of these models make fit
it an ideal choice for professionally qualified TIG welders • Reliable protection
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Optional water cooler and large cylinder trolleys are available. • Manufactured to the highest standards from
Both inverters come complete with TIG torch and adaptor, selected quality materials
gas regulator, work return lead and clamp. • CE marking throughout
All JASIC welding inverters carry in the UK and Eire a free • NATO Stock No: 22c 8415-99-8873869
five-year warranty supported by factory trained technicians offering you total peace of mind. t: 01438 740400 f: 01438 74005
t: 0161 7938127 | e: marketing@wilkinsonstar.com | w: www.Jasic.co.uk e: gotectrading.com

36 / July/August 2021 / ME
 SITE, BUILDINGS, ENERGY & WORKS MANAGEMENT / ADVERTORIAL

Combilift’s
60,000th truck
delivered
T
he Irish forklift manufacturer Combilift recently marked a further
milestone when its 60,000th unit came off the production lines
at the company HQ in Monaghan. This special forklift is being
delivered to Metroll, a leading Australian manufacturer and supplier of steel
building products.
Metroll has branches across the country, and the new Combi-CB3000
will be a further addition to its fleet of 13 Combilifts that are operating
throughout the Metroll Group, with another 10 already on order. These
range from 3t multidirectional units to a highly customised 10t model.
Combilift number 60,000 has been fitted with features such as 4.9m
triplex mast with a 3050mm spreader to safely and easily manage the
long loads that are typically handled by Metroll. requirements. There are very few other companies in the world, if any,
According to Metroll Operations Manager Vic Josephs: “Like most that can offer this level of customisation whilst manufacturing in such
businesses we are very busy and we’re also growing at a significant volume. The fi rst half of this year has also been by far the best in our
rate, so space has become a premium resource. With this unit we can 23 year history for the number of orders we have received across our
utilise our space more efficiently whilst at the same time ensuring safe complete product range. We’d like to congratulate Metroll on taking
operation, which is of paramount importance. This truck allows us to delivery of our 60,000th truck, and thank them for their continued
bring our racks more closely together to maximise factory floor space.” support over the years.”
Combilift CEO and Co-Founder Martin McVicar commented: “This
is a great achievement for Combilift, particularly as almost every www.combilift.com/60000 | www.metroll.com.au/
truck we manufacture is a one-off, designed for specific and individual Watch the video at https://youtu.be/eEuIGnhl_4U

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From the home of
innovation and
designed analysis (DGA)
British engineering:
• High-speed doors
to perform... Furfuraldehyde
• Security & Fire doors analysis
and shutters
• Bespoke door products
• Service & maintenance
Hydraulic Oils PCB analysis
excellence Dissipation Factor
Industrial
Gear Oils Interfacial Tension
(ITF)
Metalworking
0191 214 0404
Fluids Find out more
sales@hartdoors.com
www.hartdoors.com M&E Compressor Oils www.eatechnology.com
Greases
DOORS DOORS
DOORS LOCK OUT TAG OUT PRINTERS
Aerosols
Desktop technical label production

Daily Nationwide Mechanical and technical labelling is not always

square and not always one or two colours.

UK Delivery The SMS-R1 is a desk top system that can print

in multiple colours and cut any shape in minutes
and in any number of quantities.
Th
The SMS-R1 gives the process professional the
ability to create; prototype labels, part of prod-
For our latest uct labels, pipe identification, cable identifica-
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product range
brochure,
please call MORE INFO?
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CONDITION MONITORING SAFETY KNIVES

PRÜFTECHNIK – keeps your world rotating

Productive maintenance technology
PRÜFTECHNIK stands for proven
maintenance technology.
We develop, manufacture
and sell instruments and offer
service in vibration analysis and
advanced condition monitoring,
shaft alignment and geometrical
measurements e.g. bore
alignment, flatness measurement
and roll alignment. We also offer
support and training for anything
related to all these applications
PRUFTECHNIK Ltd.
with our own organization
City Wharf,
throughout UK and the world. Davidson Road,
Lichfield, Staffordshire,
www.pruftechnik.com
info@pruftechnik.co.uk
morrislubricants.co.uk
Tel: +44 (0) 1543417763 info@morris-lubricants.co.uk
Fax: +44 (0) 1543418268
MATERIALS HANDLING STEAM SYSTEMS TRAINING

