EMS DEC-full d2 Med

December 2012
$6.80 4.16 5.00
Electricity Company Practices What It Preaches Page 16
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Maintenance Best Practice
12-19
Condition Monitoring Feature
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Boilers & Burners Feature
Based in Manchester, we supply GRP grating non slip flooring constructed from fibreglass, as an ideal and cost effective alternative to traditional grating materials like wood, mild steel and stainless steel. Our fibreglass grating is exceptionally slip resistant and the gritted and concave anti-slip grating offers excellent traction in wet and icy conditions. GRP Grating Systems fibreglass grating can also be supplied in various resin finishes to allow for many and varied applications such as offshore where fire resistance and low smoke are critical or environments where highly corrosive chemicals are present. Fibreglass grating is formed using continuous interwoven glass fibres as reinforcement material and resin as the matrix with continuous solidification through a mould system. The uniform construction provides excellent bi-directional mechanical properties. It is beneficial to all industries whether it be chemical, pharmaceutical, offshore or leisure to name just a few with many applications like platforms, floorings, walkways, trench covers, ramps and cable trough covers. We like to think of ourselves as a unique one stop shop facility offering customers outstanding service and quality products. We now offer the following. Full in house supporting steelwork design and fabrication. Full in house GRP Grating and walkway design and fabrication. Design, drafting and detailing services. On site installation, assembly and erection services. Project Management and support.
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Industrial Cooling feature - Cooling Tower Safety & Maintenance
Contacts
Publisher Michael Dominguez Editorial editors/contributing: Jon Barret, Christer Idhammar Advertising Paul Clappison Paul Miles Brian Simpson Steve Aslett Production Tom Britten Email Info@engineeringmaintenance.info Website www.engineeringmaintenance.info
P:5-7 Maintenance Best Practice
P:12-19 Condition Monitoring Feature
P:20-23 Product Spotlight
P:24-27 Boilers & Burners Feature
P:47-50 Buyers Guide

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Maintec preview ( Extra print run ) CMMS Compressed air Seals & Bearing / Lubrication
Pumps / Values Health & safety Training.
The Essential Elements of Reliability and Maintenance Management. Part 1

Execute them and you will get guaranteed results. By Christer Idhammar Founder and Executive Vice President IDCON INC, Raleigh NC, USA www.idcon.com
First I like to tell you about myself and from what perspective I write this series of articles. My world is process industries such as Iron, Steel, Pulp, Power and Wood based industries such as Oriented Strand Board (OSB), medium Density Fiber (MDF), Chemical, Oil and Gas, Food and Beverage etc. In short all industries where a break down of critical equipment assets results in risk for environmental damage, personal injury, lost quality and volume in throughput or high costs for maintenance. I lose some of my important arguments if reliability is not important because then the maintenance organization has no revenue. If reliability is not important the sense of urgency and importance in the work we do, as a maintenance organization is not there. When I was a very young man I signed on a big oil tanker as an apprentice in the engine room. After nine years of maintaining and operating huge powerful diesel engines that were 33 feet (10 meters tall), pumps, compressors, lubrication oil and fuel separators, hydraulic stabilizers, heat exchangers, fans, sewage systems, boilers etc. I had also graduated as an engineer. When I first came to work in a big industrial plant in 1968 to train people in preventive maintenance and help set up a computerized maintenance management system I wondered how I would manage to do that with my marine background. My first reaction was that equipment is equipment and it was not much different than what I had operated and maintained at sea. The difference was more that in an industry I could call for help if needed. Onboard a ship you had no one to call, you operated and maintained with a very limited crew. Another difference was that onboard a ship it was a way of life to constantly inspect equipment and to keep your area of responsibility very clean and organized. You also had to get all work planned for execution in next port. I realized later in life that this was a very good background because you managed a crew, operated equipment, planned work, scheduled work and also executed work. Reliability was very important to There are some differences that make implementation and execution of best reliability and maintenance practices more or less difficult. These are more cultural differences and it is important to know and understand these. They include but are not limited to: Political Systems make a difference in e.g. how profits are calculated. Taxation rules make a difference in how life cycle costs are calculated. Living standards are different between countries. In many countries with high living standard I often find a culture of entitlements and complacency and less of a desire to improve than in other countries where people are eager to learn and improve their everybody because it was obvious that you did not want to have unreliable equipment operating a fully loaded tanker in a storm or entering through the Suez Canal and other critical passages. But the system, processes and practices used to manage reliability and maintenance are not different. Nor have they changed in the last fifty or more years. What has changed and improved dramatically is technology including much better and more affordable computer systems and tools for condition monitoring. We have much better and more affordable equipment for measurements and analysis of component condition such as: Infrared cameras. Wear Particle Analysis. Vibration Analysis. Acoustic Emission Alignment of components. Stroboscopes. Ultrasonic methodologies. Etc. performance. Labor laws, working hours and employee benefits and unionization are very different between countries. Some industrial plants have many short and long shut downs others have no scheduled shut downs. This fact only changes the way you plan and schedule work that requires equipment to be down to do work. If your plant has scheduled shutdowns you must plan work before you schedule work to be efficient. If your plant has no scheduled shut downs, or if it is easy to shut down and start up again, then you should focus more on planning and execute planned work when the opportunity to access physical asset can be done safely and at best opportunity from manufacturing point of view.
International Phenomena
Today I work on a worldwide arena and observe the same problems, or improvement opportunities, in all countries and all type of industries. If you have worked as a reliability and maintenance professional in many industries and/or countries you also know that this is true. If you only worked in one plant you believe that you are unique and different than all other plants but that is very seldom the case. The reason why reliability and maintenance management is so similar between different types of industries and facilities lies in a couple of facts. Equipment does not break down, components such as; gears, couplings, control valves, transducers, seals and bearings break down. The whole equipment e.g. a compressor does not break down. These components are the same with some variations in all industrial plants. The environment they operate in is different but if an electric motor is covered by chocolate, saw dust or pulp the consequence is the same: it will overheat and shorten electric life dramatically. Some plants have a more aggressive corrosive atmosphere but again the consequences of corrosion are the same. Reliability and maintenance management is driven by the system and processes people work in, not by the physical assets the organization maintain.
All these technologies existed before the 1960s but they have become much better and more affordable.
Figure 1. The System The market drives the production plan and all maintenance work requiring shut down of equipment must be coordinated with the production plan for best time to be executed. When maintenance work is planned and then scheduled you have set the process people work in right so they can execute work much safer and more cost effective. To plan work
Engineering Maintenance Solutions
to Albert Einsteins definition of insanity: efficiently you must have access to an up to date technical database including Bills Of Materials (BOM) and other information. After work is completed it should be recorded as to what was completed, parts and material used, update information to BOM and other valid information. The recorded information shall be used to continuously improve using Root Cause Problem Elimination (RCPE). However, most organizations do not work in this Circle of Continuous Improvement they work more in the Circle of Despair. This means that they React, Repair with low quality because of the reactive mode and therefore will have to Return to do the work again and the circle Repeat itself. To get out of this Circle of Despair you must set up the processes for Prevention, Condition Monitoring, Prioritization, Planning of work, and Scheduling of work, Execution of Work, Recording of executed work and how to do RCPE. To do the same thing over and over and expecting different results This might hold true if you do the wrong thing over and over. However if you do the right things better and better over a long period of time you will generate substantial results. I know from a very long experience in industry that: Guaranteed results will be achieved by executing the basics of reliability and maintenance (the right things) better and better forever. The basics are perhaps not as glorious to talk about as many would like them to be but I find them very interesting and challenging because I am still interested in people and equipment and the fantastic results that can be achieved when an organization execute these well. Results can even be life changing for some people. Organizations today are spending way too much time on other more complex initiatives and therefore forget where the true improvement potential lies. The basic elements of reliability and maintenance are: Maintenance Prevention Inspect Prioritize Plan work Schedule work Execute work
The next steps to do to become as good as you can be include: Root Cause Problem Elimination Apply Life Cycle Cost when specifying equipment Design for Reliability and Maintainability in early equipment design Use tools such as 5S, Single Minute Exchange of Dice (SMED), Reliability Centered Maintenance methodology (RCM), to enhance performance of work within the processes that build the whole reliability and maintenance system A holistic overview of the reliability and maintenance management system, processes, elements and tools can be described in the models per figure 1 and figure 2. The structures of system, processes and elements described above are what we call Current Best Practices (CBP) for reliability and maintenance. If you do an audit it is on the level of elements that you evaluate and discover improvement potential and the gap between how good your organization is and how good it can become. A good advice is to only focus on the right things to do and not discuss how you can do these things. That comes as the next step. The reason for this is that the first step must be to agree on the right things to do. Because the elements are all common sense, we know from a very long experience that your organization will agree. They might not agree on how you are going to implement these elements. As a leader you must show what your beliefs are and give your organization a direction and that is what you do here. Then you bring your organization with you to help execute your strategy. You can say that the well described 245 elements comprises a very well documented reliability and maintenance strategy and if this strategy is not executed you have wasted money and time to develop it. Figure 3 shows what we often find in many organizations.
The Processes
An example of a process is Planning and Scheduling, or the Work Management Process. It contains several steps and starts with Work Request then Priority of Request etc. as seen in figure one.
The Tools
The tools are used to improve the processes and enable and enhance how well you can execute the processes. It is very important that Processes and Tools are not mixed up. To be successful you must have a very well established system including its processes. Tools are good and very useful when used in the right environment. Implementation of only a tool will only result in temporary improvements. The system and processes must be in place to support sustainability and continuous improvement. Figure 2. Within the process called Planning and Scheduling each step consists of a number of elements. E.g. best practice within the work request process is that the request is not a work order and shall be done using the Computerized Maintenance Management System (CMMS), the requested priority shall be done according to a priority guideline agreed to between operations and maintenance, The object identity shall be clearly described verbally and with equipment number, etc. per figure 2. These elements are what we call the right things to do. If you do not Execute these things very well you will never have time to do what you know you need to do to become as reliable and low cost as you can be. I stress the word Execute because most organizations know what they need to do but very Anyone who have attended any conference, including conferences covering the subject of Reliability and Maintenance, have heard several speakers referring few do it. So many strategies and improvement plans are developed and so little Execution of the very basic elements of reliability and maintenance occur.
Do the Basics better and better

My advice is to never forget to improve execution of the basics of maintenance. This was true 50 years ago and it is still true. Too often we complicate things beyond what is necessary. In the field of reliability and maintenance many tend to give new names on what in the end anyway comes down to the basics. TPM, RBM, VDM, QCC, RCM and many other acronyms lead to confusion in the message you need to send to your employees in the maintenance organization. If you mix up where all these tools and concepts fit in with your strategy your organization will soon start talking about the Program of the month and they lose faith in you as a leader.
Figure 3. Many organizations are spending much time to develop and document a reliability and maintenance strategy and not much time to implement and execute this strategy. Many will even change the strategy when a new key manager arrives. This is not uncommon. It is quite obvious that a strategy must be executed otherwise it served no other purpose than to keep people busy developing it. Best organizations execute a well defined, documented and continuously communicated and reinforced strategy and the strategy is long term and does not change when new key managers are employed.
Latest Industry News
Transmitter Displays and Controls pH

and ORP Values for Process Monitoring
TX-3000 pH/mV from Sensorex provides real-time data
Garden Grove, California (30 October 2012) Sensorexs TX-3000 pH/mV Transmitter monitors changes in process fluids, displaying pH or oxidation reduction potential (ORP, measured in mV), and temperature for more accurate control in water, chemical, electronics, food production, environmental and wastewater applications. The line-powered TX-3000 can be user programmed on-site to measure either pH or ORP (Redox). Its dual output design, with an isolated (0)4 20mA output for pH or ORP readings and one for temperature measurement, eliminates the need for a separate temperature transmitter. A large backlit LCD screen displays both parameters simultaneously and two adjustable Hi/ Lo relay contacts deliver results to automated process control systems. With an extended pH measurement range of -2.00 to 16.00, the TX-3000 is suitable for a full range of applications. The NEMA 4x, IP65 enclosure can be wall, panel, or pipe-mounted for easy integration in most installations. The TX3000 can be easily programmed onsite with its push button interface. The unit can be password protected for secure installations. To learn more about the TX-3000 as well as the companys full range of sensing products, visit www.sensorex.com, email sales@sensorex.com, or phone +1 714-895-4344.
Pump Excels in Polyurethane Production Pumping Polyols and Isocyanate.

