Air compressors - Maintenance Online

Plant &
Maintenance
Deming’s 14 Points
Drives,
Gearboxes
Metalworking
Fluids
Ball Screws, EAM
Vibration Analysis
Shock Pulse
See page 31
Interview
“It all started
with a meccano
set.” Nic Goddard,
Contour Premium
Aircraft Seating
Energy &
Environment
Steam Traps
Emissions
control
Site,
Buildings
& Works
Management
Compressed Air (BCAS)
Air Curtains
Noise Protection
Motivation
Air compressors —
how to be healthy, wealthy and wise
See page 3
easyFairs® MAINTEC 2009
See page 24
Plus News | Product Reviews | Transatlantic View | Industrial Search Engine | Product Directory
Bad vibrations? Temperature too high?
Easy Check condition monitoring raises the alarm.
Just think how much easier critical machinery maintenance would be if
you had accurate, advance notice of potential failures.
That’s just what the Easy Check Condition Monitor provides - a highly visible alarm if any pre-determined
parameters for machine vibration or temperature are exceeded.
And it’s simple to install. Just bolt it to your machine (or fasten it in place with magnets) and the
self-calibrating, battery-operated Easy Check does the rest.
Easy Check is backed by the full technical resources of INA FAG, world leaders in the manufacture of
precision bearings and engine components. Call 0121 351 3833 for more information about Easy Check
and our full range of condition monitoring equipment, maintenance products and associated services.
Now Available Easy Check Online
for locations that are difficult to access
Schaeffler (UK) Ltd
Tel: 0121 351 3833 Fax: 0121 351 7686
E-mail: info.uk@schaeffler.com
Web: www.schaeffler.co.uk
Enquire using 1552
1669 at www.maintenanceonline.co.uk/ME
CON T EN TS
Vol 8 Issue 6 November/December 2008
2
ENERGY & ENVIRONMENT
Talking Shop
31–48
Editorial Comment
3
Cover Story
31
Atlas Copco Compressors – how to be
healthy, wealthy and wise
PLANT & MAINTENANCE
4
32
PAS 55-1:2008
News Review
Interview
It all started with a
Meccano set for Christmas
8
Transatlantic View
Demings 14 points
10
Drive systems
Double the drive life at one-third of
the cost
12
Gearboxes
– deliver improved
reliability and longer
operating life under cool
running conditions
14
Metalworking fluids
Recycling coolant using
centrifugal separation
17
Ball Screws
Extending
the life of
your machine
tool axis
18/19/ The Business Impact of
20
Enterprise Asset Management
24
easyFairs MAINTEC 2009
Newcomers join familiar faces
26/28 Plant Product Reviews
An Overview of Bearing
Vibration Analysis
40
Developing a
Maintenance
Strategy and Setting
Performance Targets
Downtime in a paper mill or any 24/7
facility is very expensive in maintenance
costs, but even more so in its impact
on profit because of the consequent
production loss. This article will explain
the Shock Pulse Method and why the
technique is a good choice for front-line
vibration measurement. It will then
show the resulting savings that the
Hallsta Mill in Sweden realised from
utilising it as the primary component
of its Condition Based Maintenance
Programme. Hallsta personnel calculated
the amount of this benefit when they
looked at the number of incidents
in which they were able to perform
maintenance in shutdowns that were
planned and not, as previously, forced.
Steam Traps
Surveys reveal £28,000 in
potential energy savings
Editor’s Foreword
and Contents
Vibration produced by rolling
bearings can be complex and
can result from geometrical imperfections
during the manufacturing process, defects
on the rolling surfaces or geometrical
errors in associated components. Noise
and vibration is becoming more critical
in all types of equipment since it is often
perceived to be synonymous with quality
and often used for predictive maintenance.
In this article the different sources of
bearing vibration are considered along
with some of the characteristic defect
frequencies that may be present. Some
examples of how vibration analysis
can be used to detect deterioration in
machine condition are also given.
The standard for integrated,
life cycle optimised asset
management – latest release
5
6
50
52
Emissions
Control
Curbing the
carbon to cool
climate change
54
Energy Product Reviews
SITE, BUILDINGS & WORKS
MANAGEMENT
56
Compressed Air –
Science Museum
Case Study
59
Air Curtains
An open and shut case?
61
Noise
Control
Prevention is
better than
protection
62
Motivation
Giving the best to and
getting the best from
your workforce
64/66 Site, Buildings & Works
Management Product Reviews
67
Industrial Search Engine
68-72 Product Directory
IBC
Index of Advertisers and
Product Information Service
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Enquire using 1668 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 1
TALKING
SHOP
All Change!
Volume 8 웇 Issue 6
November/December 2008
Managing Editor
David Willson, BSc
Associate Editor
Chris Pope, BA
Technical Editor
Maintenance & Asset Manageement
John Harris, MSc CEng FIMechE FInstP
e info@maintenanceonline.co.uk
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Creative Director
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Copyright
© Conference Communication 2007
Maintenance & Engineering
Conference Communication
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tel +44 (0)1252 783111
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ISSN 1748 5290
Articles appearing in this magazine do not
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W
hereas I grew up to ‘remember, remember the 5th of November,
gunpowder, treason and plot’, I suspect that in the States,
generations will forever ‘remember, remember, the 5th of
November’ as the day Barack Obama was elected as President. As a Brit
married to an American, what struck me most wasn’t the partisan nature of
the support surrounding Obama and McCain, but the sheer level of interest
and enthusiasm that the election as a whole generated.
Change has indeed come, but for me the most significant change is that people were
positively motivated all over the US to use their vote, have their say, and make a difference.
And in my working experience, nothing beats positive motivation for getting the best of
out people. I also firmly believte that positive motivation is also the best way for helping
people to become all they can be, as discussed in our motivational editorial on page 62
of this issue.
Step forward a day and the 6th of November will be ‘remembered, remembered’
for the unprecedented but widely welcomed 1.5% interest rate cut by the Bank of
England. Listening to Sir Digby Jones reminded me that responsibility is a close relative
to motivation for getting the best results. Commenting on the action of the Bank of
England, he remarked that just as it had done its duty, now it was the duty of the banks
to pass this on and for consumers to do their duty by showing more confidence in the
economy. It was a reminder that our actions and inactions impact those around us hence
the importance of taking responsibility for them.
This should be at the heart of every modern business and by being so, should go
a long way to ensure that everyone connected with the business, from the CEO down
to the lowliest part-time manual worker, is treated fairly. It should also ensure that each
person is valued and has their health and wellbeing respected and protected. Sadly,
in too many companies, workers are still suffering unnecessarily in these areas as, for
example, we look in this issue at noise related hearing damage. Modern businesses also
interact with the wider world and their operating methods can have just as much of an
impact outside as well as inside the company. Emissions control is just one example of
this and we showcase a great example of a company taking this seriously.
Step forward one more day and the 7th of November will be ‘remembered,
remembered’ – certainly in Scotland – for the surprise election victory of Labour over the
Scottish National Party. While headlines and commentators speculate over the up and
down fortunes of Gordon Brown, it reminded me that life can be incredibly fickle and
unpredictable. Yet some things can and ought to be planned for. Our headline interview
this month is with the Head of Maintenance of an award winning company who takes
the view that preventative, effective and efficient maintenance should be at the heart of
moving maintenance from being reactive to proactive.
Which takes me back to change. It is said that the only consistent thing in life is
change but I recall, only too well as I grew up, being consistently taught that, while you
might not ever be the best, you could and should always try your best. And that’s the
same for Obama, Brown, the banks and every one of us.
ABC Application Approved
Audit date: June 2008
Chris Pope, Associate Editor
PROMOTING EXCELLENCE IN MAINTENANCE & ENGINEERING
2 | Nov/Dec 2008 | ME
COVER STORY
Air compressors —
Atlas Copco Compressors
advises how to be healthy,
wealthy and wise
How healthy is your compressed air
system?
Although industry at large is highly dependent upon the
reliable supply of compressed air as a vital element within
most manufacturing processes, it is surprising just how
often the condition and efficiency of this essential utility is
taken for granted. Even with the bare minimum of regular
maintenance, such a fit-and-forget approach could actually
be responsible for generating substantial energy losses and
have a marked effect on a company’s bottom line. So, while
it is obvious that a compressed air system operating at peak
efficiency will save money, it is a fact that not every operator
is aware of just how fit their installation may be – and with
today’s upward spiralling energy costs there has never been
a better time to find out just how healthy it is.
Time for a health check?
A free Compressed Air System
Health Check can be booked
by calling Atlas Copco on
0800 181 085 or by email to
gba.info@uk.atlascopco.com
Enquire using 1671 at www.
maintenanceonline.co.uk/ME
It is with this type of investigation in mind that, as
part its continuing commitment to keeping energy and
production costs down
to the minimum, Atlas
Copco is offering industry
a free Compressed Air
System Health Check
to be carried out by an
expert specialist. It is a
non-intrusive procedure
that won’t interfere with
production processes and
is designed to examine
the entire air supply
system – compressors,
filters, dryers, pipework,
ancillaries, controls and
monitoring – highlighting
every energy-consuming
feature.
Experience shows
that the highest levels
of compressed air system efficiency are invariably obtained
through a combination of factors, so once a Health Check
has been carried out on a system, the plant operator will
be in a position to make an immediate assessment of the
remedial priorities required to meet desirable levels of
energy and cost efficiency
Examining the system
The Compressed Air System Health Check programme
includes monitoring and inspecting the running of the
compressors as well as the capacity and fitness of the dryers
and all the ancillary equipment such as receivers, filters, drains
and oil/water separators. It also examines the state of the
controls and monitoring system together with that of the
pipework and general system.
The detailed examination starts with an assessment of
the size and capacity of the compressor installation and its
running profile relative to the compressed air application.
That means noting the hours it is loaded/unloaded or
the operating hours that are actually timed during the
examination visit. Running pressure is also checked to ensure
that it is at a level appropriate to the demands of downstream
processes, as excessive downturn of the delivered air pressure
can waste energy. Any other relevant observations on
standards of performance are made at this stage.
Equally vital to the efficient running of a compressor
system is the accuracy and efficiency of the control and
monitoring systems that are in place, so they also merit a
significant degree of the examining engineer’s attention.
The next subjects on the inspection programme are
the dryers, whether they are integral to the compressors
or comprise downstream standalone units sited before the
point of use. The health check programme notes the size and
type dryer, the accuracy of the dewpoint indicator and the
functionality of the waste water drain. Then, starting with air
receivers, the inventory of ancillary equipment also undergoes
scrutiny. That means determining the operating pressures of
filters and the condition of filter elements, as well as that of
condensate drains and oil/water separators.
Pressure drops
But, without doubt, one of the largest energy-loss culprits
that the experts focus upon has to be the condition and
configuration of the airnet pipework where even the smallest
leaks can create significant pressure drops. For instance, a
3mm diameter hole anywhere within a distribution network,
caused by corrosion, can mean a compressor using an
additional 4kW of power to maintain system pressure.
The effect of pressure drops can represent more than 75%
of the running costs during the working life of a compressed
air installation. So, apart from detecting corrosion-generated
leaks and loose pipework joints and fittings, it is equally
important to ensure that pipework runs are installed at the
minimum distance between compressed air source and
the point of use if optimum system air pressure is to be
maintained.