Est 1980

PROVIDING
PRACTICAL
ENGINEERING

Have you thought

SKILLS
about outsourcing TRAINING
your steam system FOR INDUSTRY
maintenance?
• Service contracts

• Steam system audits

PIPEWORK
• Steam trap surveys

• Steam quality testing

• Boiler inspection INDEX OF

NUMBER ONE FOR
preparation
ADVERTISERS
PIPEWORK SYSTEMS • Burner servicing
ABB 24
• Valve refurbishment
Aerzen 13
FAST ASSEMBLY.
Plus much more... ARI Armaturen 17
TIGHT CONNECTIONS. Technical BEMAS 17
GALVANISED, +44 (0) 1242 521361 Training Combilift FC, 37
STAINLESS STEEL OR Solutions Dual Pumps 21
Faraday Predictive 7
POWDER COATED
Fibet 33
t: 01634 731 470 Fixturlaser 11
e: tech.training@zen.co.uk Fluke Reliability 24
jacob-uk.com +44 1694 722841 technicaltrainingsolutions.co.uk
Fulton 33
Gotec Trading 36
PUMPS THERMAL FLUID SYSTEMS TRAINING GSM Online Label Sales 19
Hart Doors 36
Humidity Solutions 23, 24
Professional Thermography Training IFM 5
BINDT Approved Training Organisation Kingston Engineering 23
ASNT-SNT TC 1A Certifications Labfacility 19
PCN Certifications
UK & International Training Locations Landia 19
In House Training Courses
Quantum Controls 15
...more than just pumps
Courses Available RMS 33
Level 1 Infrared Thermography
Level 2 Infrared Thermography Rotronic 11
Air Tightness Testing Senseye FC, 4
1 Day Introductions
1 & 2 Day Camera Operator Spectro Scientific BC
Thermal Fluid 0151 486 5120
info@irttraining.com
Sulzer
Thorite
IFC
36
Heating Visit www.irttraining.com for dates and
information
Tork 36
Total Energies 24
Technology now Turck Banner 15
for the future Infrared Training Ltd, Training & Conference Centre,
South Road, Liverpool, L24 9PZ Valuekeep 21
Water Jetting Association 37
• Up to 50% energy savings Wilkinson Star 13, 36
TRAINING
Winn & Coales 23
• Compact size
• Easy & safe to use noise vibration
• Works up to 350°C acoustics
• Low exhaust emissions
• High efficiency Diploma in acoustics and
noise control
• Requires no specialist
Short courses in:
knowledge
• Workplace noise assessment
• Corrosion free operation • Environmental noise
• Hand-arm vibration
• No chemical treatment
At IOA accredited centres throughout
the UK and Ireland.

Tel: 020 8953 7111 email: education@ioa.org.uk

info@babcock-wanson.com
www.ioa.org.uk/education-and-training
www.dualpumps.co.uk
www.babcock-wanson.com
01664 567226 01727 848195

ROUNDTABLES
Roundtables offer you the
opportunity to be the exclusive
sponsor of a topical debate of high
interest on a key market area at
an event which brings together
around eight key individuals from
the sector.
M&E is looking to host a series of roundtable
debates, bringing together senior figures from
across the industry to discuss emerging mobility
trends and issues that affect the sector and society
as a whole.
Topics of interest include:
• Made Smarter – industry digitalisation
• Skills and Recruitment, the impact of automation
• Cybersecurity and Industry 4.0
• Smart Factories
• From Condition Monitoring to Predictive
Maintenance
• Asset Management
If your company would like to host a roundtable
and see a write-up published in a future issue of
M&E, contact:
Commercial Director, Fawad Minhas 01892 553149
fawad@maintenanceandengineering.com
Business Development Manager,
Colin Campbell 01892 553143
colin@maintenanceandengineering.com
 Bringing the Power of Oil Analysis to your Plant
In our changing world, access to real-time information is business critical. In industrial plants, on-site oil
analysis with the MiniLab Series quickly provides early indications of equipment wear and identifies the root
causes of corrosion. The system’s rapid analysis eliminates the wait associated with sending samples off-site,
providing immediate actionable results. One product
delivers lab-quality analysis outside of the lab, when and
where you need it. And, when coupled with the TruVu 360
fluid intelligence software, operators receive color-coded
reports providing a clear snapshot of machinery health.

Learn more at spectrosci.com