Wanner International has introduced a range of HydraCell multiple diaphragm pumps that it has developed to meet the specific needs of polyurethane production.
Isocyanates, when exposed to air, tend to form crystals that generate premature wear in pumps with dynamic seals while Polyols, especially those containing abrasive fillers, are equally as destructive to seals and bearings. The Hydra-Cell multi-diaphragm pump has no dynamic seals and consequently handles abrasive particles with ease, significantly reducing maintenance costs. Now with new PTFE diaphragms, chemical compatibility and service life are no longer concerns. Hydra-Cell pumps with these new diaphragms have been tested extensively and shown to be able to operate reliably at full flow under flooded suction conditions. Meeting the performance standards of API 675, Hydra-Cell pumps are highly accurate and repeatable, ideal for dosing and injection duties. Being completely contained, without dynamic seals, they provide no leak paths for potentially harmful chemicals and their multi diaphragm design ensures low shear, low pulsation delivery. The service life of the new PTFE diaphragm is now extended to 240 million cycles; 4000 hrs @1000 rpm, said Nick Herrington, Marketing and Technical Support Manager. This brings diaphragm replacement into line with regular maintenance cycles.
MAINTEC Announces Movember Winner

Nick Pither, Technical Engineering Manager at Mixing Solution Ltd has won MAINTECs Movember competition.
MAINTEC, the UKs only show dedicated to industrial maintenance and asset management, challenged all those working in the industry and taking part in Movember, to share an image of themselves with their Mo. The images were then put in a special MAINTEC facebook album and assessed by a panel of judges. Commenting on the judging process Katie Morhen, Marketing Project Manager for MAINTEC 2013 which takes place at the NEC in Birmingham on 5-7 March 2013, said: We judged the mos based on growth, style and general flamboyance - with added mo points awarded for photos taken whilst people rocked their mo at work. So as you can imagine, judging was a lot of fun! We had some great entries with, appropriately, lots of mo maintenance skills on show, but Nick was the clear winner. As his prize, Nick Pither received 100 from MAINTEC to put towards his Movember fund. Movember, which takes place throughout November, is responsible for the sprouting of moustaches on thousands of mens faces in the UK and around the world. The aim of which is to raise vital funds and awareness for mens health, specifically prostate and testicular cancer. Visitor registration for MAINTEC 2013 is free. To register visit www.easyfairs.com/ maintecuk. Stand bookings for MAINTEC 2013, which takes place on 5-7 March at the NEC, Birmingham, can be made by contacting Jerry Dawson on +44 (0)20 8843 8823 or email Jerry.Dawson@easyFairs.com. For further information visit www.easyFairs.com/ MAINTECUK.
HEALTH AND SAFETY INSTANT ADHESIVES

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

Parkers standard mill cylinders are available in two ranges. The MMA series is rated at 250 bar working pressure and conforms to ISO 6022 and DIN 24 333, while the MMB series of 160 bar cylinders conforms to ISO 6020/1.
Both MMA and MMB series cylinders incorporate features such as removable glands and separate bodies with detachable heads and caps to ensure ease of maintenance and low whole-life operating costs. Steel and aluminium mills, paper mills and plastic injection moulding machines are just some of the applications where the cylinders can be used. Parkers mill cylinders are available in a wide range of bore sizes up to 320mm diameter and in stroke lengths up to 5 metres. Standard features include precision ground, hard chrome plated and polished piston rods, which are induction hardened as standard on bore sizes Mill cylinders can be used at operating temperatures of between -20C and +150C and up to 200mm diameter. Detachable threaded flanges for head and cap retention simplify maintenance, while heavy wall steel tubing honed to a high surface finish ensures a long seal life. Optional features include adjustable cushions at both ends for shock suppression and high speed cycling performance, air bleeds, gland drains and special modifications for water service. Where precise control over performance and positioning is required, feedback devices and non-contacting position switches can be specified.
Above: MMA Series 250 bar mill type hydraulic cylinder
generate up to a massive 2000kN, making them the ideal choice for high force applications in the toughest conditions. For more information, visit the companys web site at: www.parker.com Or its investor information web site at: www.phstock.com
Latest Industry News
Southern Manufacturing & Electronics 2013

The UKs top industrial technology exhibition returns to FIVE, Farnborough, 13th & 14th of February 2013.
Southern Manufacturing is the UKs premier marketplace for industry and manufacturing, covering just about every aspect of production and maintenance, including tools, consumables, safety equipment, test & measurement, labelling, storage and many more. See hundreds of top suppliers in one, easy to get to venue with free entry and free onsite car parking. See presentations delivered by an outstanding line-up of experts the shows free technical seminar programme; see live demonstrations of the latest equipment.
LEEP produced channels enhance fluid management

Functional components that use etched channels to transport liquids are becoming increasingly popular in a variety of fluid management applications, such as diffusion bonded plate heat exchangers, mixers, reactors, heat sinks and fuel cells.
Precision Micro has become a centre of excellence in the design and production of such components using LEEP, a precision chemical machining process that incorporates laser technology. Plates are profiled and channels generated simultaneously in a single etch process, before being stacked and laminar bonded, or simply held under pressure to form a functional matrix. Precision chemical machining imparts no mechanical or thermal stress on the plate that could compromise its planarity (flatness). Alternative manufacturing methods such as CNC milling, stamping or laser machining, can generate thermal distortion and machining detritus that can compromise stack bonding. The versatility of the etching process enables designers to vary the size and shape of channels and incorporate headers, collectors and port features, knowing that they can be produced economically without the need for extra process steps. A further benefit of the process is the ability to control the etchant chemistry, which in turn controls the non-directional surface finish within the channels. As well as achieving a four-fold improvement in pitch accuracy across an 800mm x 600mm sheet of components, the LEEP process guarantees top/bottom side alignment of component features. This enables highly accurate channels to be produced on both sides of the plate, and also simultaneously. In this way high channel densities can be achieved, and by interlacing top and bottom side channels, stack heights can be minimised and thermal transfer improved.
Entry and seminar registration is free, quick and easy online at http://www.industrysouth.co.uk You can also catch up with all the news from the show at http://blog.industrysouth. co.uk or by following #southmanf on Twitter and LinkedIn
University Of Greenwich Cuts 10,000 From Air Handling Bill

The University of Greenwich is set to save 10,000 on its air handling costs across its three campuses following the installation of ABB variable-speed drives at a number of its buildings. Additional savings from further projects could cut running costs by another 4,000.
The university is determined to reduce its energy bill while also cutting its contribution to CO2 emissions by targeting energy efficiency improvements across its teaching faculty buildings and other facilities. David Blackman, Building Services Engineer in the Universitys Building Services department says: The University has a five year target to reduce its carbon emissions and this is one project we had identified as being capable of contributing to that. We worked on the premise that most of the air conditioning plant is overrated and that we could reduce the speed of the fans without affecting the air flow adversely. Blackman asked ABB Drives Alliance member Mid Kent Electrical (MKE) to investigate the potential for using variable-speed drives (VSDs) on air handling units (AHUs) in buildings on the Medway, Greenwich and Avery Hill campuses. Russel Kimpton of MKE says: Starting on the universitys Medway campus, we looked at the air handling equipment across several buildings and recorded motor and fan data. During our survey of the site we found that many of the fan units have rated speeds and powers less than that of the motors. These were either being run too fast or the speed of the motor is being reduced by the pulley ratios on the belts driving the fans. We were also told that when the original system was set up, airflow was adjusted by setting dampers on vents at room level. MKE looked at air handling installations in the six buildings on the Medway campus Blake, Hawke, Anson, Nelson, Grenville and Pembroke. Monitoring was carried out on the AHU3 fan motor in Anson. Over the two day test period, while running on normal direct-on-line operation, the 4 kW motor consumed an average of 3.353 kW, for a total annual running cost of 871. Running the motor for two days using an ABB ACH550 HVAC drive consumed an average of 2.087 kW at a total annual cost of 542. These results were extrapolated to produce estimated savings for the motors in the other buildings, a total of 44 installations with a combined installed power of 127 kW. It was estimated that following the installation of VSDs on these fans, the fan applications would save some 10,472 a year in running costs, as well as reducing carbon emissions by over 57 metric tonnes per annum. MKE recommended that the applications highlighted in the report should be fitted with ABB VSDs, a project which has now been completed. MKE also recommended conducting further investigations to establish the rooms served by each air handling unit and each extractor fan. This would highlight areas where additional savings may be achieved by further adjustment of both vents and VSDs. Further investigation of the Greenwich campus revealed the potential to save 883 on the Dreadnought, Queen Mary and Stephen Lawrence buildings, with a corresponding reduction of four metric tonnes of CO2. The King William building on the Greenwich campus could save a further 1,157 a year, cutting CO2 by five metric tonnes a year. Avery Hill campus could save 2,157 per annum in running costs with a cut in CO2 of 10 metric tonnes a year. Total monetary savings from these additional projects could amount to 4,197, with a total cut in CO2 of 19 metric tonnes. Says Blackman: We were looking for payback times on the projects of around five years, yet most were much quicker than that. We are very pleased with the outcome of the project and consider it very worthwhile doing. MKE are a good company to work with and there were no problems throughout the contract. ABB (www.abb.com) is a leader in power and automation technologies that enable utility and industry customers to improve performance while lowering environmental impact. The ABB Group of companies operates in around 100 countries and employs about 145,000 people.
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Continued Success For Sensonics In The Far East

Condition monitoring specialists SENSONICS are enjoying continued success in the Far East with new contracts for their innovative Sentry G3, high performance sensor conditioning and monitoring system. In addition to a number of successful installations at power plants in China is another project in Vietnam at the PhaLai Thermal Power Plant.
shaft vibration and eccentricity, the sensor was required to monitor speeds from 3 to 300rpm when the turbine was started, with a unit of measuring um (10-6 m). Finally, a speed sensor covering the range of 0-4000 rpm (turbine rated speed of 3000rpm) was required with 2 alarms for over-speed of 10% and 16% in comparison with the rated speed. Following the installation of the Sensonics system on the older Russian built turbine, engineers at the PhaLai plant have been very satisfied with the performance and as a result have asked Sensonics to quote on additional monitoring systems for their Japanese manufactured turbine.
The completion of the installation at the PhaLai Thermal Power Plant in Vietnam project is In conjunction with local agents AKA Vietnam, Sensonics supplied transducers and a Sentry G3 Turbine Monitoring / protection system for the 110MW Russian built turbine operating at the PhaLai Power Plant. These were for a wide range of functions including; shaft position, high / low pressure cylinder expansion, turbine block expansion, shaft vibration and eccentricity speed. The PhaLai site has two power plants, an older facility with eight boilers and four 110MW turbines, all Russian built and a newer facility with two boilers and two Japanese manufactured 300MW turbines. Also, turbine block expansion to measure the expansion of the turbine block relative to the The retrofit project was fairly complex and included a number of variants which the Sentry G3 system was required to monitor. floor, specifically temperature from 55 to 65C, pressure from 15 to 20 kg sq/cm, vibration from 18 to 20 um and also oil vapour detection. For For example, Shaft position measuring and monitoring, relative to the position between the turbine shaft with the bearings. The system also automatically protects the turbine when the relative position is over the pre-set level. Specifically, the turbine will be stopped when the shaft move to the generator side 1.2mm or when the shaft move to the turbine side 1.7mm (-1.7mm to + 1,2mm). Other variants include; high and low pressure cylinder expansion, with both requiring an alarm signal. Further details are available from: Russell King, Sensonics Ltd, Berkhamsted, Hertfordshire, UK. Tel: +44 (0) 1442 876833. Fax: +44 (0) 1442 876477 Email: sales@sensonics.co.uk Web: www.sensonics.co.uk another example of continued success for Sensonics in the Far East and underlines their commitment to developing the most effective solutions for vibration, position and speed monitoring for critical machine condition monitoring applications around the world.
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Easy Mounting IML Lock eases Maintenance of Valves and Actuators