Reporting stage
After the assessment process is completed, the Atlas
Copco engineer will provide an on the spot written
assessment that shows exactly where matters can be
improved and savings can be made. Once the engineer’s
report has been submitted there is no obligation for
the compressor operator to adopt any of the report’s
recommendations, but Atlas Copco specialists will be on call
if required to assist with the implementation of any necessary
improvements highlighted by the examination and deemed
to be of benefit to economic plant operation.
With this free fitness check offer, compressed air plant
operators have nothing to lose but a little of their time, and
in today’s financial climate that may prove to be the best
investment they will make.
ME | Nov/Dec 2008 | 3
PLANT &
MAINTENANCE
We first featured PAS 55 in the 2007 Sept/Oct issue (Vol 7 No 5) of
‘Maintenance & Engineering’ – read the original article at www.
maintenanceonline.co.uk.
Here, John Woodhouse, Chairman, Developments & Standards, Institute of Asset Management
and Managing Director, TWPL, reviews the latest
release of the PAS 55 Standard.
PAS 55-1:2008 —
the standard for integrated, life
cycle optimised asset management
T
here is, at last, a consensus-developed, clear definition
of good asset management and what needs to be done
to maximize asset life cycle value-for-money.
PAS 55 was originally developed by a multi-industry
consortium of 26 organisations to address the growing
need for clarity in terminology and for better definition
of the requirements for responsible governance in the
management of critical infrastructure. Since its publication
in 2004, there has been a rapid increase both in awareness
of asset management as a professional discipline, and in
recognition of the value of such joined-up thinking. Public
services, utilities, transport, manufacturing, mining, oil & gas,
defense, pharmaceutical, process and heavy engineering
companies have come to recognize that long-term thinking,
risk-based decisions and other attributes of professional asset
management are core to their businesses. Certification
against PAS 55 has even been adopted in some industries
(e.g. electricity & gas networks) as a
regulatory requirement to demonstrate asset
management competency. PAS 55 thus
provides tangible evidence of systematic,
cross-disciplinary and optimized management
that correctly blends responses to short term
requirements with sustainable long term
performance.
In contrast to the simplistic view that ‘asset
management is just maintenance by another
name’, many organisations have recognized
that the real requirement is for a more rigorous
and joined-up approach to all aspects of
the asset life cycle: from the recognition
of requirements to design, acquisition,
construction, commissioning, utilization or
operation, maintenance, renewal, modification
and/or ultimate disposal. This involves juggling competing
requirements of asset exploitation (utilization) and asset care
(maintenance), of initial capital investment and downstream
operating costs, performance and risks, of short-term and
long-term performance and other trade-offs or compromises.
Such a joined-up approach requires clear understanding
of corporate priorities, clear criteria for defining criticality,
risk-based decision methods, cross-functional teamwork, long
term planning and a range of other ‘enablers’.
4 | Nov/Dec 2008 | ME
PAS 55:2008 has built upon the original 21-point checklist
through the inputs of over 50 organisations in 15 industry
sectors in 10 countries. Published this month, the new
standard has a bigger glossary, revised structure and clarifies
many of the requirements for risk management, life cycle
planning and other key processes, with appropriate focus
on data, information and human factors. Following the
Deming Cycle of Plan-Do-Check-Act (and aligned to other
management standards such as ISO9000, 14000, 18000 etc)
the revised PAS 55 clarifies how to integrate the ‘top down’
pressures on an organization (e.g. competing stakeholder
expectations) with the ‘bottom up’ realities and opportunities.
It provides a common language for technical or engineering
staff to converse with financial managers and business
leaders. And it provides the framework for understanding
how all the parts fit together.
The components of the standard
PAS 55 is a ‘Publicly Available Specification’ – a BSI
standard with the same status as OHSAS 18000. It comprises:
쐍 Definition of terms in asset management
쐍 Requirements specification for good practices
쐍 Guidance for the implementation of such good
practices.
It is published in two parts: Part 1 is the checklist of
what needs to be in place, while Part 2 provides extensive
guidance and illustrations of what should be done to achieve
the requirements of Part 1. The combination enables
organisations to test, to
BSI PAS 55
identify weaknesses, and
왌 A clear, internationally recognized definition of
to plan improvements. It
what good asset management really means.
provides an objective
왌 28-point checklist for good practices in life cycle
standard across all aspects
planning, cost/risk optimisation and joined-up
thinking.
of good asset management,
왌 Developed over 6 years, by over 50 public and
ranging from the
private organisations in 10 countries and 15
development of life cycle
sectors.
strategies and plans for
왌 The hallmark for demonstrating competent
capital investments, asset
governance of critical infrastructure.
왌 Applicable to all sectors and all asset types.
utilization, maintenance,
왌 Extensive glossary and definitions of key terms.
renewal and disposal - and
왌 Detailed guidance and examples of good
the cost/risk/performance
practice.
optimisation of the whole
Basis for:
picture. Most of all, it is a
쐍 alignment of understanding.
definition of the integrated
쐍 self-assessment,
쐍 benchmarking,
approach required to make
쐍 improvements planning,
the most of an organization’s
쐍 independent audit,
assets, to meet conflicting
쐍 certification,
stakeholder demands and
쐍 contractor selection,
to deliver best value-for쐍 demonstration of competence.
money in a sustainable
manner. PAS 55 is thus the checklist and benchmark to
assure customers, owners, employees, regulators and other
stakeholders that the business is in good hands.
It is also used to identify and delivery very significant
tangible performance improvements. Organisations who
have adopted it quote benefits such as 30% reduction in the
total cost of asset ownership, 25% improvement in service
delivery, higher reliability, better regulator and customer
relations and a range of other core business improvements.
Publicly Available Specification PAS 55 is published by
British Standards and is distributed and supported worldwide
through the Institute of Asset Management (www.theIAM.org).
NEWS REVIEW
David Brown under New Ownership
L
eading engineering company David Brown has been acquired by Clyde Blowers, the East
Kilbride-based group owned by Scottish entrepreneur Jim McColl, as part of a $1 billion deal,
involving four separate Textron businesses: Swiss-based Maag Pumps, US and Penistone-based
Union Pumps, Dorset-based David Brown Hydraulics and David Brown Gear Systems.
David Brown Gear Systems currently employs around 380 people on its main Huddersfield
site and another 1113 personnel at 9 manufacturing sites around the world. The company was
established in 1860 and remains
a premier, global manufacturer of
engineering products.
Commenting on the deal Jim
McColl said; “This is a great boost for
Britain at a time when some of our
biggest companies are being acquired
by foreign businesses. Here is a story
of a British company having the clout
to buy an entire division from a global
company ranked 202 in the American
Fortune 500.”
David Brown’s general manager
Ian Farquhar added; “This is great
news. It has been an open secret for some time and there is now a mood of optimism within the company
that, with Clyde’s support and investment, we have a bright future.”
Schaeffler (Uk) Ltd wins
Manufacturing Award
S
chaeffler (UK) Ltd’s plant in Llanelli, South
Wales, manufacturing high precision engine
components for the automotive market, has been
awarded the prize for Manufacturing Excellence at
a recent Wales Quality Awards 2008 ceremony - an
annual competition based on the EFQM European
Excellence Model.
Assessors from the Wales Quality Centre
visited the plant in October to look in detail at
the factory’s manufacturing performance over
the last three years, as well as the systems and
processes that enabled this. Other key factors
measured included leadership, impact on the local
community and social responsibility. In addition,
the plant submitted a full report against the EFQM
model.
Accepting
the award
with four of
his colleagues,
Plant Director,
Roger Evans
commented:
“We are
absolutely
thrilled to win this award at our first attempt, as it
reflects the outstanding manufacturing performance
of this plant and its workforce.”
Winning a Quality Award is a genuine
accolade for any business, indeed, many
companies who have taken part in the process,
do so year on year, and use it as a fundamental
part of their company’s planning process to drive
business improvement.
Hazardous
Chemicals
Regulation
S
mall businesses, using potentially
harmful chemicals, have just two weeks
to meet the registration deadline of an EU
environmental regulation, or face being
penalised.
Firms must record any of the hazardous
substances they buy, sell or use under the
Registration, Evaluation, Authorisation and
Restriction of Chemicals regulation (REACH)
by 1 December 2008. If they fail to register
by this date, they will be forced to cease
manufacturing and importing chemicals
until they have signed up.
Forum of Private Business (FPB) member
Francis Pound, of specialist chemical firm
AV Pound & Co Ltd, has had to employ two
full-time members of staff working extra
hours in order to comply with the REACH
Regulation. In addition to checking existing
substances, Mr Pound must account for any
future chemicals he may want to import.
“We’re in the process of dealing with this
now. The whole thing is stupid. It’s a complete
nightmare because it’s so complicated. It’s
taken us three months just to get to the stage
where we can register,” said Mr Pound. “We
have to write to all of our customers to ask
what they do with the products we supply
them with, and also to our own suppliers. You
can imagine what kind of answers we get!”
More information on REACH is available
from the FPB’s helpline on 0845 130 1722.
Keep an eye on
all your equipment
with LEM split core
current transducers
Integrated transducers combine
the most advanced sensing
technologies with signal conditioning
electronics in very compact cases.
Easy to install high quality current
transducers are ideal for designing
cost-effective, accurate and reliable
solutions for condition monitoring,
process control and automation.
l DC and AC (True) RMS
current measurement
l Measuring ranges from 2 to 2000A
l Self-powered, loop-powered
or +24..48V power supply
l Isolated standard outputs,
e.g. 4-20mA, 0-5/10VDC,
switch or relay
l Large sensing aperture
(cable or busbar)
for non-contact measurement
www.lem.com
Energy & Automation
ME | Nov/Dec
2008
Enquire
using 1670
at | 5
www.maintenanceonline.co.uk/ME
Meccano set
It all started with a
At a recent awards ceremony, Contour
Premium Aircraft Seating won 1st place in
the coveted IT in Manufacturing category
for its professional and successful
implementation of a production planning
and scheduling system in conjunction
with a major Lean initiative. The
company prides itself on a proactive
approach across all areas in ensuring it
achieves the best it can, and the area of
maintenance is no exception. With 70% of
all components manufactured in-house,
including 90% of all metal items for the
manufacture approximately 200 premium
seating assemblies, that means a lot
of maintenance
to manage.
Overseeing
this task is the
responsibility of
the maintenance
department managed by Nic Goddard.
M&E: Nic, thanks for talking to Maintenance and Engineering.
Where did your interest in engineering come from?
GD: NG: I suppose it all started when I was about 8 years of
age when one Christmas my brothers and I had a joint present of
a Meccano set. This was followed by taking my Gran’s iron apart
and, later, a toaster which would not pop up - it never worked at all
after I tried to fix it! I also worked on a spin dryer, where key parts
disappeared into an abyss, never to see the light of day again.
M&E: How did you move from this to your current role within
Contour Premium Aircraft Seating?
NG: My first job in the engineering/manufacturing sector was
as a maintenance electrician in a factory making components for
bicycles, with various machine tools such as auto-capstans, manual
6 | Nov/Dec 2008 | ME
and CNC lathes, vertical and horizontal mills of the manual and
semi-automatic production type. Over the last 25 years within this
industry I have had varying roles, mainly in sub-contract machine
shops, but also in the aerospace and automotive sectors. These
have ranged from CNC programmer, contractor CNC programmer/
method engineer, to Works Manager and company Managing
Director. I returned to a maintenance role within Contour Premium
Aircraft Seating based in Cwmbran,
South Wales after joining the
company four years ago as a
production engineer. After being
with Contour for a few months I
was asked if I would like to head
up the maintenance department
and add my extensive experience
to supporting this area within the
business.
M&E: Who were the
key influences on your career
development? Is there one person
or event that stands out in your
mind which helped you realise the
importance of maintenance within
a manufacturing/engineering
company – if so, why and how did
this affect you?
NG: Firstly my wife, who
has constantly supported
my decisions over the years –
especially through the bad times
when there were a few occasions
that redundancy impacted. She has encouraged me to pursue
my goals and ambitions to achieve a successful career. Secondly,
during my childhood, my brother could not let go of the fridge
door handle when he was electrocuted as a result of burnt wiring
and a detached earth. Luckily this was not fatal but it was serious
enough to make me appreciate the importance of maintaining
all equipment – especially within a manufacturing/engineering
environment.
M&E: How would you sum up your own personal vision for
maintenance and developing a maintenance strategy?
NG: My personal vision is: “To provide both an effective and
efficient service to the maintenance department’s customers.” This
can be achieved by having an effective maintenance programme
strategy and ensuring that a prompt response is made to all work
requirements and requests, and minimising downtime in order that
manufacturing is able to maximise the utilisation of available plant
and machinery at all times.
M&E: In your experience, what are the current trends in
maintenance and the role of maintenance within an organisation
and how have these changed over the past decade or so?
NG: Currently there is a lot of ‘buzz’ about vibration analysis;
this has an obvious role to play within manufacturing. It can give a
far earlier indication of potential bearing failure in moving pieces
of equipment. Local heat source and thermal imaging monitoring
& analysis are other useful work tools. Local TPM (Total Productive
Maintenance) program development, where operators undertake
minor regular, routine tasks, also plays a vital part in ensuring that
plant and machinery is maintained at optimum. There are, of course,
more methods than these and every company has its own view on
which best suits its own needs.
INTERVIEW
M&E: Generally speaking, what role do you see maintenance
playing in the future in terms of overall importance to organisations/
companies etc?
NG: Ultimately if organisations/companies have a robust
strategy then, theoretically, they should never have any breakdowns
to deal with. This would result in the achievement of optimum
full production at all times. However, in order to attain this, a
maintenance department
can only be successful if
PPM (Planned Preventive
Maintenance) takes place as
and when it is scheduled to
do so.
M&E: What is the role of
maintenance within Contour
Premium Aircraft Seating?
NG: Maintenance within
Contour over recent years
has had a difficult time, in as
much that it has struggled
to keep up with the rapid
growth of the business. Firstly,
the Seats assembly factory
was opened about 8 years
ago in Cwmbran. Since then,
about 5 years ago, the seats
Manufacturing Unit (MU) was
transferred from Camberley
in Surrey. This was followed
by an extensive expansion,
over the last 3 years, in the MU.
For example, the machine shop
department alone in the MU
has almost doubled in size and
currently has 47 CNC machines,
plus several semi-automatic
and manual machines. This
has resulted in maintenance
becoming more of a fire-fighting
department. Undoubtedly, we
are not unique in this; we are
not the first, nor will we be the
last, to experience this and, like
others before, we have to find ways to rise to the challenge, resolve
the issues and overcome the adversity.
M&E: What are the key maintenance challenges within the
company and how are these being overcome?
NG: The main challenge is to develop positive pro-active
plans to achieve success as a department through inter-action at all
levels within the business. To achieve this, key machinery has been
identified, where a plan is currently being put in place to extend
PPM so that, eventually, all plant and machinery is covered. We have
also started running workshops and have begun to implement TPM
on all plant and machinery.
M&E: What are the biggest obstacles to you overcoming these?
NG: Having adequate resources and finding extra funding to
cover the additional costs in providing PPM and implementing TPM
throughout. Raising the awareness of the importance of TPM and
how, in most cases, it’s simple actions that have the most significant
positive effect.
M&E: To what extent does IT play a part in your maintenance
strategy?
NG: Recently we have introduced software that will assist
greatly in the management of PPM. In a year or so, this should
start to provide meaningful historical data that can be analysed to
assist in the decision making process to plan a strategy for future
development and investment within the business.
M&E: Much is made of the need to incorporate maintenance
at a board room level so it is seen as an integral component of the
overall running and success of any organisation. How do companies
achieve this?
NG: How much is made of this depends on individual
companies and their stance. Maintenance in any industry is only
one element of an integral process. If, for example, maintenance
is stretched, you need to manage the constraint. There is much
written about this by Eliyahu Goldratt in a number of publications
covering the Theory of Constraints (TOC). This can be summed up
thus: Identify constraints, set the goals and how to achieve them,
follow this through and use it as part of an ongoing process to
continually improve, adapt and change.
M&E: What would you want your contribution to have been at
Contour Premium Aircraft Seating?
NG: To provide a legacy of simple, effective, relatively low-cost
measures which can provide long-lasting solutions that prevent
costly breakdowns and lost production time. This will assist the
continual growth and success of the company.
M&E: Lastly, if you had 10 minutes with every manufacturing/
engineering MD in the country, what 3 general items of advice
would you want to share with them about the role of maintenance
in their company?
NG: First, listen to your
work force. They have a wealth
of knowledge that is generally
overlooked and, more often than
not, will give you the solution, if not
immediately, then in a very short
space of time. Rather than taking a
chance that can prove needlessly
expensive, by simply going to your
work force and asking “what is your
opinion or how do you think this can
be resolved?”, you will be amazed at
the results.
Secondly, do not look at
maintenance as a necessary evil. It needs to be part of the success
process, just as it is vital to have well orchestrated production
schedules. The same goes for PPM. Well maintained equipment will
be more reliable, less prone to breakdowns and provide consistent
results with optimum performance.
Finally, implement the thorough training of your workforce and
have good housekeeping policies throughout. In particular, the
thorough cleaning of machines is not something that only needs
to be done when machinery is due for scheduled maintenance or
when it breaks down, it needs to be done frequently. More often
than not, breakdowns occur because machinery is not being
maintained thoroughly enough at frequent intervals. There is
nothing more disheartening for a maintenance team member, than
having to go back and re-repair a machine, only to find that it is as
a result of neglect from the operator, and that it could have been
avoided by implementing better training and a higher standard of
house keeping.
ME |Nov/Dec 2008 | 7
PLANT &
MAINTENANCE
Deming’s 14 points
04
I recently dusted off an old textbook of
mine when someone inquired about
W. Edwards Deming’s famous “14 points”.
Deming believed that the cause of
inefficiency and poor quality is the system,
not the employees. Furthermore, he stressed that it is the
responsibility of management to correct the system in order
to satisfy goals and objectives.
End the practice of awarding business on
the basis of price tag. Instead, depend on
meaningful measures of quality, along
with price. Eliminate suppliers that cannot
qualify with statistical evidence of quality.
Almost all CMMS packages track supplier history
including quality of products and service. If
improvements are not forthcoming, spare parts
can be sourced from an alternate supplier.
05
David Berger
Find problems. It is management’s job to
work continually on the system (design,
incoming materials, composition of material,
maintenance, improvement of machine,
training, supervision, retraining).
The CMMS is a great tool to help management
find, troubleshoot and track maintenancerelated problems.
A
s you read through Deming’s points (adapted from
W. Edwards Deming, Quality Productivity, and
Competitive Position, Cambridge, MA:MIT, 1982,
pp.16-17), think about how you and your maintenance
department can play a key role in supporting the
underlying principles that resonate still today.
01
Create constancy of purpose toward
improvement of product and service with a
plan to become competitive and to stay in
business.
Deming’s first point emphasizes the importance
of continuous improvement. A CMMS can be
used to continually plan, track, and correct, in
support of improved quality and productivity.
02
Cease dependence on mass inspection.
Require instead, statistical evidence that
quality is built in. Prevent defects rather than
detect defects.
This point is the essence of the argument
for favouring predictive maintenance over
preventive maintenance over reactive
maintenance. Condition monitoring data from
a CMMS prevents equipment failure (a defect),
rather than detect that failure has occurred.
8 | Nov/Dec 2008 | ME
Institute modern methods of training on
the job.
Unquestionably, on-the-job, practical training
that is well supported by Maintenance
management is a critical addition to the theory
learned from classroom, video, or computerbased training.
07
We can no longer live with commonly
accepted levels of delays, mistakes, defective
materials, and defective workmanship.
The maintenance department can help using
the CMMS to reduce delays, mistakes, etc. for
maintenance personnel, and to assist Operations
in improving the quality of output and
productivity through, for example, improved
equipment reliability and performance.
03
06
The responsibility of supervisors must be
changed from sheer numbers to quality
... [which] will automatically improve
productivity. Management must prepare
to take immediate action on reports from
supervisors concerning barriers such as
inherited defects, machines not maintained,
poor tools, fuzzy operational definitions.
A CMMS provides helpful information, such as
equipment history, to determine how much
money should be spent on what resources for
which activities, in order to identify and remove
the maintenance-related barriers referred to by
Deming.
08
Drive out fear, so that everyone may work
effectively for the company.
A participatory approach to managing change
goes a lot farther than management through
fear and intimidation.
09
Break down barriers between departments.
People in research, design, sales, and
production must work as a team, to foresee
problems of production that may be
encountered with various materials and
specifications.
T R A N S AT L A N T I C V I E W
CONDITION
MONITORING
Protect your critical rotating plant
If only Deming had included the maintenance
department in his list of people that must
work as a team. Then perhaps Operations
and Maintenance would have found greater
common ground more quickly over the years.
10
Eliminate numerical goals, posters, and
slogans for the work force, asking for new
levels of productivity without providing
methods.
We must be fair to our maintainers by not
just setting aggressive goals, objectives and
performance targets, but providing the means
for tracking and achieving them. To this end,
we need improvement methodologies such
as Total Productive Maintenance, Lean, and
Six Sigma, as well as tools such as a CMMS for
identifying improvement opportunities.
11
Remove barriers that stand between the
hourly worker and his or her right to pride
of workmanship.
Deming would say, for example, that when
maintainers are in fire-fighting mode and
pushed for time, they are less likely to feel the
pride of workmanship that comes from doing a
quality job.
13
14
O Vibration
Monitoring
Supervisory
O Displacement Measurement
O Overspeed Protection
O Bearing Condition
O Seismic Monitoring
O Turbine
API 670 Compliance
ATEX Hazardous Area
O IEC 61580 SIL
O
O
keeping industry turning
Eliminate work standards that prescribe
numerical quotas.
Deming is rightly concerned that maintainers
who are driven primarily by labour standards
or estimates on a work order, may do so at the
expense of a quality job.
12
SENSONICS predictive maintenance systems are used and
appreciated around the World, providing cost-effective,
monitoring for all types of critical rotating plant.
Institute a vigorous program of education
and retraining.
T: +44 (0) 1442 876833 - sales@sensonics.co.uk
Enquire using 1673 at www.maintenanceonline.co.uk/ME
INTELLIGENT MAINTENANCE
Rail
Mining
In order to establish and sustain a continuous
improvement program in Maintenance, new
skills are constantly required for evolving
techniques, equipment, tools, and so on.
Petrochemical
Create a structure in top management that
will push every day on the above 13 points.
Nuclear
This is Deming’s way of reiterating the
importance of creating a culture of continuous
improvement. Senior management must
recognize the impact Maintenance can have on
profits, in light of the rising complexity of critical
assets and the growing consequences of their
failure.
www.sensonics.co.uk
Northridge Road, Berkhamsted, Herts HP41EF
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ME | Nov/Dec 2008 | 9
PLANT &
MAINTENANCE
Many drive systems go to an early grave after only about
10 years of operation. Reconditioning an existing drive
system could enable it to operate reliably for another
decade and can be achieved for just 30-40% of the cost
of a new drive system. Peter Wright, Drives Products
Service Manager for ABB in the UK explains how.