Smith Flow Control (SFC) has introduced its ISO-pattern IML intermediate lock with universal mounting.
The IML lock uses an operating key to lock the actuator in an open or closed position so that the valve cannot turn -- no matter what. No custom brackets are required; any valve or actuator with ISO standard mountings is compatible with the IML lock. In normal operations, actuated valves respond to process commands in a pre-determined way. But during maintenance, the command architecture may need to be stopped. Ensuring that the valves are set in their failsafe position enables work to be done safely. The IML intermediate lock is available as a key-operated system from the control room or as a standalone lock-out system. Lock Boxes are available with base tags that match up to each lock-out key for ease of identification. The IML lock is made of sturdy 3/16 stainless steel built for harsh environments. All ISO 5211 patterns F05, F07, F10, F12, F14, and F16 are covered by the IMLs six models. For more information, please visit the companys website at: www.smithflowcontrol.com or call +44 (0) 1376 517901
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Schaeffler Provides Online Condition Monitoring Of Turbines At Crystal Rig Wind Farm
an alarm. The vibration monitoring data can be
Bearings and condition monitoring specialist Schaeffler (UK) Ltd has supplied five online condition monitoring systems to wind farm developer and operator Fred.Olsen Renewables (FOR). A further 20 condition monitoring systems from Schaeffler are expected to be installed later this year on the remaining turbines.
In May 2012, FOR installed five FAG WiPro s condition monitoring systems from Schaeffler on five wind turbines at the Crystal Rig wind farm in Scotland. These systems continuously monitor the condition of the main rotor bearings, gearbox and generators, with Schaeffler UK also providing remote monitoring services on a 24/7 basis. Crystal Rig wind farm is located on the Lammermuir Hills, approximately 40km east of Edinburgh in the Scottish Borders. When Crystal Rig wind farm commenced operations in October 2003, it was the largest onshore wind farm in Scotland, with a rated output of 50MW. The hub heights of the Phase 1 wind turbines are 60m with a rotor diameter of 80m. The system combines all control modules into In phase 2, a further five wind turbines were installed at Crystal Rig, bringing the total number of turbines to 25, generating a total capacity of 62.5MW from May 2007. Stuart Naylor, Operations Manager at Fred.Olsen Renewables UK commented: We are delighted with the condition monitoring systems and remote monitoring services provided by Schaeffler and we look forward to continuing and further developing this working relationship in the future. Back in September 2011, when we were looking for a FAG WiPro s monitors vibration conditions, which if left undetected, can cause costly unplanned shutdowns of wind turbines. These conditions include damage to bearings and gears, as well as shaft misalignments. If a specified threshold value or alarm limit is exceeded, the system triggers a single compact housing, which measures just 260 x 150 x 90mm, enabling easy installation in control cabinets. The integrated multiplexer enables the recording of signals from up to eight different sensors. suitable UK-based supplier, we found Schaeffler to be extremely professional and competitive, as well as demonstrating confidence that their system could provide us with the most suitable condition monitoring system. Additionally, Schaeffler offered flexible training, remote monitoring and reporting services to meet our requirement. Schaefflers FAG WiPro s is an online condition monitoring system that is suitable for the permanent monitoring of wind turbines. The system is extremely compact, with the monitoring unit and multiplexer integrated in a single unit, which offers a high degree of flexibility for end users.
analysed directly on site at the central control station or this data can be retrieved via a TCP/IP communications link and analysed by either the end user or by Schaeffler. Integration of oil quality (particles) as part of the monitoring is also possible. On each of the five wind turbines being monitored at Crystal Rig wind farm, weve installed six vibration acceleration sensors, stated Dr Steve Lacey, Engineering Manager at Schaeffler UK. One of these sensors is a special, low frequency vibration sensor that monitors the main rotor bearing and there is also a low frequency vibration sensor on the input shaft to the gearbox. Two additional standard vibration acceleration sensors are installed on the power train gearbox, with a further two vibration sensors on the generators. These sensors provide us with 24/7 vibration data including both timebased and frequency-based vibration data which enables us to look for faults or to detect problems early. Since the condition monitoring systems were installed in May, weve picked up a couple of faults in the generator bearings and identified early problems with some gears on a planetary gearbox. These faults were confirmed by Fred.Olsen by using fibre optic cameras [endoscopes] to look inside the gearbox, he added. For more information on Schaefflers condition monitoring systems for wind turbines, please call Schaeffler UKs Marketing Department on 0121 313 5870. Alternatively, email info.uk@schaeffler.com
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Electricity Company Practices What It Preaches

When it comes to high voltage electrical inspection a high end thermal imaging camera is undoubtedly the best choice.
Quite simply, a more powerful camera allows an image to be seen in far greater detail over distance. And this is vital for the safe thermal inspection of high voltage lines and substations. For this reason the Electricity Supply Board (ESB), Irelands premier electricity utility, uses FLIR P-Series cameras. These state-of-the-art cameras were supplied by FLIR Systems Irish distributor, Butler Technologies in Maynooth. They have the highest resolution detector in the predictive maintenance market, thermal sensitivity of up to 30mk and come with a wide range of built in features for efficient thermal imaging and advanced analysis. All four of ESBs FLIR P-Series models have interchangeable optics, so in addition to the standard 24 or 45 lens supplied, each camera was also ordered with a 7 lens. This provides almost 3.5 x magnification by comparison with the 24 lens and is therefore ideal for inspecting overhead power lines. There are of course many other applications involved in maintaining the efficient running of a substation that lend themselves perfectly to thermal inspection. Some of these do not present any arcing risk and can therefore be conducted safely within a shorter range. It was for this purpose that ESB sought a camera model that would provide the same level of image detail as the FLIR P-Series at a closer distance from the target. I conducted a trial on site with one of ESBs senior engineers whereby we compared the temperature measured by his FLIR P660 camera with that captured by a top-of-the-range FLIR i-Series Another significant benefit of this upgrade for ESB is the ability of the FLIR E50 and E60 to accept different optics. Whilst the 7 lens is only suitable for use with the FLIR P-Series, the E-Series can be fitted with the 45 wide angle lens or a telescopic 15 lens, considerably broadening application potential. Both have an integral 3.1 Megapixels visible light camera, thermal fusion for merging visual and infrared images for easier analysis and scalable picture-in-picture that allows the user to clearly identify areas of interest. A laser pointer is provided as standard as is Wifi for the wireless transmission of images to a smart phone or similar mobile device. These models are also MeterLink enabled which means they can receive measurement data from a similarly equipped clamp meter. Founder and Chief Executive of Green Workplaces, Siobhan Hamilton said: The ESB scheme provides employees with a tool that assists them in their personal space. And one of the best ways for organisations to engage employees in workplace sustainability initiatives is to show them how they can make cost savings at home. This is a scheme that could be adapted to work in other organisations and community groups. FLIR Systems Ltd. Tel: +44(0)1732 220011. Fax: +44(0)1732 843707. Email: sales@flir.uk.com Web Site: www.flir.com With the introduction of the new FLIR E-Series, ESB has since been able to obtain even better camera performance for its wider engineering community. The original FLIR i-Series cameras have now been replaced with the FLIR E50 and E60 models. Standard features and high resolution belie the entry-level status of these cameras. The FLIR i-Series cameras supplied by Butler Technologies are also the lynchpin in a brand new award winning initiative introduced by ESBs Sustainability Team. Through this scheme, ESB staff can borrow a FLIR thermal imaging camera to learn how efficiently their homes use heat. A phenomenal level of interest has been shown, with over 320 staff registering within the first two weeks of operation, necessitating the purchase of another FLIR E-Series camera to meet demand. The success of the scheme has been acknowledged by Green Workplaces established to provide a resource for likeminded companies to share ideas on safeguarding the environment and promote best practice. The organisation runs its annual Challenge competition to recognise excellence in endorsing environment efficiency and this year it judged the ESB scheme a worthy winner. camera which I operated over a much shorter distance, explained David Doyle from Butler Technology. The results were the same. So this camera was also approved for use, allowing more ESB engineers to take advantage of thermal imaging without the company needing to rely solely on its FLIR P-Series cameras. It was a highly cost effective solution. Making thermal imaging available to more ESB engineers was certainly the driving force behind the companys second wave of thermal imaging camera investment but it has now been able to extend this privilege to its entire workforce.
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New Fluke Visual Thermometer Makes Infrared Imaging Affordable