Double the drive
life at one-third of the cost
N
DRIVES
use a short optical transmission to transfer a signal while keeping
elements electrically isolated. The output of these devices reduces
over time and the signal gets weaker.
As a consequence of a lack of maintenance, false trips may result.
Changes in switching pattern will be experienced as a reduction
in the performance of the drive. In the worst case, the power stage
might fail, which usually means an expensive repair bill. During
reconditioning, the power boards themselves are not replaced, but
the components that impact on them are. Failure to replace these
components in time may result in a costly power device failure.
A reconditioning service should include visual inspection,
cleaning, a thorough faultfinding analysis, preventive maintenance
according to the schedule, repair if needed and functional testing.
Reconditioning an existing drive achieves more than just
maintained reliability. It helps retain the expertise of the staff that has
learned to work with a particular piece of equipment. It also retains
the value of the spares stock which, if the drive is renewed, will
become redundant.
ot so long ago, a variable speed drive was considered a piece
of solid state electronics that, once installed, could be left to
itself. In many places, maintenance teams still overlook the
Reduced lifecycle cost
drives and hope for the best, but downtime and costly repairs can
be the consequence, if older drives do not get proper attention.
The cost of reconditioning is 30-40% of the cost of a new drive.
“ABB was among the first companies to recognise that drives require
By doing this halfway through the drive’s service life, the user can
service. In the early 1990s, we were already issuing maintenance schedules expect another decade of reliable operation. The cost of failure is in
for drives,” says Wright.
many cases much higher than the cost of drive reconditioning.
“But still, 60 percent of our field activities and 85 percent of our
Reconditioning is a very effective way to reduce the life
workshop requests are reactive repairs. This means that significant
cycle cost of high power drives, but for drives of 50 kW or lower,
attention and money is spent on costly plant
recovery following unplanned downtime.”
According to Wright, the normal life
expectancy of a drive is 15-20 years. In that
time certain maintenance activities are
required to ensure that a long and troublefree service life is achieved. Every drive comes
with a maintenance schedule that outlines
the manufacturer’s recommendations. This
includes routine maintenance, for instance
annual air filter replacement and fan renewal
every three or six years dependant upon
the fan type. Such maintenance activities
Failed IGBT due to faulty gate pulses
Example of good gate pulses
can be easily carried out by the in-house
maintenance team or with the assistance of a local engineering firm.
replacement tends to be a better option. Reconditioning should be
considered for drives in excess of 100 to 150 kW.
Components ageing
Reconditioning practice varies between industries. In the water
industry, reliability is important, as loss of water supply can be costly
But after about 10 years, some of the electronic components
and reconditioning is easy to carry out here. Pumping stations
begin to reach the end of their lives. The ageing of the components
almost always have duty, assist and standby pump sets, so one drive
will begin to have an impact on the reliability of the drive. In
can be taken out of service without any problems and taken back to
particular, the electrolyte in the capacitors dries up. This affects
the workshop for reconditioning.
the performance of the gate driver boards, which provide energy
However, the area where drive reconditioning takes place most
storage for switching. This can cause pulses of different shape and
frequently is in the process industries, in sectors such as cement,
size compared to when the drive was new.
“At this stage, we recommend reconditioning of the drive,” says Wright. metals, sugar and paper. Here, the maintenance teams are acutely
aware of the fact that downtime costs money. For instance, a paper
“We normally schedule reconditioning to take place in the ninth service
machine can have 30 to 50 drive sections and if one of these goes
year, to ensure it happens before any problems are experienced. But if the
down, the whole machine stops. Maintenance is regarded as a profit
drive is used in a high ambient temperature, this may be needed sooner.”
centre and a way to prevent failure. In this light, downtime becomes
Poor connections
the cost of inadequate maintenance. Success, to these maintenance
teams, is 100% availability, not a quick and effective repair job.
As well as capacitors, potential problem sources include
corrosion of ribbon cable, or worn-out gold plating on sockets
Equipment availability a priority
where cables are frequently plugged in and unplugged, with poor
connections as a result.
PT Riau Andalan Kertas (RAK) in Indonesia is the world’s
Optocouplers also deteriorate with time. These are devices that
largest pulp mill, producing 2 million tonnes of pulp per year and
10 | Nov/Dec 2008 | ME
350,000 tonnes of uncoated fine paper. It is an advanced paper mill
and equipment availability plays a key role in the company’s operating
strategy.
Maintenance schedules and preventive maintenance kits are keys
to sustaining availability of the company’s No 1 Paper Machine. This has
an ABB drive system comprising 49 drive sections, commissioned in 1997.
During the first five years, operation was excellent, but then the drive
maintenance team noticed a slight decline in availability. To restore and
sustain the original high availability, RAK and ABB teamed together and
made a site survey to analyse the situation.
Based on the survey results it was concluded that all the
maintenance according to the maintenance schedule had to be
performed. Up to this point, RAK had been conducting maintenance
according to its own maintenance plan. However, the maintenance
schedules based on the latest experience were not available at the early
years of operation of Machine 1. As a result of the new maintenance
regime, availability has improved significantly.
Drive plans for life
Another example is Borealis, a leading provider of plastics solutions.
The production site in Porvoo, Southern Finland, manufactures
petrochemical products and polyolefin plastics. It has a capacity to
produce approximately 2 million tons per year.
The plant has used ABB drives for several decades and ABB has a
preventive maintenance contract for all of them.
The objective is to maintain high drive reliability and minimise
lifecycle costs, as well as
to guarantee rapid spare
part and repair work
deliveries. The contract
also contributes to the best
use of plant maintenance
resources and availability of
service engineers. Borealis
uses scheduled production
shutdowns to carry out
drive maintenance. Most
production lines have
Poor gate pulses that have resulted in IGBT failure at least one weeklong
scheduled maintenance
shutdown each year and the annual maintenance work on the drives is
carried out during these production shutdowns according to schedule.
In addition to planned maintenance, ABB’s lifecycle plans for drives help
define the time when a drive should be reconditioned or replaced.
Maintenance policies vary
“Policies on drive maintenance and reconditioning vary a great deal
between companies,” says Wright. “Some are proactive, others just install
their drives and hope for the best. Some get away with this, others don’t. But
particularly those that have drives operating in hot environments should be
aware that component ageing is an issue that needs to be dealt with seriously
and that solutions are available.
After reconditioning, the drive should perform as good as new again –
we even give a full one-year warranty on the whole reconditioned drive, not
just the replaced parts.”
Drives under 400 kW can be returned to the workshop and
reconditioned. The controlled conditions at the workshop help ensure
that the service job is as effective as possible. However, removing
the drive from the site is not always feasible. Reconditioning then has
to take place on site and ABB has developed methods for effective
decontamination.
Enquire using 1676 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 11
PLANT &
MAINTENANCE
GEARBOXES
T
A thermographic image of
a gearbox showing that is
running too hot and requires
action to prevent it from
failing prematurely
here are substantial benefits to
be gained, in terms of improved
reliability and longer operating
life, for users who monitor and actively
control the operating temperatures of
their gearboxes. The first step on the road
to achieving these benefits is to select
the right gearbox for the job. This usually
means selecting helical, bevel helical
or planetary units, which are over 90%
efficient, rather than worm boxes, which
struggle around the 50% mark.
Cooler running temperatures can help
extend the life of bearings and oil seals;
experience shows that a reduction in temperature of around
14°C can double the life of nitrile seals used in gearboxes,
whereas an increase of 14°C can halve it. For example, a
gearbox may operate for 12,000 hrs at 52°C, but another (in
same application) may only operate for 6000 hours at 65°C
before seal failure occurs.
This effect is not limited to nitrile seals; Viton seals,
lubricant and internal gearbox components also suffer
Gearboxes deliver improved reliability and longer
operating life under cooler running conditions,
says Bain Nicholson, Operations Manager,
Deritend RMB Large Rotating Machines
Gearboxes stay cool!
The wear life of components in
a gearbox driving a conveyor
system such as this can be halved
if the gearbox is running too hot
without anyone noticing – here it
looks normal to the naked eye
adversely from operating at excessive temperatures for long
periods. If this is allowed to continue, then several problems
may arise including: burnt lubricant, scoring on bearing
raceways, and damaged seals and gears, all of which can lead
to premature failure of the gearbox.
Having established
that too much heat is bad
for gearboxes, the question
is: How can gearbox users
gauge the correct operating
temperature? Well a general
rule of thumb used to be
that if a person could hold
their hand on a gearbox
housing for a few seconds
without discomfort, then
the gearbox temperature
was not too high. What
makes this test redundant
are today’s Health and Safety
regulations, and the fact
that all humans have a different tolerance to heat: the limit of
human touch is generally in the range from 54°C to 60°C.
Today, planned maintenance programmes mean that
instruments, rather than hands, are used for measuring
temperature - contact thermometers, thermocouples or, in
applications where direct temperature measurement is not
possible, non-contact infrared thermometers. These units
12 | Nov/Dec 2008 | ME
absorb ambient infrared (IR) radiation given off by a heated
surface. In addition, increasing numbers of companies are now
using thermal imaging to detect when a gearbox is running
hotter than normal. The benefits of this technology are that
it can also detect leaks, by revealing hot oil running down
gearbox casings.
The heat generated in gearboxes is the result of friction: as
load increases, temperature increases, and as load decreases,
temperature decreases. In addition, friction caused by faulty
bearings, misalignment, imbalance, misuse, or just normal
wear can also lead to excessive heat generation, along with
the usual prime suspect of inadequate lubrication. Finally,
there is the case where gearboxes are exposed to direct
sunlight, the radiated heat raising the normal operating
temperature to unacceptable levels.
In the case of bearings, heat problems occur when a large
temperature difference builds up between the shaft inside
a bearing and the housing surrounding the bearing (due to
misalignment, for example). The differential thermal expansion
causes the bearing to lose internal clearance and become
pre-loaded. This results in increased heat generation which
will increase the differential temperature, leading eventually to
thermal runaway and melt-down
Although bearings can have major issues with
temperature, by far the most the most temperature critical
component in a gearbox is the lubricant. This performs a
dual function: it reduces friction by separating the moving
components and transports and distributes the heat from
the friction points: gears, bearings and seals, to the gearbox
housing, enabling it to dissipate the generated heat.
The viscosity of the lubricant decreases drastically with
increasing temperature, impairing its ability to maintain
an Elasto Hydro Dynamic (EHD film) between the moving
components in contact, so the choice of viscosity is critical.
However, there is generally not a problem within one ISO
grade, but it is better to err on the high side of two viscosity
grades where there is any uncertainty.
The maximum housing limit on most industrial gearboxes
is in the range 82°C to 93°C, with limits for standard rubber oil
seals at 100°C; fluorinated rubber oil seals at 150°C; mineral oils,
100°C, and synthetic oils, 150°C, plus. Bearings and steel gears
have temperature limits that typically exceed 1200 to 150°C,
and usually do not limit the thermal capacity of most generalpurpose industrial gearboxes.
If the housing temperature of a gearbox exceeds the
manufacturer’s limit, then there are a few options to consider.
Where physical space allows, a larger reducer should be
considered or auxiliary cooling should be employed. This
may include shaft driven fans, electric fans or radiant cooling
systems. In cases where the gearbox is subjected to strong
sunlight and there is no facility for forced cooling, then the
gearbox should be painted a reflective colour and partly
shielded, so as no to interfere with natural convection.
About Deritend RMB
Deritend RMB specialises in 24-7 industrial gearbox repairs,
refurbishment, replacement, machining and fabrication and
offers one of the most comprehensive gearbox breakdown
engineering, machining and fabrication services in the UK.
Deritend RMB became part of the Deritend Industries group
of companies in August 2007 and also supplies a wide range
of premium brand replacement gearboxes, motors, drives and
general power transmission products.
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ME | Sept/Oct 2008 | 13
PLANT &
MAINTENANCE
Peter Rose of Alfa Laval looks at the
use of centrifugal separation systems for
recycling metalworking fluids.
Clean up to clean up
M
etalworking fluids used to lubricate and cool cutting
tools are specialised and expensive to replace. They
generally contain mineral oils or synthetic lubricants
and may be used neat or in a water-mix. Referred to as
‘coolant’, ‘suds’, ‘slurry’, ‘soup’, ‘water’ etc, they are applied to
the workpiece to provide cooling, lubrication, swarf removal
and corrosion protection. They may also contain emulsifiers,
stabilisers, corrosion inhibitors, biocides, fragrances and
extreme pressure additives to enhance their performance.
During use they become contaminated with swarf, metal
fines and tramp oils which, if not quickly removed, impair
coolant efficiency – with knock-on effects on tooling, cutting
accuracy and product quaity – and any impurities picked-up
can cause severe health and safety problems for machine
operators. In addition, the expense of replacing large volumes
of contaminated
£
fluid grows with
5% Coolant @ approximately £2 per litre
600
every new round
Disposal costs @ 4p per litre x 4 times per year
40
of environmental
2000
Time taken for changeover (allow 2 hours
legislation, so failure
downtime @ £250 per hour for each
to address the
changeover) x four times per year
problem can, literally,
Total per machine
2840
lead to pouring
Total for five machines
14200
money down the
Table 1
drain. The numbers
are not insignificant, either - a machine shop with just five
machine tools, each with a sump capacity of 1500 litres, could
spend in excess of £14,000 simply to replenish the sumps four
times a year – see Table 1.
If, instead of replacing the equivalent of
20% of the coolant over the course of a year, a
machine shop recycled virtually 100% on an
almost continuous basis, it is easy to see the
savings that would accrue. That is precisely
what modern centrifugal separation systems
are designed to do. Ranging from the small and
mobile to the large and fixed, these systems
reach speeds of up to10,000 rpm to generate
G forces as high as 10,000; ie10,000 times the
force of gravity. This centrifugal force separates
the fluids, metal fines and tramp oils to purify
the coolant or cutting fluid and enable it to be
recycled almost indefinitely.
There are altenatives to centrifugation,
ranging from simple paper band filters to
coalescers and Lamella separators. Paper band
filters are very cheap since they involve no
running costs and separate out solid particles
very effectively, but they are very inefficient at
removing tramp oils. Likewise, coalescers cope well with free
Industrial fluid
oil removal but are extremely inefficient at separating out
14 | Nov/Dec 2008 | ME
COOLANT
metal fines and other particles. None of these technologies
can compete with centrifugal separation in terms of overall
performance and efficiency, let alone its ability to pay for itself
within a relatively short time scale.
Treating and disposing of spent coolant is not the only
expense involved in dealing with contamination. There is also
the less visible, but no less real, impact on cutting efficiency,
quality and the work environment. ‘Monday morning’ odours,
caused by bacterial growth in the coolant tank, are not only
unpleasant but can also create
severe health issues for machine
operators; particularly dermatitis
and other skin problems.
According to the Health &
Safety Executive (HSE) dermatitis,
asthma and similar illnesses cost
the UK metalworking industry
millions in lost work days every
year. Between 1999 and 2001, for
instance, around 4,300 new cases Cutting fluids in use
of work-related skin disease were diagnosed each year, of
which approximately 80% were contact dermatitis. In June
last year, the HSE reported the results of an investigation into
an outbreak of ocupational lung disease at a former motor
industry plant in Birmingham, where 101 workers had been
diagnosed with either occupational asthma or extrinsic
allergic alveolitis, caused by inhaling mist from metalworking
machinery. Further investigation identifed the probable trigger
for the diseases as bacteria and contaminated metalworking
fluids. At their most serious these ailments can lead to
long-term absence and, often, early retirement. Such ‘Invisible’
costs can make the more obvious expense involved in fluid
replenishment and disposal seem relatively light.
Take the case of a large precision engineering company
in England producing a wide range of milled and turned
components in a machine shop equipped with CNC machines,
including vertical machining centres and six-axis milling/turning
machines. Metalworking fluid became contaminated with
hydraulic oil, swarf and metal fines and, apart from affecting the
precision and efficiency of the cutting tools, these tramp oils
also changed the fluid’s pH and concentration, providing ideal
breeding conditions for the bacteria which cause dermatitis.
Despite using barrier creams and following Best Practice
advice from the HSE, the company couldn’t eradicate the
skin problems some of their machinists were experiencing.
Changing to a different type of coolant, and changing it more
frequently, seemed to do the trick initially, but failed to solve
the problem long-term and increased coolant costs. The
company, therefore, decided to look for a longer-term solution
and investigate systems for purifying the coolant instead of
having to dispose of it. Of these, Alfa Laval’s alfie centrifugal
separator proved to be the most efficient at removing tramp
oils and swarf.
Since they started to use alfie, the incidence of dermatitis
in the plant has been reduced to the point where it is no
longer a major problem. Not only have they contained the
threat of skin disease but they have also extended coolant
life significantly, while improving efficiency into the bargain.
All of these improvements have meant lower direct coolant
costs, less frequent replenishment or disposal with reduced
environmental impact and, as important, an enhanced
bottom line.
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Thermal Imaging
with Fusion
Technology
Radir.com
Infra Red Image in Visual Picture
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ME | Sept/Oct 2008 | 15
...maintaining excellence
NE
W
J&P group
As a strategic maintenance partner to some of Europe’s
leading aerospace & automotive manufacturers, J&P Group
have proven experience in devising and implementing
maintenance strategies that deliver quantifiable:
Reductions in production downtime
Reductions in production costs
Increased asset lifecycles
Improved quality control
A unique design offering:
• EXTREME LOW CO-EFFICIENT OF FRICTION
• HIGH RETENTION OF RIGIDITY
• ELIMINATION OF REVERSAL ERROR
• REDUCED PRE-LOAD OF BALL NUT
• LOWER LEVELS OF HEAT AND NOISE GENERATION
We augment our core engineering services with a range of
expert services that include:
Spares Asset Management
Facilities Management
Supply Chain Management
Consultancy
THE RESULT: increased long life performance,
smoother operation and high accuracy.
To discover how J&P Group can add value to
y o u r manufacturing operation, please call the
telephone number below for a free, no-obligation
consultation.
Red Hill House, Hope Street, Chester CH4 8BU
Tel: 01244 671460 Fax: 01244 524272
info@jandpgroup.com
www.jandpgroup.com
www.jena-tec.co.uk
Jena Rotary Technology Limited
Willow Drive
Sherwood Park
Annesley
Nottinghamshire
NG15 0DP.
Service Hotline: +44 (0)1623 726010
Fax Hotline: +44 (0)1623 726018 Sales@jena-tec.co.uk
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Get Shear Mode Technology
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© 2008 PCB Group, Inc. SensorLine is a service mark of PCB Group, Inc. PCB, ICP and IMI with associated logo are registered trademarks of PCB Group, Inc.
LOW-COST INDUSTRIAL VIBRATION SENSORS
PLANT &
MAINTENANCE
CNC MACHINE TOOLS
Ball Screws —
extend the life of your machine
tool axis, says Kevin Ewing
Ball Screw assemblies (BSA’s) are important components in modern
CNC machine tools that convert rotary motion into linear motion.
T
hey comprise a Ball Screw, with an
external helical groove or raceway, a
Ball Nut, with an internal helical groove
or raceway, and a system for re-circulating
balls, which are rolling elements fitted
between the Ball Screw and the Ball Nut.
BSA’s are supplied in different lead accuracies,
with or without pre-load depending upon
the application. There are also different
Kevin Ewing,
pre-loading methods - for machine tools,
Technical Manager,
BSA’s will usually have a two point angular
Jena Rotary
contact pre-load.
Technology
In machine tools, BSA’s most commonly
drive each of the three axes (‘X’ ‘Y’ & ‘Z’)
coupled with a servo-motor and encoder.
Standard CNC machines are fitted with a control which is
linked to the servo motor and encoder, but more expensive
machines may also have linear feed-back via a scale attached
to the axis. The servo-motor can make very small angular
movements which, when coupled with the BSA, moves
the axis as little as 1μm. Clearly, positional accuracy and
repeatability of the BSA is an important part of overall machine Examples of rolling
tool accuracy.
contact fatigue on
BSA’s fail for a number of reasons. The theoretical useful
ballnut raceway
life of a BSA, or fatigue life (L10), is determined by the formula:
and steel ball
element.
L10 = (Ca/Fm)3 x 106
Fatigue wear occurs when the surface of a material is
weakened by repeated cyclic loading resulting in material
fatigue. However, there are many extraneous variables which
affect the life of a BSA in the field, such as contamination,
incorrect lubrication, misalignment, or even application errors.
However, a BSA’s life can be considered in another way, known
as its ‘wear life’ - the number of revolutions it can make before
its positional accuracy deteriorates. For machine tool designers
and maintenance engineers, wear life is an important factor
to consider, as this will gradually deteriorate over time. This is
especially evident in today’s machine tools, which increasingly
need improved positional accuracy and increased acceleration
and linear speed.
Ball Screws have traditionally been designed using
conventional materials. The Ball Screw and Ball Nut are
most commonly manufactured in bearing steel and the
Jena Tec XLF
rolling elements (balls) are manufactured in carbon chrome
ballscrew using
ceramic balls
steel. However, during any sudden acceleration or change
and proprietary
of direction, conventional rolling elements will not have a
coating.
true rolling motion but will initially be prone to sliding and
galling. This leads to adhesive wear and micro or cold welding
because of the steel-ball-to-steel-raceway interaction, where
surface projections, or asperities, are plastically deformed
and eventually welded together by the high local pressure.
As sliding continues, these bonds are broken, producing
cavities on the surface, projections on the second surface,
and frequently sub-micron abrasive particles - all of which
contribute to future wear in surfaces causing surface
roughness, excessive heat and eventual Ball Screw failure.
Of course, one way to improve this in traditional BSA’s
is to have them serviced at regular intervals, replacing
the worn rolling elements, super finishing the raceways
and re-preloading the assembly. This will increase the life
significantly (if not left too late and material fatigue has not
already occurred) and will also improve the positional accuracy.
To overcome the disadvantages of traditional ball screw
manufacture, Jena Rotary Technology, part of Avingtrans
plc, has developed the XLF range, which uses ceramic rolling
elements, typically Silicon Nitride Balls, combined with a
0.5μm proprietary wear resistant coating in the raceways of
the Ball Nut and Ball Screw. The load bearing property of the
coated film is extremely high (300,000psi) and, with a dynamic
coefficient of friction of 0.03, provides an exceptionally low
friction surface. In field tests it has been shown that ceramic
balls, combined with a coated BSA, achieve a noticeable
reduction in adhesive and abrasive wear, resulting in lower
operating temperatures, better thermal stability and lower
vibration and noise levels than assemblies using steel balls.