Just over 200 years ago, the famed British composer and astronomer Sir William Herschel discovered infrared radiation.
Today, test tools using Herschels infrared discovery enable professionals in many fieldssecurity, healthcare, maintenance, HVAC, automation, building inspection and energy managementdetect and fix problems otherwise invisible. Now a new innovation, the Fluke VT02 Visual Thermometerdeveloped with British innovator Infrared Integrated Systems Ltd, (Irisys)is bringing affordable infrared testing to technicians who once had to choose between limited IR thermometers and costly thermal imagers. The VT02 is genuinely a new category of product, said Tim Wheatley, Chief Technical Officer for Irisys. I dont think its right to compare it to either a spot radiometer or a thermal imager. Its neither of those things. Its very much a completely new style of product. Early infrared sensors detected infrared radiation using single element detectors, and created line images. The military learned to use these infrared images to see targets, even in darkness or smoke. But these early infrared sensors were costly, and some types had to be actively cooled to function. A new type of uncooled sensor, the microbolometer, was developed in the late 1980s. Now thermal imagers could be built small enough to be hand held, at a cost more users could afford. Today thermography is widely used. Firefighters use it to see through smoke. Installation and maintenance technicians use thermography to detect faults in electrical, mechanical and steam systems. Building analysts detect air leaks and insulation faults. Fluke and Irisys: a Legacy of Infrared Innovation In the second quarter of 2012, Fluke Corporation, a world leader in calibration and hand-held test instruments, acquired the privately-held British firm Infrared Integrated Systems Ltd, (Irisys), to enhance the companys R&D capabilities in thermography. Founded Your Time or Your Money Until now, infrared testers were divided into two categories: infrared thermometers and thermal imagers. The low-cost (<75) answer was the in 1996, award-winning Irisys is based near Northampton in the UK. The company invests a double digit percentage of revenues in R&D and holds more than 70 patents. One in six employees and one in three on the R&D team has a PhD. Both firms have a long record of innovation in thermography. Fluke, world famous for the durability of its test tools, offers both tough infrared thermometers and a line of thermal imagers designed for extreme field use. Irisys used its expertise with infrared sensors and software to create the field of queue management, using heat sensors to count gathering customers and software to predict their likely behaviour. Irisys systems signal retailers and service firms to add service staff when queues grow long, or reassign staff to other tasks when lines are short. The result: greater productivity and happier customers. No-one asked us to invent queue management, said Irisys Technical Director Lindsay Galloway. We came up with the concept because we developed the technologies and saw a new way to use them. Then we asked our customers, if we could do this for you, would you buy it? The answer was yes, and Irisys still dominates the international queue management industry. Today Irisys continues developing new ways to use thermography, with innovations in security, healthcare applications and industrial diagnostics. With the new Fluke VT02 visual thermometer, the two firms have created a thermography tool that sets a new standard in performance per dollar, and puts thermography in the hands of a broad new group of technicians. infrared point and shoot thermometer, which measures the average surface temperature of a spot that varies in size depending on the specification of the thermometer and its distance from the target. Like other infrared testers, these deliver the advantage of safety (taking readings from a safe distance). They require little or no training to master, and they are inexpensive enough to provide one to nearly every technician. But there are disadvantages. Taking a detailed temperature profile of a system requires the technician to see and write down multiple temperature readings and record where they were made. In addition, its hard to know exactly how large an area or spot the sensor is seeing and measuring. Thermal imagers provide far more detail and sophisticationat a price. A single image can provide hundreds or thousands of individual temperature readings, one for every pixel in view. These pixels display a heat map that makes for rapid identification of hot spot problems. Some imagers make it possible to blend thermal and visible light images, making it easier to locate a problem. These images can be recorded, and processed for viewing using software. But it takes considerable training to get the most from
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heated. That variable resistance is then read out. The method that we use actually uses a pyroelectric ceramic sensitive to changes in surface temperature. It creates a charge proportional to the change in temperature on the surface of the device. Its the charge, effectively, that we read out. Pyroelectric technology costs much less to manufacture than a microbolometer, but getting it to form a thermal image was a challenge. The most common use of pyroelectric technology is in motion sensors, like those used in Irisys queue management systems. But rather than creating a thermal image, Wheatley said, signals from queue management sensors detect changes in temperature, and drive sophisticated artificial a thermal imager, and its cost (>1500) means most shops will have only one. In some industry segments, such as heating, ventilation, air conditioning and refrigeration, the cost and training requirements have prevented many from adding a thermal imager to their portfolio. Shops that face the impending departure of many senior technicians may resist investing in thermography training for their replacements. Yet the value of infrared testing is unquestioned. The answer: a new kind of infrared tester, the visual thermometer. The Head of a New Class of Infrared Testers To fill the space between the two infrared technologies, Fluke set out to design a product to provide quick, easy temperature readings in a visual contextone affordable enough that every technician on a team could have one with him at all times. Traditional thermal imaging technology was not the answer. Thermal imaging is based on the microbolometer, which requires vacuum sealing and very precise manufacturing that makes it too expensive for this type of application. Meeting the goals of affordability and ease of use was going to require a new technology and manufacturing approach. Enter Irisys. The approach that Irisys has used to develop our infrared sensors is fundamentally different from the standard bolometer technology, said Wheatley. Basically, the microbolometer works by having a resistance that changes when its intelligence algorithms that help merchants respond to customer activity. For the Fluke VT02, Irisys developed a unique hyper-thin film on which it can manufacture an array of elements dense enough to create an image. This is the engine that drives the Fluke VT02 Visual Infrared Thermometer. Its multiple pyroelectric sensors enable the Fluke VT02 to deliver far more than a single temperature reading. The user sees a thermal map of the test area that shows exactly where the hot and/or cold areas are. The tester shows the temperature at the centre crosshairs, and the hottest and coldest spots in the image are marked. In addition, the Fluke VT02 can record a visible light image of the test area. By combining the thermal and visual views, the technician can More Images, More Data for More Users The new Fluke VT02 Visual Thermometer makes a powerful set of capabilities available to many who thought such sophisticated infrared testing was out of reach. Many technicians have known about thermography and wanted a thermal imager, but just could not justify the capital investment required, or spare the time for the training needed to get maximum value from an imager. If such a tool were available, it was likely reserved for use by a trained plant engineer. With the Fluke VT02, those limitations are history. Now the HVAC installation and repair technician, the smaller industrial user, and the general facilities maintenance technician can afford this rugged, highly capable toolto carry on a regular basis or add to the shop tool inventory. Theres no need for time-consuming training to make the most of this tool. This is really placing the ability to do thermal analysis into the hands of tradesmen, said Wheatley. For professionals like these its a new day for infrared testing. That day dawns with the Fluke VT02. make it clear exactly where the thermal image is recordedand where any maintenance issue can be found. Visible gives you a certain level of information that you cant get from thermal, Wheatley said. If you scan something thats got writing on it, for example, you cant see that with a thermal imagerso the visual overlay helps you do that. But traditionally it does tend to be more of a high-end imaging function. Its essential to see the problem, but may be even more important to document your discovery and report the solution to your boss or your customer. Thats where Fluke SmartView Thermal Imaging Analysis and Reporting Software proves so valuable. The Fluke VT02 is shipped with SmartView software, a proven suite of tools to view, optimise, annotate and analyse thermal images. With SmartView the technician can generate fully customised, professional reports in a few easy steps. Its easy to use for customers with basic needs, yet delivers the performance that advanced users demand. All future software upgrades are included.
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SPM Instrument Announces The Release Of Leonova Diamond

SPM Instrument, announces the launch of its next generation of handheld measuring devices, the Leonova Diamond; a portable instrument for condition measurement in rough industrial surroundings.
Alongside SPM HD, Leonova Diamond also offers highly sophisticated vibration analysis capabilities. The instrument boasts an excellent signal-to-noise ratio and provides razor-sharp spectrums even where signals are weak and low in energy content. The wide frequency range, covering from 0 to 40 KHz, enables measurement where absolute position is vital. For machinery This heavy-duty yet sophisticated instrument brings powerful analysis and troubleshooting capabilities to your condition monitoring program, offering unique productivity and efficiency. with journal bearings, Leonova Diamond reliably measures dynamic and centerline movement of the shaft. Multi-channel measurement enables the use of triaxial transducers and multi-axes vibration monitoring while cutting long measuring routes Condition monitoring the SPM way is uniquely easy to learn and utilize. Highly advanced measuring techniques, optimized for a minimal and smooth learning curve, quickly brings your maintenance department up to speed, providing organised management for large numbers of routine measurements. Immediate, on the spot condition evaluation is also a trademark of all SPM measuring devices. Leonova Diamond incorporates highly advanced and innovative order tracking functionality. The powerful HD Order Tracking, applicable in an RPM range from just a few to thousands of revolutions per minute, enables more precise measurements Building on the successful Leonova platform, Leonova Diamond features state-of-the-art digital technology and a robust, rugged design. Leonova Diamond is the first portable instrument offering the recently patented and award-winning SPM HD measuring technique for condition monitoring of rolling element bearings. Capable to reliably measure machine condition in the 1-20.000 RPM range, the method has broadened the potential scope of condition monitoring to include more machinery than ever before. SPM HD brings to light machine problems which are impossible to monitor with traditional vibration measurement techniques. The powerful Condmaster Ruby software fully supports the Leonova Diamond features, providing setup of personalized default settings for the instrument and all the expert knowledge needed www.spminstrument.co.uk email info@spminstrument.co.uk and more detailed spectrums than ever before. On machinery operating under variable speed, vibration analysis with HD Order Tracking provides reliable data and crystal clear measuring results also under large RPM variations. Corrective maintenance techniques such as run up-coast down measurement, shaft alignment and dynamic balancing can be added to the instrument as optional modules. For technical details, please visit: http://www.leonovabyspm.com/ www.spmhd.com down to a minimum of time. Providing maximum value, performance and control, Leonova Diamond is the perfect tool for the beginner as well as the advanced vibration analyst. Stan Jackson, Managing Director of SPM Instrument UK, comments on the launch of the instrument: Leonova Diamond is the latest proof of our commitment to developing first class condition monitoring products for more profitable maintenance. In a direct response to feedback from SPM customers worldwide, we developed a durable, high-performance instrument that will deliver long working life under the toughest, most demanding circumstances.Leonova Diamond puts portable intelligence and productivity in the palm of your hand. Leonova Diamond is engineered for performance. It is a dependable and highly capable analysis tool, addressing all condition monitoring needs. The instrument offers a full range of sophisticated measuring techniques as well as all the supporting diagnostic and troubleshooting capabilities. Designed for heavy industry, the look and feel of the instrument reflects its intended use. For use in hazardous areas and hostile environments, an intrinsically safe version of the instrument is available. to evaluate machine condition. Condmaster Ruby is modular and system functionality can be tailored to specific customer needs.
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Product Spotlight
Biozyme Spill Control Products To Meet ISO 14001

Blue Diamond offers a complete range of spill control kits meeting the requirements of the ISO 14001 standard for Environmental Management.
This stringent standard requires that organisations storing or distributing liquids have adequate precautions to deal with accidental spills and leaks. Blue Diamond offers a market leading range of spill control products available directly from stock. Spill control kits are ready for immediate use, typically comprising absorbent pads, socks and pillows, protective wear (goggles, gloves and coverall suit) and disposal bags. The contents can also be custom designed to meet individual requirements.
New 24VDC Power Supplies from Panasonic Electric Works

A new range of 24VDC Power Supplies is now available from Panasonic Electric Works to compliment their range of Factory Automation products that include PLCs, HMIs, Photo Electric Sensors and Automation Components.
The FP-PS24 Series is a range of three PSU models offering the following specifications. 24W/1A (Input: 100-240Vac, Output: 2 x 24Vdc/1A) 60W/2.5A (Input: 100-240Vac, Output: 2 x 24Vdc/2.5A) 120W/5A (Input: 100-240Vac, Output: 2 x 24Vdc/5A)
The compact design of the series has been optimised for cooling, allowing them to operate in temperatures up to +70C without the need to derate. Each model offers over voltage, over current and short circuit protection and complies with international approvals (IEC60950, UL60950, CSA22.2-60950, EN60950) for global use. For further information on FP-PS24 Series of Power Supplies or any other Panasonic Factory Automation products please contact: www.panasonic-electric-works.co.uk | info.pewuk@eu.panasonic.com
Blue Diamond Technologies Limited, Rolwey House, School Close, Eastleigh, Hampshire SO53 4BY Tel: (023) 8025 8966 Fax: (023) 8025 8989 Email: bdsales@rolwey.com Website: www.blue-diamond.co.uk
Welded Plate Heat Exchangers

The Company Barriquand is specialized in the design and the supply of Easy to Clean All Welded Plate Heat Exchangers called PLATULAR and patented by our company since many years.
New Gas-Pro Confined Space Gas Detector from Crowcon

Crowcons new Gas-Pro portable gas detector is designed with just one purpose ensuring safety in confined spaces. It is robust, reliable and simple to use with a bright, easy to read display and long battery life.
The Gas-Pro has a number of special features specific to confined space entry (CSE) work.
The Gas-Pro is therefore ideally suited for CSE work. Personnel The PLATULAR is of a robust construction manufactured from either stainless steel or higher alloys. To enable it to be broadly used with all different types of media, an independant and generous spacing can be provided between the heat transfer plates, whilst removable access covers and optional wash systems simplify routine cleaning and maintenance. More information are directly available on our website at the address: http://www.barriquand.com Crowcon company contact and reader enquiries: Louise Early Tel: +44 (0)1235 557700, Fax: +44 (0)1235 557718 E-mail: sales@crowcon.com | Website: www.crowcon.com entering these spaces can now focus on their core activities, safe in the knowledge that their gas detector is focused on its core activity.
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Product Spotlight
Ambrell Is A Leading Manufacturer Of Induction Heating Solutions.