The lower operating
temperatures are
the result of the near
perfect roundness
of ceramic balls
which, together with
the much greater
smoothness achieved
in the manufacturing
process, reduces friction by up to 70%.
The reduced mass of ceramic balls - about 40% of that
of steel balls - greatly reduces impact damage in the transfer
mechanism for re-circulating balls, another common failure
mode observed in conventional BSA’s. There is no metal
to metal contact and ceramic balls do not react with steel
raceways, again eliminating micro or cold welding and
associated adhesive and abrasive wear. They are also much
harder, wear resistant, and have been shown in tests to be
‘self improving’ - if
swarf or debris is
allowed to enter the
Ball Nut, the harder
ceramic balls will force
the material into the
softer bearing steel
rendering it harmless.
The design of the
XLF series results in
superior performance
when compared with conventional Ball Screw technology.
Whilst the costs of coating and ball material results in a higher
unit price compared on a like-for-like basis, the extended
life of the XLF Ball Screw (typically up to twice that of a
conventional assembly) means that the new series offers
a valuable improvement in equipment reliability and cost
savings in the longer term. It is particularly suited to high
volume repetitive operations, eg in the automotive and
process industries, where downtime and machine repair can
have alarming cost implications in terms of lost productivity.
ME | Nov/Dec 2008 | 17
PLANT &
MAINTENANCE
ENTERPRISE ASSET MANAGEMENT
The Business IMPACT
of Enterprise Asset Management
The serialisation of IBM’s new Enterprise Asset Management book
continues in this issue with the publication of ‘Green’ (Chapter 5) and
‘Risk Management’ (Chapter 6). Thus far we have covered; ‘The Changing role of the Plant Engineer’ (Vol 8 Issue 3); ‘Convergence’ and ‘An
Ageing Workforce’ (Vol 8 Issue 4); and ‘ERP vs EAM’ in Volume 8 Issue
5. The book aims to give you a straightforward, jargon-free insight into
the way EAM is changing the world of business, and helps you sort out
what are the biggest trade-offs and challenges in the world of asset
management. The serialisation concludes in the January 2009 issue of
M&E with ‘Best Practice’.
Chapter 5
Green
Being good and being clever
From our earliest years, we are taught that there is a
straight choice between merit and money – that you can’t be
righteous and rich. Most of us muddle along somehow – but
when someone offers you the chance to do both at once,
to do the right thing and the
profitable thing at the same
time, then it’s hard to turn it
down.
That’s what the
environmental movement is
saying to the world of business.
For years, thinking about
the planet has been vaguely
uncomfortable. You may get a
warm glow inside from driving
a smaller car than you’d like, but
it doesn’t ease the discomfort
of having your knees pressed
up against your ears. You may
feel good about avoiding the
airliners, but the back yard
doesn’t match Barbados as a
holiday destination.
But now it’s different. The
greener your organisation is, the
less money you waste; cutting
your carbon footprint is cutting
your costs. Your Chief Finance Officer will be just as pleased
by the result as the Friends of the Earth are. Keeping the
money men happy …
So let’s be honest – the main reason most organisations
are interested in going green is because it makes sound
financial sense. Energy costs have risen, are rising, and are
18 | Nov/Dec 2008 | ME
going to rise some more: in the IT budget alone, the cost of
energy is expected to rise from 10 per cent of the budget
today to around 50 per cent in the next three years7. Anything
that can cut fuel bills without compromising efficiency has
got to be worth looking at.
And there are other business reasons as well: companies
are always looking for growth, and many of them have
already filled their IT data centres to capacity. There is no
more power available for them to draw, and if there was, the
heat created by all the equipment would be too great for
the computers to work. So their choice is either to put their
growth plans on hold, or invest in a new data centre.
But if an effective asset management system could cut
energy use by up to 50 per cent – which is what is claimed –
then that expensive decision could be postponed for several
years. The sums are startling: capital, like energy, is expensive.
For each year that investment of around £45 million for
a 50,000 square foot data centre can be postponed, the
company has saved nearly £4 million7.
Similar calculations could be done throughout the
organisation. Fleets of trucks, a plant full of production
equipment, office photocopiers, or heating and lighting
systems – until the energy requirements of all the assets can
be properly measured and monitored, it’s impossible even to
start to make savings.
Polishing the company’s image …
But the incentives for adopting a green asset
management strategy go beyond the simple cost savings to
be made, significant though they are.
It’s clear that in the future, government or local taxes and
other charges will exact a direct price from companies that
waste energy. Carbon taxes are firmly on the political agenda,
and the UK government, for example, has announced that
it plans to cut greenhouse gas emissions by 60 per cent by
20508.
And in the present, with the dangers of global warming
in the news and increasing numbers of customers looking for
green products, many companies are seeing the benefits to
their public image of cutting back their carbon footprint. A
company that can demonstrate that it is taking a responsible
attitude towards the environment and the use of energy can
both save money and improve its public image.
So reducing the overall carbon cost is important
throughout the organisation. Chief Information Officers
will see gains to be made in the provision of an effective IT
infrastructure; Chief Finance Officers will see reductions in
costs and the avoidance of tax liabilities; and Chief Executives
will see a significant enhancement of the organisation’s
brand. Green asset management makes sense all around the
boardroom.
Seeing what’s really happening …
Managing assets means monitoring their performance in
use, not just taking the manufacturers’ declared figures.
For instance, though the manufacturer can tell you that
flat-screen monitors will use just over half as much power as
conventional models – a significant energy saving when you
consider the number of desktop computers in a mediumsized company – they can’t tell you how those computers
Continued on page 21 THE
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ME | Nov/Dec 2008 | 19
New!
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you identify the exact problem area
The Fluke Ti25 and Ti10 make thermal imaging easy to
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20 | Nov/Dec 2008 | ME
PLANT &
MAINTENANCE
ENTERPRISE ASSET MANAGEMENT
Green
Continued from page 21
will be used. A desktop PC may use 60W when running a
screensaver programme, compared to 40W when the normal
Windows desktop is displayed, and less than 2W in hibernate
mode8.
But those figures again are only estimates. To know the
actual figures, you have to turn to your asset management
software, which can tell you not just how much energy a
particular piece of equipment should use, or might use, but
how much it does use, which is often a very different figure.
It can produce a comprehensive picture of energy use
across the organisation, supplying a graphic map of the
workplace to show where the energy hot-spots are, or it
can zoom in on a single piece of equipment to monitor and
display its actual energy consumption.
It can check on which assets are efficient, and which
need attention; it can provide an automated preventive
maintenance schedule, so that assets are kept working
at optimum efficiency, and it can keep a constant check
on temperature, humidity, and airflow in the working
environment.
Effectively, it can highlight every plughole in the
organisation down which energy – and money – are
trickling away.
Being good by being clever …
With that information, senior management can take
firm control of energy use and develop a coherent strategy
to manage and control it. They can budget and plan
growth – remember the £4 million a year that could be saved
by postponing the construction of a new data centre – and
they can be confident that all their equipment is properly
maintained and running efficiently.
So the organisation’s current spending is reduced,
its potential for growth is improved, and its image is
improved among a public that is increasingly concerned
with environmental damage. And at the same time that it’s
achieving all that, it also has that agreeably smug feeling that
it is being virtuous and doing the right thing. It really is being
good by being clever.
Chapter 5
Risk management
Happy days …
A child thinks that nothing will ever go wrong; an
adolescent lies awake at night worrying that it might; and a
grown-up does something about it.
In an ideal world there would be no need for risks to
manage – but in the one we’re in, risk management needs
to be efficient, effective, and automatic. There’s no room for
chance, delay, or inefficiency.
In an ideal world, every piece of equipment would work
perfectly all the time, no employees would make mistakes,
and even if they did, customers would just smile and shrug
their shoulders. No-one would ever sue, accidents wouldn’t
happen, people wouldn’t get hurt, and there would be no
sudden unforeseen business shocks.
And of course, that being the case, there would be
no need for laws, rules, and regulations to govern the way
that companies did business, so compliance wouldn’t be a
problem either.
If you live in such a world, then congratulations – and you
might as well skip this chapter.
But then again ….
Welcome to the real world …
Risk management, on the other hand, is about dealing
with the real world – the risk, for
example, in the manufacturing industry,
of catastrophic breakdown in either
equipment or process; or the risk that
you may just have to find out what
has been done, who’s done it, and
when – and how you can stop it being
done again.
It’s particularly important today.
Companies need to optimise their
assets, cut costs, and reduce the danger
of upsets, outages, and downtime to a
minimum.
And at the same time, the growing
complexity of the manufacturing
process and supply network means
that breakdowns somewhere in the
system are increasingly likely. The more
complicated a process is, the more likely
it is that some component will fail. The
more there is to go wrong, the more
will go wrong.
But risk management, particularly in asset-intensive
industries such as oil and gas, chemicals, plastics, automotive
or industrial equipment manufacturing, is more than just
an insurance policy. It’s a business-oriented strategy which
enables managers to take control of problems at an early
stage. It can cut costs across the organisation and, by
integrating the engineering and manufacturing processes,
significantly reduce the time it takes to get a new product to
market.
And those are not just the concerns of asset-intensive
companies or big multinational organisations: throughout
industry, risk management is increasingly seen as an
important driver of increased long-term profitability.
Settling on a strategy …
Risk does exist, particularly in business. It’s a part of life.
We’re not adolescents, though, we’re grown-ups. We don’t lie
awake and worry about possible problems, we do something
about them.
And the first thing to be done is to work out what specific
risks there are, and how they can be mitigated. Whereabouts
in the organisation’s systems are the risks of failure greatest?
Which is most likely to happen? Which would cause most
immediate damage? Which would have the most devastating
long-term effects? The possibilities have to be assessed,
quantified, and prioritised: before there is a problem, the
organisation needs to have a coherent risk management
strategy in place.
One common compromise is to manage only those risks
Continued on page 22
ME | Nov/Dec 2008 | 21
PLANT &
MAINTENANCE
ENTERPRISE ASSET MANAGEMENT
Risk management
Continued from page 21
that are part of a company’s financial systems – but today,
that is no longer a sensible option. Increasingly, the focus is
on the manufacturing process as well. Operational disasters
can cripple a company in hours, leading to lost production,
lost revenue, and lost reputation.
For a multinational company, an asset failure can
bring damaging worldwide headlines; a severe safety
or environmental incident may incur costs measured in
hundreds of millions of dollars.
The strategy in action …
The test of the strategy will come when the inevitable
happens, and then quick action is the key. If you can respond
quickly and efficiently – that is, before there is operational
or financial loss to the company – then you can prevent an
incident from turning into a problem.
Once it has become a problem – once the production
process has stopped, for instance – then the next priority
is to keep downtime to a minimum. Again, fast information,
alerting the correct staff, and getting the work in hand to
correct what has gone wrong, are the vital elements of the
risk management strategy.
And it doesn’t have to be the sort of incident that makes
the machines stop. The effect of other problems can be
harder to spot, but just as damaging. If the calibration of
sensitive equipment is slightly out, for instance, it can mean
wasted energy as they run at less than peak performance, or
even wasted production if the goods they produce prove to
be faulty. Once again, fast information from a system that can
monitor all the assets in the organisation is vital.
And what then? Once the problem is sorted and the
production line is running again, once the equipment is
running again exactly as its designers intended, the risk
management process still isn’t over. A mistake is only a
mistake, a wise man once said, if it happens twice: the first
time, it’s a learning opportunity.