Industry-Leading Induction Heating Solutions from Ambrell Ambrell is a leading manufacturer of induction heating solutions. With systems ranging from 1kW to 800kW, its solutions can tackle heat treating tasks such as annealing, tempering, through and case hardening. Other common applications include brazing, shrink fitting and curing. Ambrell has installed over 10,000 systems in more than 50 countries. With a free half-day of applications lab testing available, you can be sure your system will meet your requirements prior to placing an order. Ambrells systems are manufactured in an ISO-certified facility in the United States, and Ambrell has local offices around the world, including in the United Kingdom, Netherlands and France. Visit www. ambrell.com for more information. Ambrell Ltd, Phoenix Works, Saxon Way, Cheltenham, Gloucestershire, GL52 6RU +44 (0) 1242 514042 salesuk@ambrell.com
The Beamex MC6 Advanced Field Calibrator and Communicator is a solution to the new process industry requirements.
The MC6 is an advanced, high-accuracy field calibrator and communicator. It offers calibration capabilities for pressure, temperature and various electrical signals.
The MC6 contains a full fieldbus communicator for HART, FOUNDATION Fieldbus and Profibus PA instruments. The usability and ease-of-use are what really makes the MC6 unique. The large 5.7 color touch-screen with a multilingual user-interface makes the MC6 an ideal portable measurement device for field use in various industries.
For more details and enquiries please email: beamex.ltd@beamex.com
Our Customers Want To Eliminate Future Replacement Costs And Maintenance Associated With Traditional Materials Of Construction.
Creative Pultrusions pultrudes an array of decking, flooring, grating and panel products that are used extensively around the world where corrosion resistance, lightweight, ADA compliant, low maintenance solutions are sought. Our customers want to eliminate future replacement costs and Typical applications maintenance associated with traditional materials of construction. Our pultruded products will not rot, rust spall or corrode. include, cooling tower decks, mass transit decks, industrial walkways, highway bridge decking, pedestrian walkways and docks and piers. Visit our web site at www.creativepultrusions.com to see first hand our products and solutions.
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Product Spotlight
Flow Pulse A Major Advance In Non-Invasive Flow Measurement

Flow Pulse from Pulsar Process Measurement is a compact, cost-effective pipe flow monitor that promises exceptional repeatability and simple installation with no down time, perfect for monitoring flow rates in fluid distribution systems, for pump efficiency, in process plant or sewage pumping stations.
Easy installation - just clamp a small sensor to the outside of a pipe and immediately get a reliable, repeatable flow measurement. Virtually no installation costs, no interruption to service, clean and simple. Ultrasound is fired through the pipe wall then reflected from bubbles, particles and vortices in all directions and at a wide range of frequencies, the reflections received back into Flow Pulse. Flow Pulses Refracted Spread Spectrum Analysis (RSSA) digital signal processing analyzes and integrates received signals over a wide frequency range, then slices them for realtime analysis and flow rate calculation. Flow Pulse operates in a flow range from 0.3m/ sec through to 4m/sec, with minimum particle size of 100 microns and concentration of 200ppm or above. Pipe material can be rigid plastic, stainless steel, mild steel or cast iron. Corrugated pipe is not an issue and even light corrosion will give a good result. Flow Pulse provides repeatability and accuracy of around 5% (up to 14in pipe dia).
For more details go to: www.pulsar-pm.com
GAST Group Air Motors Full Range Now Available With ATEX Approval
Known industry-wide for their rugged construction and reliability, the Gast Groups range of compact, lightweight air motors are now available with II 2 GDc T4 +1C < Ta < +40C ATEX approval, which means they will work in ambient temperatures up to 40C.
The motors are also classed as intrinsically-safe in hazardous environments, which reduces the possibility of explosion from the ignition of flammable gases. The air motors can be used in a variety of industrial and manufacturing sectors such as food and beverage; medical, healthcare and laboratory; and environmental, with typical applications including mixing equipment; pump and conveyor drives; food and pharmaceutical packaging; and hoists and winches. Gasts non-lubricated air motors are available in Air motors can be mounted in almost any position and users can choose from hub, foot, face, NEMA C-Flange or Metric D Series interface mountings, and clockwise, four basic models from 0.13 to 1.86 kW (0.18 to 2.5 HP), with motor speeds up to 4,000 RPM. Oil-lubricated versions are available in seven basic models from 0.33 to 7.1 kW (0.45 to 9.5 HP) with motor speeds variable from 300 to 10,000 RPM. A range of recommended accessories is also available and bespoke versions can be manufactured to special order for OEM quantities. For further information on the Gast Groups range of ATEX-approved air motors, call +44 (0)1527 504040, email sales.gast@idexcorp.com or visit www.gastmfg.com. counterclockwise or reversible rotations. Four vane models are available as standard, with eight vane models available for smoother running and better control for short-run applications including winches, hoists and hose reels.
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Product Spotlight
The CLEAN OIL Alternative

Clean Oil Services offers a range of LUBEMASTER Oil Cleaning Equipment for cleaning fuels and all grades of lubricating oil designed to keep lubricating oil in perfect operating condition and extend machine life.
For years the accepted practice has been to change oil in equipment on a predetermined scheduled basis regardless of whether the oil is spent. Mostly, used oil is simply loaded with contaminants such as dirt particles, wear metals, water and gases, while the oil remains within specifications and suitable for continued use. If the contaminants can be adequately removed without affecting the additives, there is no reason why oils cannot remain in service. LUBEMASTER is innovative & very cost effective and enables oil life to be extended many fold, resulting in cost savings of more than 50%. Cleanliness levels achieved by LUBEMASTER are much higher than other systems & particularly pore membrane filters which allow the small particles to remain in circulation and for the filter to block once a particle larger than the pore size is caught in the element. As well as lubricating oil, LUBEMASTER can be utilised for : Cleaning contaminated diesel fuel Cleaning and restoring transformer oils Effectively cleaning heat circulating systems Cleaning waste oil suitable for use as a diesel substitute to burn off in diesel engine fuel Advantages of LUBEMASTER include: Easy to operate & low energy requirement Cleans oil while host machine continues operating Has few moving parts thus minimal wear For more information please visit our website: www.cleanoilservices.com Or contact: Bob Smith Email: bob@cleanoilservices.com mail@cleanoilservices.com Expensive filters not normally required Cleans all grades of oil at full flow rate Removes particles to sub-micron size Removes all types of water (free, emulsified & homogenized) Cleans system to cleaner levels than oil change.
Low Cost Fuel Klenze Filter Means Clean Fuel and Efficient Engines
In the quest for engine performance, efficiency and environmental benefits, technologies are emerging at an impressive rate. But modern engines are increasingly sensitive to fuel contamination, which can cause engine wear and damage to components.
Fuel cleaning with the low cost Fuel Klenze Filter will ensure optimum fuel quality, keep fuel injectors, filters and tanks clean, minimise maintenance and downtime and provide optimal engine efficiency and performance. Most filters rely on paper, which needs regular replacement and generates waste. Its far better to eliminate contaminants before they enter the engine, as it will operate more efficiently, have an increased lifespan, benefit from improved fuel consumption and generate fewer harmful emissions. Using an entirely new and unique filter design, the low cost Fuel Klenze Filter fundamentally delivers cleaner fuel - virtually eliminating filter volume and saving time and money on repairs. The system uses a long-life filter element; an osmotic process separates fuel from 99.9% of visible water - including emulsified water allowing only pure fuel to pass through. A 30 micron stainless steel mesh removes 95% of solid contaminants, further purifying the fuel. Separated water, sediments and sludge are drained using the valve at the bottom of the unit. No replacement of filter element or cartridge is required. The reusable long-life filter element is easily washed in clean fuel should it become blocked, and reinstalling this requires no tools. Various models are available to suit engines of all sizes, from 150 up to 1200 horse power.
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RAISING THE BAR FOR BOILER EFFICIENCY

Tony Green, Sales & Marketing Director of Byworth Boilers, looks at recent developments in boiler technology.
Twenty years ago industrial boiler design was driven mainly by the demands of equipment buyers and specifiers for boilers which produced maximum output at minimum purchase price. While fuel was relatively cheap and emissions not high on the agenda, purchase price probably was the most important factor to consider. Many boilers therefore were designed to be small in size with the least steel, tube and insulation possible without greatly affecting reliability and output. This resulted in mediocre efficiency, with higher fuel and power consumption and NOx emissions. The latest development in steam boiler technology has seen the introduction of the pre-heated combustion air boiler. This recovers otherwise wasted heat from the exhaust gases using a recuperator. When combined with X-ID tubes tests have shown efficiency gains of up to 7% when benchmarked against Byworths Flue gas economisers are a proven concept and can improve boiler efficiency by up to 5%. The heat in flue gases, which would otherwise be lost up the stack, is utilised in an air to water heat exchanger to pre-heat the feed water to the boiler. The economiser seen here in the photo is a drawer type for ease of maintenance and located above the rear smoke box. not be required. The recuperator does not contain any moving parts and its robust Even after the flue gases have passed through the economiser there is still usable heat and they can be combined with a recuperator to preheat the combustion air. The air-to-air heat exchanger shown here above the economiser is of the drawer type to minimise its footprint. A Leading boiler manufacturers have responded quickly to this need, with new boiler designs shifting the emphasis from low purchase prices to low running costs and emissions. bypass is incorporated into the ducting should pre-heat design ensures a long life. the furnace reduces the flame temperature and less thermal NOx is formed. For sites which require ultra-low NOx levels, Byworth will design bespoke furnaces to match the particular requirements of the preferred burner supplier. Byworth Yorkshireman2 waste heat combination boiler
Pre-heating Combustion Air
Flue Gas Economisers
How things have changed. Now, with the exception of those organisations lucky enough to have a ready source of cheap fuel, there cannot be any boiler project which doesnt prioritise running costs and reliability over purchase price.
Design
Add-on Technology
To support the increased efficiency of the boilers themselves there have been significant technological advances in burners and boiler Byworths pre-heat boiler showing the flue gas economiser and air-to-air heat exchanger. already efficient Yorkshireman 3-pass boiler. Advantages of pre-heated combustion air are controls. Burners with electronic air and fuel control give better efficiency right across the turn down range and also reduce NOx emissions. Variable speed drives on burners and feed water pumps will greatly reduce electrical consumption whilst automatic blowdown and TDS control systems also increase efficiency and reduce risks associated sludge build up and foaming.
Boiler shells and furnaces should both now be generously sized, not minimized to save on steel costs. A steam space which is too small causes priming and carry over of water in the steam system resulting in wet steam, dissolved solids in the process, scaling and water hammer.
In order to reduce NOx emissions, the furnace length to diameter ratio should ideally be 3.5 to 1: the lower volumetric heat release rate in
that it is completely synchronous with the burner operation and that it maintains a high efficiency gain with turndown, 5% at one third firing rate.
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Spirax Sarcos Expertise Helps Provectus With Rare Decontamination Project

When contaminated land specialist Provectus decided to take a novel approach to cleaning up the soil from an old printing works, Spirax Sarco provided the steam system expertise to help turn the concept into reality.
The site, located in Somerset, was contaminated with toluene over many years and developers were looking to extract the flammable solvent so the land could safely be used for housing. In what is believed to be the first project of its kind, Provectus decided to dig out the soil and treat it above ground using an extensive system of steam heating coils. The contractor brought in Spirax Sarco to design a steam distribution system to do the job. The conventional approach for toluene decontamination is to inject live steam into the ground to vaporise the volatile solvent. But the local geology meant there was a risk that the toluene would migrate into the surrounding ground, rather than rising to the surface. Provectus also judged that the 24-hectare site was too big to install an effective underground barrier around the operation to prevent such leaks escaping. The company therefore decided to treat the soil ex-situ, where it could control the process more effectively. It meant we could homogenise the material better and improve the transmissivity, says Provectus Director Steve Langford. It also prevented any contaminated vapour from migrating into the surrounding area through the fractured geology. In addition, using heating coils rather than direct steam injection was more efficient in terms of energy and water. Spirax Sarco advised using steam as the heating medium in the coils rather than hot water, because it would remain at a constant temperature, rather than cooling down as it passed through the system. Spirax Sarco engineers devised a series of trombone-shaped coils, laid flat across one of the old concrete factory floors. Several thousand metres of pipework were needed to provide a big enough heating area to treat the batches of soil that were piled on top. It was tricky to calculate the necessary heat transfer area, because the ability of the soil to conduct heat changed as the material nearest the heating coils dried, making it more difficult for the heat to flow through to the remaining soil. Bristol-based contractor Engineering Services assembled the necessary pipework according to the Spirax Sarco design, complete with steam traps and associated controls to ensure that the system worked smoothly. The company also provided a 1250kW containerised boiler to generate the steam. It was quite a complex arrangement, but the biggest challenge for us was the physical site conditions, says Bob Clark, managing director of Engineering Services. We were working exposed to the weather for the whole time. The process ran over the four weeks, heating around 4,000m3 of material and collecting the resulting vapour in plastic sheeting. From there the solvent passed through a system of activated carbon beds, which absorbed the toluene before discharging clean air to the atmosphere. Wed never seen a project like this and neither had the Environment Agency personnel who inspected the operation, says Mr Langford. Wed cleaned up the first batch of soil within two weeks and the site is now suitable for even the most sensitive developments residential housing with gardens. Im more than happy with the support we got from Spirax Sarco, which helped us to complete the project so quickly and efficiently. The solution prevented us from having to send the contaminated soil off to landfill and bring in replacement material. Weve worked on projects with Spirax Sarco for over 20 years, adds Mr Clark. This was the first time anyone had attempted to do a clean-up this way and the results were outstanding.
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HOSPITAL MAKE EMERGENCY CALL TO KINGS BOILER HIRE

When Addenbrookes Hospital Cambridge recently had a major failure on one of their main 35,000lb/hr steam boilers they contacted Kings Boiler Hire Ltd. Kings, whose Mildenhall branch is close to Cambridge, were asked to urgently provide a temporary boiler to help cover the hospitals steam demand. The emergency unit was delivered and on line with the minimum of loss to the hospital.
Kings involvement did not end there however. Being Europes largest stockist of re-conditioned boilers, Kings had an almost identical 35,000lb/ hr steam boiler in stock at their Mildenhall branch. Kings Director, David King, offered the unit to Addenbrookes, who promptly decided to purchase. The boiler was fully re-furnished and delivered to the hospital six weeks later. Engineers at Addenbrookes were delighted to have sourced an almost identical boiler locally and with such rapid delivery, and also benefit from the large financial saving over buying a new boiler unit. We are delighted that both Kings Boiler Hire and Sales departments were able to assist Addenbrookes in such a timely manner said David King. We are proud to have developed an excellent working relationship with the trust.
Cochran complete Turnkey Installation at Cumbrian Specialist Paper Mill

Cochran Ltd are the largest manufacturer of industrial boilers in the UK, and have over 130 years of history providing energy solutions. Our customers have come to depend on our quality engineering and service, and our boilers are in use the world over.
One such company has been Billerud Beetham Ltd, a world leader in the manufacture of speciality papers for health care and food packaging markets. Seeking to replace three of their aging boilers, they searched the market for a company that offered a one-stop solution, designing, manufacturing and managing the whole process. Cochran Ltd was best placed to meet those requirements, and to provide the long term service support that Billerud needed. Cochran designed and built a new energy centre comprised of two Thermax steam boilers complete with flue gas economisers. These high pressure boilers have a rating of 10210 kg/hr, and were fitted with matched Cochran Equinox pressure jet combustion systems providing electronic combustion control, variable speed FD fans and exhaust gas analysis equipment to optimise the boiler output and performance. As well as installation, Cochran undertook the replacement of the existing steam manifold system and integration of the boiler into a new balanced steam header arrangement. The remaining Cochran boilers at the site are over 35 years old but are still in good condition. These are currently being updated with the latest combustion and control equipment as part of Cochrans continued service contract. As a result of the modernisation of their steam generation and distribution system, Billerud have reduced their fuel bills by up 13% per annum. Tony Halhead, Engineering Manager at Billerud said: The support we received from the Cochran site team and their head office engineering teams was first class. The project went as well as could be expected and was delivered on time and on schedule.
East Midlands Enterprise Centre harnesses bio-fuel technology

Atlantic Boilers of Oldham have installed dual-fuel boilers at the new Corby Enterprise Centre in Northamptonshire. The 8.3m centre is home to 15 workshops, 38 offices and a caf area.
The entire space heating requirement is met by two 90kW R-Series dual fuel boilers B100 bio-diesel and natural gas. The R Series is a year-round high efficiency condensing boiler which bridges the gap between gas condensing boilers and bio-mass boilers by providing combustion which burns traditional fuels and also green fuel. Liquid bio-fuel boilers are at an advantage to other green boilers such a bio-mass boilers for several reasons. Liquid bio-fuel is easier than bio-mass to store and feed to the boiler and produces 37 megajoules of heat per kilogram against 17 megajoules of heat per kilogram for good standard biomass. In addition, the UK has a surplus of waste and home-grown vegetable oils which the developing liquid bio-fuel boilers are ready to burn with efficiency and minimum noxious emissions. The boilers were specified by BSD of Corby and installed by Mitchell & Hewitt of Derby. For more information see www.atlanticboilers.com
ETC Launches Combustion Controls for Waste Fuel Firing

Energy Technology & Control Ltd, a UK manufacturer of electronic Burner Management Systems, has expanded its range of combustion controllers to allow waste and bio-fuels to be fired either independently or simultaneously with a conventional gaseous or liquid base fuel.
Simultaneous firing of fuels can usually be achieved using conventional products but waste and bio-fuels are often characterised by variable availability and inconsistent calorific values. To overcome this an algorithm within the controller software enables safe and efficient combustion to be achieved; an external signal is used to indicate the proportion of waste fuel that should be used across the firing range. Oxygen trim ensures that any variability in either the fuel calorific value or external atmospheric conditions does not compromise combustion efficiency. The ETC6008 caters for liquid and gaseous fuels to be fired either independently or simultaneously. A second new model the ETC6009, is designed to allow a gaseous base fuel to be mixed with a gaseous bio or waste fuel and includes the provision for valve proving on two separate gas trains. The ETC6009 can be further enhanced to facilitate the firing of a back-up liquid fuel. The full range of ETC peripherals including a 10.4 touchscreen, CANbus servo motors, and temperature and pressure sensors are all fully compatible will all the new models. Contact for enquiries for ETC products sales@energytechnologycontrol.com Tel: 01273 480667
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Product Spotlight
J+J Motorised Valves using the original Smart Red Box

The EU designed and manufactured J+J electric valve actuator distributed by J+J Automation in Worcestershire continues to see healthy growth due to its impressive array of standard features, and its unique ability to have its function changed from on-off to modulating or failsafe using the J+J plug and play conversion kits.
The weatherproof J+J actuator offers multivoltage connectivity via supplied external Din plugs, eliminating the need to remove the actuators cover to connect electrically, saving time and money on installation. With selectable manual override the J+J actuator can be operated manually during commissioning, and automatically resets any actuators over-travelled whilst in manual mode, when switched back into Auto. End of travel confirmation via volt free contacts for remote position indication, and an external local visual indicator lets operators see the actuators position at a glance. A top mounted LED gives continuous visual indication of the actuators operational status, a constantly lit LED advises all is well, whereas a blinking LED indicates non-operational status, either due to manual mode being selected, or the electronic torque limiter has detected a valve problem. Modulating functionality via the J+J digital positioning system (DPS) provides either 0-10V or 4-20mA input and corresponding output, standard or reverse acting, and the J+J battery failsafe system (BSR) provides an alternate, constantly trickle charged power supply in the event of external power interruption. The BSR can be configured normally open or normally
Contact J+J Automation UK Ltd on 01386 552254, visit www.jjautomation.com, or email info@jjautomation.com for more details.
closed. Installing both conversion kits gives failsafe modulating functionality. The J+J electric valve actuator is known as the Smart Red Box for a reason.
JDN HOISTS PROVIDE 200 TONNE HANDLING CAPACITY ON OFFSHORE RIG

Four J D Neuhaus type EH50 air operated monorail hoists have been supplied and mounted by Westcon Lfteteknikk AS of Bergen to the Maersk offshore rig Guardian.
These products have been specified for the synchronised lifting and handling of an 18.3/4 15,000psi BOP unit before and after drilling operations. Two hoists are each mounted on twin parallel overhead rails, with each hoist providing 50 tonne load and 20 metre lift capacities for between deck operations. With the two sets of hoists operating together, a combined lift capacity of 200 tonnes is made available. Synchronised operation of all linear movement and lifting operations is provided with the F type multi-function pendant controllers also supplied by JDN. These tough, ergonomically The hoists provided are part of a range of well-proven JDN monorail hoists with individual lift capacities from 10 to 115 tonnes. All these products are fully ATEX rated providing reliable, robust and efficient performance. They are ideally suited for working in hazardous areas designed controllers are suitable for the outdoor, heavy-duty operations that can be experienced offshore. A main air emergency stop together with load monitoring device is incorporated in the controllers. A complete offshore documentation package was supplied together with all hoists having JDNs full protection kit for offshore corrosion protection.
Further information is available on request to: J D Neuhaus GmbH & Co. KG, 58449, Witten-Heven, Germany Telephone: +49 2302 208-219 Fax: +49 2302 208-286 e-mail: info@jdngroup.com www.jdngroup.com
and the drives are hermetically sealed-off from the environment. They incorporate integrated overload protection with a fully enclosed, robust gear motors and extremely low noise emissions and with optional air or hydraulic hoist operation.
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Product Spotlight
The HS-630 Series Vibration/ Temperature Meter Kit

The HS-630 Series Vibration/Temperature Meter Kit provides all of the key tools required for monitoring velocity and bearing condition and temperature measurement in a convenient, protective, portable case.
The kit comes complete with a mains or in-car charger and rechargeable battery, while a sensor/cable fault indicator provides warning against error. The HS-630 Series can provide measurements in either imperial or metric and conforms to ISO 10816-3. The temperature measurement function of the HS-630 differentiates this unit from the HS-620 Series Vibration Meter Kit, which otherwise offers the same reliable performance and range of features as the HS-630.
The ROTRONIC HygroGen2

The ROTRONIC HygroGen2 has become the benchmark for transportable humidity and temperature calibrators due to unsurpassed chamber stability, speed to reach set-point equilibrium, and extended operational ranges 299 %rh and -560 C.
Fully user programmable, with an embedded PC controller and colour touch screen interface, it satisfies the stringent demands of Quality and Compliance regulations. HygroGen2 has the capability to calibrate instruments from any manufacturer over their full working temperature and humidity ranges; it is embraced throughout industry as the leading calibrator in its class. HygroGen2 is now optionally available with AutoCal - fully automated calibration, with adjustment of up to six probes. PDF calibration certificates are generated, with set-points and pre- and post adjustment values as required. Contact Rotronic for a technical datasheet and to arrange a demonstration. Tel: 01293 571000 Email: instruments@rotronic.co.uk Web: www.rotronic.co.uk
For more information on the extensive range of Hansford Sensors products, please visit: www.hansfordsensors.com.
Smallest thermal GigE camera

Xenics Gobi-640 uncooled thermal camera with GigEVision interface and Power over Ethernet (PoE) is now also introduced with a CameraLink version.
The cameras feature a 640x480 image resolution and 17m pitch microbolometer detector. The novel and compact platform meets the demand of reduced weight, size and power consumption for machine vision applications. It detects very small temperature differences down to 0.05 oC and delivers thermal images at 50 Hz. The Gobi-640-GigE is the first official certified LWIR camera with MVTecs HALCON imaging software. More vision software such as Cognex VisionPro is supported as well. Xenics headquarters Ambachtenlaan 44 BE-3001 Leuven, Belgium Tel +32 16 38 99 00 sales@xenics.com www.xenics.com
Protect your IT Investment. Dont Wait Until Its Too Late!