So the next phase of the risk management strategy is
to see that managers and department heads are provided
with the information and the analysis they need to see that
what has gone wrong doesn’t happen again. Data has to be
gathered, assessed, interpreted and circulated.
Perhaps products need to be recalled; perhaps there
are warranty issues to deal with. In either case, it is essential
to have the record available so that the precise phase of the
production cycle where the problem has occurred can be
highlighted, and the batch of goods which may have been
affected can be identified.
Throughout the process, speed is crucial, whether to get
the production line moving again, or to limit damage to the
company’s reputation by getting faulty goods exchanged
as quickly as possible. The surest way to handle all these
different phases of the process – the development of a
strategy, the immediate response, and the action to see that
the incident isn’t repeated – is to automate the whole process.
Such an automated process, if it is properly integrated
with the organisation’s asset management system, can alert
the necessary staff, manage the workflow as they put the
problem right, and produce a clear and unambiguous paper
trail to show what has gone wrong. Then it can archive the
22 | Nov/Dec 2008 | ME
information so that staff will have a clear idea of the best
solution if there is a next time, and keep the damage to a
minimum.
Sticking to the rules …
But there is an additional reason to implement a risk
management strategy: in this real world that we’re stuck with,
government regulations have to be observed, international
standards complied with, legal liabilities met. It’s no
coincidence that the industries that are leading the way in
risk management are those such as motor manufacturing,
aerospace, oil and gas, and pharmaceuticals, which are
among the most heavily regulated.
The risk of legal penalties and the damage to the brand,
and the company’s reputation that comes with them, means
that they can’t afford to run the risk of non-compliance.
But once again, the need for compliance isn’t limited to
those high-profile sectors. In the US, there is the Occupational
Safety and Health Administration, or in the UK it’s the Health
and Safety Executive – but whatever the name on the brass
plate, everyone has to obey health and safety legislation.
Then there’s the International Organisation for
Standardisation (ISO), or the IEEE’s international technology
standards. Virtually every industry has its own regulating
body with its own requirements.
And these rules matter. An automated and integrated
risk management system that monitors every aspect of the
performance of an organisation’s assets can guard against
the possibility of involuntary non-compliance, keeping the
organisation on the right side of the law and out of the
headlines.
Protection from disaster
If you’re not convinced by the arguments, maybe
WinstonChurchill – a good man to have on your side – may
be more convincing. “If I had my way, I would write the word
‘insure’ upon the door of every cottage,” he once said. “For
sacrifices so small, families and estates can be protected
against catastrophes which would otherwise smash them up
forever.”
He was talking over forty years ago, of course, and
thinking of private households – but there’s little doubt that
if he’d lived in the age of risk management, he would have
thought much the same about the protection it offers to
companies.
And if Churchill isn’t persuasive enough, then a revealing
statistic might do the trick. Recent research9 shows that in the
manufacturing industry, “bestin- class” companies are 55 per
cent more likely than others to have their senior management
involved in organisation-wide risk management initiatives.
Protection from disaster and building a long-term
reputation; keeping costs down and driving long-term
profitability – and all from the same risk management
strategy.
Perhaps it is an ideal world after all.
Don’t miss the final instalment, ‘Best Practice’, in January
2009 – Volume 9 Issue 1
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ME | Nov/Dec 2008 | 23
ENERGY&
ENVIRONMENT
easyFairs® MAINTEC
L
ike all successful trade shows, easyFairs MAINTEC
has evolved…and the 2009 event, at Birmingham’s
NEC from 17-19 March, is no different.
Suppliers of mechanical equipment, lubricants,
buildings and facilities management, and energy
efficient products will feature more prominently;
there’s a new easyFairs MAINTEC Summit where
key industry issues will be debated; and plans are in
place to introduce a ‘Student Zone’ where exhibitors
and visitors can chat with engineering innovators of
tomorrow.
As a result, it continually attracts event newcomers
to exhibit alongside easyFairs MAINTEC stalwarts who
have used the show as a platform to meet influential
industry professionals for many years.
For more than three decades, easyFairs MAINTEC has been the
event for asset management and condition monitoring.
Showcasing the latest developments in hazard detection and
predictive maintenance technologies, MAINTEC has become an
industry byword for cost and efficiency savings — considerations
that, due to the economic slowdown, have been propelled up the
priority list of Plant Managers and Engineering Directors.
Newcomers join
familiar faces at
easyFairs MAINTEC
New product launches
쐌 For stand bookings contact and
more information contact Sunita
Puee on 0208 622 4416 or e-mail:
sunita.puee@easyfairs.com
24 | Nov/Dec 2008 | ME
Almost 100 companies are already committed to
next year’s show (organisers are confident of surpassing
the 2008 tally of 150 exhibitors) with around 10 per cent
appearing for the first time.
Amongst the debutants are circuit breaker
retrofit specialists Santon; cable supplier Lapp
Group; Leicestershire-based Enercom – which offers
instruments to monitor and meter electrical grid
networks to protect against power disruptions – and
multi-key management solution providers Keytracker.
Others include Olympus Industrial – a leading
manufacturer of advanced testing instruments such
as remote visual inspection devices, ultrasound, eddy
current, and high-speed video – and Eurotron, experts
in calibrators, infrared thermometers and combustion
gas analysers.
And the added focus on industrial facilities
management providers has led to Promanex – an
industrial support operation in Hurley, Warwickshire,
that offers traditional FM, asset management, and
maintenance services – signing up to easyFairs
MAINTEC 2009.
Promanex Group Marketing and Communications
Manager, Gemma Tunley, said: “We’ve chosen MAINTEC
as it gives us the opportunity to promote our services to
key industry buyers and decision-makers, and the handy,
central location makes it an easy event to man.
As a company, we’re committed to reducing the
environmental impact of our activities, so I was delighted
to learn of easyFairs’ eco credentials and that they’re a
low-carbon footprint trade show.”
Several multi-nationals will also be appearing
at easyFairs MAINTEC 2009 for the first time. These
include Shell Oil Products – which will demonstrate
how effective fluid management can help reduce
operational costs and boost efficiency – and Festo,
a world-leading supplier of pneumatic and electrical
automation technology.
Their arrival, alongside smaller players, emphasises
easyFairs’ ethos of time- and cost-effective shows
that are accessible to companies ranging from niche
suppliers to those turning over in excess of £1 billion.
And as the economic slowdown sees a shift to
low-cost alternatives, the easyFairs’ proposition is
proving even more appealing to businesses.
easyFairs UK Managing Director, Peter Heath, said:
“In good times, people might be more inclined to visit larger
industrial shows and buy a complete new system. But now
plant managers are more interested in buying replacement
parts and upgrades to existing systems…easyFairs®
MAINTEC is a unique trade show market for these kinds of
technologies and products.
Companies are naturally more focused than ever
right now on getting a great return on their investment.
easyFairs MAINTEC enables exhibitors to do business,
develop new contacts and make sales at a fraction of the
cost of a traditional trade show.
Large trade fairs are demanding both in terms of time,
resource and budget and there is a lot of casual footfall.
That may be great for making a brand statement but if
we’re heading, as many people predict, towards further
economic uncertainty is that really enough? Exhibitors
want a tangible return on investment in addition to raising
their profile”.
International appeal
easyFairs MAINTEC 2008 attracted almost 2,000
industry decision-makers – and next year’s show is
expected to be a ‘must do’ diary date for even more
manufacturing and processing leaders.
Visitors will discover the latest product innovations
not just from UK-based companies but, thanks to
easyFairs’ network of trade events across Europe, firms
that have been convinced to attend after enjoying
success at sister shows.
Arms Reliability Engineers, based in Victoria,
Australia, and SPX Hydraulics Technologies – which has
its HQ in Eygelshoven, Holland – will both be making
their debuts in the 2009 easyFairs MAINTEC exhibitor
guide.
SPX’s Sales & Marketing Manager, Sander Magnin,
visited an easyFairs maintenance show in Brussels
recently and, after being won over by the low-fuss,
business-focused concept, will be showcasing its new
range of hydraulic torque wrenches at easyFairs’ expos
in Malm_, Antwerp, Zurich, Dortmund and Birmingham
next year.
Similarly, Arms Reliability Engineers – based in the
Victoria coastal town of Ocean Grove – were persuaded
to exhibit at easyFairs MAINTEC 2009 after their
appearance at easyFairs’ Belgian maintenance show
generated a large number of new business leads.
Company Business Analyst Josh McIntosh, said: “We
provide Asset Reliability Improvement Solutions across a
wide range of industries. By predicting the performance of
their assets, we are able to help clients align maintenance
and engineering practices with strategic business goals,
which in turn helps them design more efficient plants,
modify existing plants, and maintain their assets over a
chosen lifecycle.
The MAINTEC show promises to put us in front of
exactly the right kind of industry decision-makers.”
ME | Nov/Dec 2008 | 25
PR0DUCT
REVIEW
PLANT&MAINTENANCE
New Pressure Regulator
Application Guide
Fluke’s Free 1-2-3 Power Quality
Troubleshooting Offering
E
F
merson Process Management has published
Edition VI of its Industrial Pressure Regulator
Application Guide. It serves as a unique reference
for technical applications and pressure data on
Fisher® industrial regulators, and is designed to
provide assistance in selecting the right pressure
regulator for a broad range of applications.
The technical section includes several new
and updated areas such as regulator components;
principles of direct- and pilotoperated regulators; selecting and
sizing pressure reducing regulators;
over pressure protection methods;
principles of relief valves, series
regulation and monitor
regulators; temperature
considerations; sulphide
stress cracking; conversions;
equivalents; and physical data.
Request a copy: call +44
(0)870 240 1978, uk-irelandsales@
EmersonProcess.com or enter 1735 at www.
maintenanceonline.co.uk /ME
Order your Pump Check
Up – Today!
I
n many pump systems more than
half of the energy consumed by the
pumps could be saved by switching
to more efficient and correctly sized
models. Grundfos have developed a ‘Pump audit
Tool’ that will tell you how much money you could
save by optimising your pump system. It checks
the overall efficiency of your current pumps and
highlights how much energy you could save by
switching to a more efficient model.
To find out more call +44 (0)1525 775407 or email
ukindustry@grundfos.com or enter 1737 at
www.maintenanceonline.co.uk
Know your Gearbox
Inside & Out
H
ansen Transmissions
can now offer
boroscope inspections for
gearboxes. This provides a
detailed look inside a gear
unit to reveal early visual indications of potential
problems and offers maintenance managers
a simple, quick and cost-effective method of
inspecting the internal components of gearboxes
which can detect certain issues that other
methods would find impossible. 6mm diameter
probes, with various tip attachments, are used to
take detailed digital images, even inside the rolling
elements of bearings. Planned inspections can
be co-ordinated with plant shutdowns to avoid
disruption – a real money saver!
Jane Mellor t: +44 (0)1484 431414 jmellor@
hansentransmissions.com or enter 1738 at
www.maintenanceonline.co.uk /ME
26 | Nov/Dec 2008 | ME
luke is offering a free 3-fold approach to electricians and electrical engineers
involved in troubleshooting the causes of poor power quality in industrial electrical
installations and equipment. The 1-2-3 approach includes a free DVD, a web-based
or local hands-on seminar and an online information library of Case Studies and
Application Notes. Fluke offers a complete range of rugged Power Quality tools for
single and three-phase systems, offering a choice of solutions for pinpointing power problems faster. More
information can be found at www.fluke.co.uk/pq
New Models added to Fluke’s Colour
Scopemaster Series
F
luke has added two new models to its range of Colour ScopeMeter®s. As well
as an Industrial Bus Health Test capability, the Fluke 225C (200 MHz, 2.5 GS/s)
and Fluke 215C (100 MHz, 1 GS/s) include all the features of Fluke’s market-leading
199C Colour ScopeMeters, making these instruments the signal analysis tool of
choice for engineers working on electronic and electrical systems.