BTI provide monitoring systems for IT and their environments that will alert you wherever you are day or night, weekday or weekend of potential problems within your computer room whether it be High Temperature, UPS on Load, Water Detected or Critical Server Failure.
Early detection enables you to take immediate action, preventing the situation escalating to anything from business disruption to a full scale disaster. BTI monitoring systems have become a valuable asset to many organisations large and small, and is an essential part of any Business Continuity Plan. BTI Computer Systems (UK) Ltd. t: +44 (0) 1527 598500 w: www.bticomputer.com
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CMMS Software
CMMS Software Good Practice for FM Implementation

With organisations looking to manage their budgets more tightly given the current economic climate, utilising the capabilities of a comprehensive CMMS (Computer Aided Maintenance Management Software) application can have a number of positive operational benefits to any organisation.
Managed correctly, CMMS Software enables organisations to optimise the reliability and efficiency of assets, property and equipment to reduce costs and improve service. It automates and manages scheduling activities, such as testing, inspections or health and safety; can determine elements that affect the reliability, servicing and repair of an asset; whilst supporting the creation of unique and flexible maintenance regimes. The first step for any business when reviewing CMMS software is to consider the benefits offered by the software and align these to requirements within the business. On average, a business should aim for a return on investment within two to three years. Initial costs that should be taken into account are the CMMS For any company seeking to invest in, or update existing CMMS software, it is important to cost justify the investment by identifying how the new system will produce cost savings, so that the project is self-financing. Current business processes should be reviewed and where appropriate, procedural improvements The development of an effective and realistic implementation plan is a very important step in ensuring that the timely delivery of the new software solution meets the needs of a business. It is crucial to develop and agree a formal project plan with all stakeholders to enable resource demands to be met and clearly defined project milestones to be achieved. software licences, professional services such as consultancy, data manipulation, training, ongoing maintenance and internal costs associated with the project. To receive a complimentary copy of Service Works white paper Best Practices for Successful CMMS Implementation, please call: 0208 877 4080 Whilst developing the implementation plan, it is also useful to put in place some key or email info@swg.com In summary, if properly implemented and maintained correctly a good CMMS Software application can ensure that an organisation optimises operational efficiency whilst reducing costs. considered, in order to determine the scale and scope of benefits that a CMMS software system could potentially deliver. performance indicators (KPIs) against which the success of the project can be measured. These should include key project milestone dates that must be achieved in order for the supplier to claim progress payments.
Once the initial development and implementation is complete, it is vital to have excellent support from the CMMS software supplier to ensure the long-term success of the system. It is important to understand what is included in any maintenance fees, i.e. access to future upgrades of the software and the scope of the support offering (telephone, remote and/or on-site).
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Industrial Cooling
Cooling Tower Safety and Maintenance

The Importance of Aligning Debris Management With Water Treatment Procedures
By Randy Simmons
The following is an important reminder of the need for all companies and institutions utilizing cooling towers, to adopt diligent maintenance and water treatment programs; Why? - Because whats at stake is worker health & safety, operational efficiency and the companys reputation.
In recent years a major worldwide auto manufacturer experienced a tragedy when four of its maintenance workers became ill with pneumonia-like symptoms that ultimately claimed the lives of two. The cause - Legionnaires Disease due to Legionella bacteria found in one of the manufacturers cooling towers. The company quickly moved to conduct a cause analysis by inspecting its cooling towers and boiler systems worldwide to identify how systems were being maintained and to identify best maintenance practices. This ultimately led to the establishment of a world class maintenance and monitoring system that ensures such a tragedy will never be repeated. This photo shows serious maintenance neglect. Tower has high organic content and heavy scaling. This tower is a health and safety hazard. easy for companies to develop a false sense of security that their cooling towers are safe when they are chemically treating the water; however, if organic debris management isnt in alignment with water treatment dosage levels, there is an increased probability of the tower becoming a health and safety hazard. It doesnt matter how large or small a company and its cooling tower is; bacteria doesnt discriminate - it will thrive in any poorly managed cooling tower!
How a Legionella Outbreak Can Occur

When someone becomes ill from an unsafe cooling tower it most often isnt the result of the companys blatant negligence; rather, its typically the result of not having a clear understanding of the need for the water treatment program to be in alignment with effective debris management. It is well known that cooling towers are highly efficient air scrubbers; airborne debris drifting past one is likely to get caught in its draft and be sucked-in. When organic debris such as pollen, cottonwood seed, leaves, insects, grass, birds etc. get into the water and decompose, the warm temperatures create a nutrient rich environment for bacterial growth including Legionella. Further, if the volume of decomposing debris exceeds the chemical dosages ability to provide control, then the tipping point has been reached and the cooling tower will silently
An Obvious Question
What is the appropriate ratio of water treatment chemicals to the debris load inside the cooling tower to ensure cooling tower safety? Although the question is obvious, the answer isnt. Organic debris is drawn into cooling towers in different concentrations depending upon location and time of year. Every type of debris places a different demand upon the biocides and scale inhibitors being dosed into the water; therefore, there is no known ratio that will hold constant for every cooling tower. However, it is safe to say that if you dont deploy diligent maintenance procedures that include debris
Cooling Tower Basin With High Organic Debris Content
grow dangerous even while chemical dosing continues. The fact of the matter is that its
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Industrial Cooling
and managing debris in the tower come together. Today, companies have many options available for managing debris; they include a variety of water based filtration technologies and air intake filtration. Water filtration can help manage waterborne and other debris after it gets into the cooling water while Air intake filtration technology is highly effective at stopping airborne debris from getting into the tower by filtering the air as it enters the system. When determining what maintenance and debris management technology to use, it is important to first determine what the source of the debris Legionella as found in cooling towers and boiler systems
Photo Compliments of Centers for Disease Control
is. If the source of debris is waterborne (e.g.; sediment, algae from pond or river, or water with
management, more water treatment chemicals will be required to keep it safe. Some may say, Load the tower up with chemicals to ensure safety, however, local environmental guidelines typically place restrictions on the amount and type of chemicals that can be used, therefore the use of chemical treatment alone is not the solution. Furthermore, adding chemicals to offset poor maintenance practices is a shortcut that will do little to prevent fouling and clogging of the fill, strainers, blow down valves, chiller and heat exchangers and could eventually lead to health and safety problems and a reduction in equipment performance. Although the answer to the chemical ratio to debris question isnt apparent, the answer to keeping a safe cooling tower is crystal clear and can be simply stated - Keep the cooling tower free of debris and deploy a good water treatment program and your cooling tower will operate safely and efficiently.
of Building Services Engineers in Europe (CIBSE) and the American Society of Heating, Refrigerating & Air-Conditioning Engineers (ASHRAE) in the US have provided excellent recommendations and guidelines for cooling tower maintenance. In addition to recommending maintenance activities, they also call for establishing procedures that are measurable. Although the suggested guidelines are excellent, companies must ultimately weigh the operational and economic realities of any maintenance program they deploy. If maintenance procedures are too frequent, cumbersome or complex, they commonly results in more downtime, lost productivity and higher maintenance costs. Conversely, if the intervals between maintenance are too long, it may be more cost effective, but the condition of the cooling tower at each maintenance interval may be less than desirable and potentially place maintenance workers, employees, tenants and the public at risk. So the answer largely lies somewhere in the middle where water treatment
a high dissolved solids content), water filtration in combination with a good water treatment program is typically the best solution and will help protect the tower and its piping from scaling and fouling. However, if the source of debris is airborne related then Air Intake Filters are the best solution because debris is stopped at its point of entry while water filtration can only help manage the airborne debris once it gets into the water basin. In combination with a good water treatment program, Air Intake Filtration is highly effective at stopping the kind of debris that clogs strainers, blow down valves, fill, chillers and heat exchangers. In extreme cases where both waterborne and airborne debris is problematic, both air intake filtration and water filtration in combination with a good water treatment program may be required in order to keep the cooling tower safe and operating efficiently.
Personal Safety
No matter what cooling tower maintenance procedures are adopted, personal safety precautions must be integral to the maintenance
How to Keep a Safe Cooling Tower

In recent years The Chartered Institution
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Industrial Cooling
the responsibility of working with consultants, water treatment professionals, maintenance employees and contractors to establish a global water management program that encompasses specific maintenance tasks, procedures, schedules, management accountabilities and reporting guidelines at the facility level. A representative at each facility is accountable to a regional representative who reports activities and results to the oversight committee. The establishment of the oversight committee and its global management network ensures uniformity of their program plus, gives the company a vehicle to quickly implement changes and
Legionella Bacteria multiplying inside of cultured human lung tissue. Photo Compliments of centers for Disease Control
enhancements that provide continuous improvement to their global water management program.
procedures. Best practices require workers to wear respirators, gloves and protective clothing to help prevent exposure to water treatment chemicals and bacteria, especially Legionella. Important Note: cooling water doesnt have to look dirty to be dangerous - just because the water is clear doesnt mean its clean or free of bacteria - Every cooling tower can harbor bacteria. Always take precautions because unless the water is routinely tested for Legionella and other bacteria, the bacteria will never announce its presence until its too late.
willingness to buy goods & services should a Legionella outbreak become public. (Especially risky for food and related processors). Loss of income to families when a loved one becomes ill or dies from Legionnaires Disease. High cost of litigation which usually follows. Higher company insurance costs when claims due to job related sickness or death occur. In comparison to the cost of a proactive maintenance initiative, the incidents listed above when considered individually or collectively carry staggering cost.
It Doesnt Take Rocket Science

It simply requires that companies using cooling towers step-up and initiate proactive and on-going maintenance procedures that align effective debris management technology with effective water testing and treatment techniques because when these elements are in alignment, the result is a safe, healthy and efficient operation.
Randy Simmons, is President of The Newway Company dba / Air Solution Company manufacturer of Intake Filter Screens for cooling towers and condenser coil based cooling systems. For questions or information, he can be reached at Tel 513-860-9784 in the US or, visit their website at: www.airsolutioncompany.com
Consider The Cost Of A Sick Tower

Companies that dont insist upon diligent cooling tower maintenance procedures put not only their employees health and safety at risk, but also their business and reputation. Consider the cost of a single cooling tower related Legionella incident: Reduced employee moral and productivity due to an unsafe work environment. Negative customer perceptions and their
Follow A Leader
So, you may be wondering exactly how the major automotive company mentioned at the beginning took a tragic situation and turned it into a world-class maintenance program. They formed an oversight committee sponsored by executive management that is charged with
For availability in the UK, please contact ECEX on 01635 244 100 or visit their website at www.ecex.co.uk
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Industrial Cooling
Heat Recovery Helps Metal Treatment Company Reduce Energy Costs

A Midlands based metal treatment company contacted ICS Temperature Control regarding a solution to replace their ageing, inefficient cooling system which provided chilled fluid at 10C to a number of anodising tanks.
Requirement...
ICS Temperature Control were requested to investigate the most energy efficient solution that would have minimal disruption of the production site during installation, and that needed little input from the customer. An after care support package was also requested to maintain the efficiency and life expectancy of the new equipment. ICS Temperature Control were pleased to be able to utilise their wealth of knowledge and experience in delivering streamlined, turnkey solutions and offer the customer a number of options for consideration. In the first instance an energy analysis was carried out which determined the most energy efficient solution for the application. One option considered was partial or full heat recovery, which is the reutilisation of heat energy from a cooling system which would otherwise be lost. The energy analysis estimated that by using heat recovery on a new chiller at an operating temperature of 10C, the savings on energy costs could reach 45%. If the discharge temperature were to be 5 degrees warmer, the savings could increase
to 50%, which is significant. From this savings potential the customer would be seeing a payback in approximately 2 years with savings on energy continuing each year after. To explain the savings figures; In cooling only mode, the existing chiller consumes 47% more power than the proposed unit when running at a full load capacity of 705kw. The two units consume 2,196,329kWh (existing) & 1,158,746kWh (proposed). When operating the chillers in heat recovery mode the existing chiller will provide 852kW of recovered heat for a total power input of 219.2kW & the proposed unit provides 801kW of recovered energy for 171kW of total power input. The existing chiller has a Global efficiency ratio of 6.94 versus the proposed unit having a Global efficiency ratio of 8.4
ICS energy efficient air cooled chiller

process is working at maximum efficiency. A turnkey solution was provided and had little impact on the facility during installation thanks to the experienced ICS Temperature Control Project Manager. An air-cooled chiller with full heat recovery using a heat exchanger was installed and the results were fantastic, as estimated. ICSs Service packages come in standard and bespoke form to best meet their customers requirements. For this project, a 3 year extended warranty package was chosen, giving the customer complete peace of mind that their new equipment would be maintained and that ICS would be there 24hr a day to support with servicing.
Solution...
With continuous improvements in technology and design, new equipment proves to be much more efficient than running old equipment for years. Frequent review of equipment is vital to ensure your
A Complete Solutions Provider of Equipment & Maintenance Support

ICS are specialists in providing cooling and temperature heating and controlling solutions. Working with a wide range of industries including food, chemical, plastics and healthcare, ICS offer standard and bespoke packages to best suit their customers requirements. With Nationwide Service Support, ICS have a team of experienced engineers to visit sites on either the same or next day to review the business requirements, recommending the most resilient and economic solution. Industrial Cooling Systems ICS House, Stephenson Road, Calmore Industrial Estate, Totton, Southampton, SO40 3RY t: 023 8052 7300 f: 023 8042 8366
Heat recovery process
e: info@icstemp.com
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Product Spotlight
NEW ARMAFLEX DUCT INSULATION COVERS ENVIRONMENTAL REQUIREMENTS

The range of specialised insulation materials manufactured by Armacell now includes Armaflex Duct, a purpose developed solution for the fast and effective outer cladding of ductwork systems in commercial air conditioning systems.
This closed cell, fibre-free material offers low thermal conductivity values to limit heat and energy losses whilst preventing moisture ingress, an important feature for controlling condensation on cold air ductwork. The flexible material also features in-built Microban anti-bacterial protection to minimise the potential for surface microbial growth which can contribute to the symptoms of sick building syndrome. In addition, Armaflex Duct has good noise absorption properties, helping to reduce breakout noise and decreasing the transmission of air and structureborne sounds within commercial buildings. Armaflex Duct insulation is available in rolls of both 1 and 1.5 metre widths, and in a range of insulation thicknesses from 9 to 40mm. The product is also available with or without a self-adhesive mounting surface and can also be supplied with or without a protective aluminium facing on one surface. This dust and fibre-free material is highly flexible for easy installation on rectangular or circular ducting surfaces. The selfadhesive version in particular reduces installation times, while the aluminium faced option has an easy-clean external surface. This aluminium surface also provides protection against
Further information is available on request to:
mechanical impact for the underlying Armaflex insulation layer.
Armacell UK Ltd, Mars Street, Oldham, Lancashire OL9 6LY Telephone: 0161 287 7015 Fax: 0161 633 2685 e-mail: info.uk@armacell.com www.armacell.com/uk
LOSS-FREE CONDENSATE DISCHARGE WITH HI-LINE ZLD DRAINS

The ZLD series of condensate drains now available from Hi-line Industries Ltd are designed to eliminate accumulated contaminants from pressurised air systems.
They incorporate a level control which ensures zero air loss during the condensate discharge process which is via a diaphragm valve. Contaminants contained in the airline condensate (including oil, water, rust and other accumulated debris) can be highly detrimental to production processes, including in-line equipment as well as production batches. Condensate drains are designed to remove this damaging material from pressurised air systems at minimum expense and in the safest manner. The ZLD series zero-loss products incorporate a large cross-section diaphragm valve to flush out the condensate under the fault-free operation Four models are available in the range, suitable for operation with airline pressures up to 16 bar, within a temperature range of 1 - 60C. They are designed typically for operation with compressor aftercoolers, refrigeration dryers and airline filter units, covering throughput capacities from 180m3/h up to 95000m3/h.
Further information is available from: Hi-line Industries Ltd, 5 Crown Industrial Estate, Oxford Street, Burton on Trent, Staffordshire DE14 3PG Telephone: 01283 533377 Fax: 01283 533367 e-mail: enquiries@hilineindustries.com www.hilineindustries.com
of the valve. At the same time, the condensate is prevented from forming an emulsion which would incur expensive condensate treatment. A volt-free alarm contact is also incorporated in the ZLD products to monitor the condensate drainage process.
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Tips And Things To Think Of When Ensuring That Industrial Doors Are Well Maintained
Servicing of industrial doors, gates, loading bay equipment and other goods in and out associated equipment is seen by leading industrial door companies, such as BID Group, to be the most beneficial and cost effective measure of ensuring continually safe and reliable operation.
In the same way that you get your car serviced at regular intervals to ensure reliability, having your door serviced at regular intervals, will prolong the life of the asset and greatly reduce unwanted and potential costly breakdowns. While most companies view the maintenance of machinery on their production lines as vital, many overlook the maintenance of their industrial doors, failing to appreciate that the production line could come to a standstill if a goods-in or goods-out door were to jam shut for example, resulting in costly down time and lost production. Furthermore, as with any other piece of machinery a door that is not regularly serviced is more likely to breakdown incurring high repair costs. All industrial doors and associated access equipment should be serviced periodically, since routine checks and visual inspections help identify problems before they escalate and become costly. The frequency of servicing per year will depend on the usage of the asset and the environment in which it operates. An industrial door that is in a high usage area, i.e. a goods in and out loading bay in a 24 hour operating distribution centre, would be ideal to have at least 2 services a year. Compared to an industrial door that is designed for security purposes. Therefore an annual inspection would be sufficient. When companies are putting in place provisions for having a regular programme of maintenance, they should give due consideration on how they would proceed with implementing the programme. Either having in-house competent personnel, (A trained and qualified engineer) which can dedicate time to carry out visual inspections/checks and can carry out vital repairs, while keeping accurate records. Or for peace of mind, employing an external industrial door company that can carry out this work at a nominal cost. Thus enabling on-site maintenance personnel to carry out their day-to-day duties. Having a service and maintenance programme or an agreement in place with BID Group a competent industrial door maintenance specialist, provides assurance that companies are meeting their obligations under the various health and safety regulations; Fire Precautions (Workplace) Regulation, Provision and Use of Work Equipment Regulation and Workplace (Health and Safety and Welfare) Regulation. At BID every service agreement is tailored to each individual sites requirements; the number of doors and associated assets, the usage and the working environment. We take all the hassle away from the company by carrying out the service and inspection. Providing peace of mind that not only are companies complying with the current regulations but also their doors, which are an integral part of the day-to-day operations, are fit for purpose and remain that way. In addition to on-site engineers, BID Group also has an extensive technical department that can diagnose that vast majority of faults and in some circumstances can advise companies own maintenance staff how to rectify the problem without having to place a call-out. Tips: General maintenance and periodically visual inspections will Prolong the operational life of the door Keep the doors in a safe and efficient condition Help prevent potential downtime Keep it legal
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CMMS Solutions from CWorks Systems Inc

We provide innovative, flexible, easy to use, affordable solutions to your maintenance needs.
CWPlus, affordably priced MSAccess solution, over 500 installations world wide. CWSQL for larger and multi-site application. Also includes remote site solutions. CareWorks/Easy, web-based, no upfront costs, provided as SaaS via a modest monthly fee. All solutions include Handheld device options for remote updating of Work Orders, Spare Parts and Meter Readings.
Olivo Contain Dry Ice Pellets
Olivo portable insulated containers have been manufactured for over fifty years and are the market leaders in the distribution of temperature-sensitive food products. In the dry ice sector, Olivo containers are used by many leading names- Air Liquide, Messer, Linde, BOC, Praxair, Coljet, Yara, etc. The combination of high quality insulation and robust plastic construction with steel fittings
Fully supported worldwide via our offices in USA, Australia and Malaysia with Qualified Agents in UK, Canada, South Africa, and Latin America. On-Site and remote training available. Contact David@CWorkssystems.com www.cworkssystems.com
ensures that the containers have a very long life. The ease of movement on casters or feet makes the containers very easy to handle so that the dry ice pellets for blast cleaning can be taken direct to the point of use and still at exactly the right temperature.
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Doors
What Is The True Cost Of A Door Closer?

Mechanical door closers are frequently specified on the basis of initial purchase cost, but all too often the low purchase price masks on-going maintenance and performance issues which can lead to costs spiralling out of control, says Paul Barrows of Ingersoll Rand Security Technologies.
Door closers are regarded as a commodity product, with very little thought given to their performance other than the initial purchase price. By the time anything goes wrong, the subcontractor who originally fitted them can be difficult to contact, leaving the end user to inherit the problem and its associated costs. The problem with a purchase price approach to specification is that mechanical door closers are often subject to very heavy usage, particularly when fitted in high traffic areas in public buildings. A large department store entrance for example will have around 5,000 openings per day which equates to 1.5 million annually. However, the problems dont stop with the mere opening and closing of doors. Real world conditions impose strains on mechanical door closers which do not come to light in manufacturer test bed conditions. A school entrance door will have circa 1,250 openings per day or 225,000 annually and a hospital ward door will typically be opened 350 times a day which equates to 128,000 openings annually. With door closers, as in many other walks of life, you get what you pay for and a cheaper product will often be unable to withstand this volume of use. For example, forced openings and door misalignment lead to sagging doors and frames and bent arms, amongst other problems. In turn, this causes damage to the internal workings of the door closer and can ultimately lead to the door closer failing to perform as it should. At this stage, bigger problems start to occur. There will be a loss of door control, with unreliable closing and associated safety and security risks. Inevitably, this will lead to increased costs for door replacement, maintenance and door frame repairs. For more information about Ingersoll Rand Security please visit www.ingersollrand.co.uk.
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Data Loggers
Get your MITs on Meggers new insulation testers!

Meggers new high-voltage insulation resistance testers (IRTs) offer exceptional versatility in a compact, rugged and light unit that weighs little more than half as much as its predecessors.
Capable of providing accurate measurements up to 10 T for 5 kV versions and 20 T for 10 kV versions and having facilities for automatic timed IR tests and more advanced diagnostic tests; PI, DAR, DD, SV and ramp tests. Meggers new IRTs are available in three versions. The MIT515 is an entry-level 5 kV test set which offers insulation resistance (IR), timed insulation resistance (IR(t)), dielectric absorption ratio (DAR) and polarisation index (PI) test modes.
AlphaTemp Technology are exclusive distributors to the EnviroMon product range developed by Pico Technology.
It is an extremely versatile, expandable data logging and alarm system, ideal for real-time monitoring of a wide range of parameters such as temperature, humidity , energy use and can also be used with third party sensors. It can take measurements over large areas such as warehouses, greenhouses, cold rooms and factories. EnviroMon is made up of a number of different modules including sensors, converters, alarms and a logger. You can network up to 15 mixed converters to a logger, and add alarm options if required.
NEW WiFi Temperature Monitoring Sensors

With audible alarm indicators and WiFi capabilities, the EL-WiFi range are the ideal ultra compact temperature and humidity monitoring device.
These accurate and versatile sensors will automatically transmit air temperature and humidity data without disturbing the environment in which they are placed. Temperature data is then wirelessly streamed live to your PC. No need for cables. The free software enables the user to customise high and low alarms plus data transmission times. An audible alarm warning will indicate as soon as temperatures reach above or below the selected settings. The received data can be immediately displayed in graph format or transferred into other applications.
MSR165: data logger records shock for up to six months

Swiss Technology Company MSR Electronics GmbH launched its MSR165 data logger, complete with a built-in three-axis digital accelerometer.
The MSR165 is capable of making 1600 shock and vibration measurements/s in all three axes for up to 6 months. It can also measure temperature, humidity, pressure, light and record 4 analogue input signals. Boasting a memory capacity of over 2 million measurement parameters, the MSR165 monitors shock up to 15 g, 32 measurement values are recorded even before the event takes place. Using a microSD card, the memory capacity can also be significantly increased which is particularly useful for recording vibration measurements. MSR Electronics GmbH
www.corintech.com 01425 655655
Tel. +41 52 316 25 55 | Fax +41 52 316 35 21 info@msr.ch | www.msr.ch
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Buyers Guide
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