Bus Health Test analyses the electrical signals on the industrial bus or
network and gives a clear ‘Good’, ‘Weak’ or ‘Bad’ validation mark for each relevant
parameter, next to the actual measured value. Measured values are compared to
standard values based on the bus type selected, or personal reference values if
users need different tolerances.
Maintenance Kits Offer Savings of 27%
C
ontinuing with its 60th Anniversary celebrations, Fluke is offering 4 money-saving Industrial Maintenance
Kits suitable for engineers, electricians and technicians charged with everyday
troubleshooting tasks within an industrial environment. Offering savings up to
27% over individual product purchases until 31st December 2008, each kit
comprises a set of rugged and reliable handheld tools ideal for carrying out
a range of electrical and thermal measurement functions, all stowed in a
rugged tool bag. The full range of Kits, together with other key industrial
maintenance test tools, can be found at www.fluke.co.uk/60years
Ken West t: +44 (0)207 942 0700 UKenquiries@fluke.com or enter 1736
at www.maintenanceonline.co.uk /ME
Maintenance-Free Polymer
Ball Bearings
D
ue to positive customer feedback plain
bearing specialist, igus®, has expanded its new
“xiros” (from the Ancient Greek ‘xsiros’, meaning
‘dry’) polymer ball bearing range. There is now a
temperature resistant (up to 150°C ) dry-running
ball bearing, which has enhanced wear resistance,
and a maintenance-free ball bearing for broader
use within the temperature ranges normally
associated with plastic.
Application areas for anti-magnetic and
highly corrosion-resistant open systems include
medicine, the chemical, food & pharmaceutical
industries, and bio-technology.
t: +44 (0)1604 677240 sales_uk@igus.co.uk or
enter 1739 at www.maintenanceonline.co.uk /ME
New Smaller Connector
provides Compact
Vibration Sensors
F
ollowing the
introduction of the very
popular M12 connector
to its range of vibration
sensors, Hansford Sensors
are now using the new
compact M8 connector
to produce the much
smaller range of HS-130
accelerometers. This
reduction in size gives the
HS-130 a much smaller
footprint making it ideal for
monitoring vibration levels on smaller machinery
and allowing them to be used where space is
limited.
Sealed to IP67, the M8 connector is a part
of a well-proven industry standard and can be
supplied in a wide variety of tailored assemblies
of differing lengths, enabling cost-effective
installation.
Suzanne Pearl t: +44 (0)845 680 1957 suzanne.
pearl@hansfordsensors.com or enter 1740 at
www.maintenanceonline.co.uk /ME
Precision shaft
alignment pays
From just
£3,549.00*
See More With the
Accurate shaft alignment extends rotating
machinery lifetime and reduces maintenance
expenses.
Testo 880
Thermal Imager
Ideal for electrical and mechanical
fault finding, preventative maintenance,
production quality assurance control
and building energy monitoring
• Large 3.5” display with high resolution image
• Exchangeable wide angle (32°) and telephoto lenses
• Thermal sensitivity <0.1°C
®
OPTALIGN smart Ex
For quick and precise shaft aligNment
• Integrated digital camera
• Minimum focus distance - 10cm
• Built-in laser spot locator
®
Latest technology and powerful functions make OPTALIGN
smart EX user-friendly and a high performing intrinsically
safe alignment system.
Continuous and precise measurement during shaft
rotation
Automatic evaluation of the alignment condition
Live correction by monitoring the machine
UniBeam® technology for quick adjustment of laser
beam
3-machine train alignment
Conforms with ATEX and IECEx requirements
• Save up to 1,000 images to SD memory card
• Powerful software with full reporting features
• Demo available online
www.testo.co.uk/880
PRÜFTECHNIK Ltd
Plant Lane Business Park,
Burntwood
STAFFS
WS7 3JQ
Tel: +44 1543 448350
Fax: +44 1543 275472
eMail: info@pruftechnik.co.uk
Call Now:
01420 566 814
www.pruftechnik.co.uk
Enquire using 1719 at www.maintenanceonline.co.uk/ME
menov@testo.co.uk
www.testo.co.uk/880
* Price for Testo 880-1. Valid
until 31st December 2008
Enquire using 1691 at www.maintenanceonline.co.uk/ME
ME | Sept/Oct 2008 | 27
PR0DUCT
REVIEW
PLANT&MAINTENANCE
J&P Group win Facilities Management Contract
from STTS UK
J
&P Group have announced that they have been awarded a 2-year Facilities Management contract by
pan-European aeronautic painting and sealing group, STTS.
Under the terms of the contract, J&P Group will provide a turnkey Facilities Management service for
STTS’s painting facility at Airbus UK’s wing manufacturing plant at Broughton, North Wales.
J&P Group will be responsible for the
maintenance of all infrastructure services
within the 43,000 sq ft Wing Painting Facility…
in addition to providing skilled personnel to
operate the cranes and manipulator systems
that transport the aircraft wings throughout the
facility.
The Broughton plant manufactures wings for
the complete range of Airbus aircraft including
the new Super Jumbo A380.
On announcing the contract award, STTS
Fran McCollum, STTS’s Operations Manager looks on as
J&P Group’s Business Development Director, Alan Mackey
UK’s Operations Director, Jon Gray commented:
(centre) shakes hands with Jon Gray, STTS’s Financial
“J&P Group have been providing us with a range of
Director outside STTS’s wing painting facility at Airbus’s
Broughton plant.
expert services since the purpose-built Wing Painting
Facility was opened at Broughton just over a year ago They have supported us from the beginning and have
been an essential partner in the successful launch of STTS’s operations in support of Airbus in the UK.”
John Begley, J&P Group’s Managing Director commented: “There is a growing market trend for
companies to prefer a single-source provider for their engineering, maintenance and facilities management
requirements and we believe that J&P Group is one of the few UK companies that possesses both the resources
and expertise required for such turnkey solutions.”
Alan Mackey, J&P Group on +44 (0)1244 671460, alan.mackey@jandpgroup.com or enter 1729 at
www.maintenanceonline.co.uk /ME
E
merson Process Management announces wireless solutions which
combine its Mobrey® float switches with the company’s Rosemount®
702 wireless transmitter.
Owing to the high cost of wiring, most process plants have
hundreds or even thousands of discrete measurement points that
are not connected to the control system. The advent of wireless
communications allows process plant managers to save up to 90% of
installation cost compared with wired technologies, enabling them to
collect more data at central locations than has ever been possible before.
Peta Glenister t: +44 (0)1753 756600 peta.glenister@emersonprocess.
com or enter 1730 at www.maintenanceonline.co.uk /ME
M
ajor UK utility South West Water is now specifying
Siemens Automation & Drives’ high efficiency
Flender Motox geared motors on all of its sites, as part
of its ongoing drive to improve operating efficiencies
and maximise asset life. The geared motors, which
incorporate eff1 motors from Siemens, were specified
due to their high performance, reliability and low
maintenance features. Over the next few years South
West Water plans
to replace all of its
older or obsolete
geared motors
with Siemens units.
Anna Grimshaw
t: +44 (0)1274 657700 anna.
grimshaw@siemens.com or enter 1733
at www.maintenanceonline.co.uk /ME
28 | Nov/Dec 2008 | ME
D
utch valve specialist
Netherlocks BV
has designed a directmounting, add-on gearbox
to reduce torque for handwheel operated valves – the Nethergear unit. This
fixes onto valves without any modification, and can
be fitted on-site without taking the valve offline.
The adaptor is based on the company’s interlock
design - used as a safety system for over 15 years.
It can be fitted without stopping production, the
valve itself remaining untouched. Once attached,
the handwheel can be simply fitted onto the unit in
one of two positions. One of these will provide the
torque reduction benefits of the gear mechanism;
the other lets it function as it would have originally.
Albert Buschgens t: +31 (0)172 471 339 sales@
netherlocks.com or enter 1731 at www.
maintenanceonline.co.uk /ME
ATEX Approved Shaft
Alignment
P
Wireless Float Switch Solutions
SW Water insists on Siemens
Gears & Drives
Add-On Gearbox for
Flangeless
Hand-Wheel
Valves
Sensonics help
Romanian Turbines
run smoothly
S
ruftechnik AG,
manufacturer of the
famous OPTALIGN system
which pioneered the use
of laser shaft alignment
systems, has introduced a
brand new ATEX approved,
intrinsically safe system. OPTALIGN Smart is a
modular mid-range alignment system which can be
programmed to perform both shaft and geometric
alignment applications.
Its intuitive operation, ergonomic design and
high contrast colour screen makes the alignment of
machinery such as pumps, motors, gearboxes and
compressors, simplicity itself. When the additional
geometric modules for flatness, bore concentricity
and straightness are added the system becomes a
comprehensive alignment tool equipped to meet any
alignment task.
t: +44 (0)1543 448350 info@pruftechnik.co.uk or
enter 1732 at www.maintenanceonline.co.uk /ME
ensonics have supplied over 25 Sentry
vibration monitoring systems for a wide
range of hydro-electric turbine plants in Romania. The
equipment has been utilised in all applications providing
measurements of absolute bearing vibration and shaft
eccentricity in combination with speed and rotor to stator
air gap at selected locations. A phase reference module
is included in each system for the generation of a once
per revolution timing pulse to enable detailed dynamic
and balancing analysis of the plant. The company has
provided all installed hardware, including junction boxes,
plant cabling, Modbus communication modules and
required set up and configuration software.
Russell King t: +44 (0) 1442 876833 sales@sensonics.
co.uk or enter 1734 at www.maintenanceonline.co.uk /ME
/P"TTFNCMZ
3FRVJSFE
®
The patented DODGE® ISN roller bearing can be installed
or removed up to 8 times faster than many competitive
adapter-mounted bearings. All in one box, the fully assembled
and greased bearing assembly is simple to install. Just tighten the
adapter on the shaft and bearing clearance is set automatically
with no feeler gauges.
Plus, the ISN’s patented fully-concentric 3600 contact ring virtually
eliminates shaft fretting corrosion while reducing heat and inherent
vibration. No assembly. No fretting. No competition.
www.dodge-pt.com
Germany
sales.de@baldor.com
+49 89 90 50 80 (Munich)
+49 2234 37941-21 (Cologne)
www.baldor.com
Italy
sales.it@baldor.com
+41 91 640 9950
Spain
sales.es@baldor.com
+34 90 2110834
> Unmatched Quality
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Switzerland
sales.ch@baldor.com
+41 52 647 47 00
United Kingdom
sales.uk@baldor.com
+44 1454 850000
Enquire using 1692 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 29
Enquire using 1693 at www.maintenanceonline.co.uk/ME
Enquire using 1695 at www.maintenanceonline.co.uk/ME
HOSE & COUPLING SOLUTIONS
FOR ALL INDUSTRIES...
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Enquire using 1694 at www.maintenanceonline.co.uk/ME
30 | Nov/Dec 2008 | ME
NEW CATALOGUE
OUT NOW!
Volume 23 No 6
Nov/Dec 2008
contents
editorial
THE INTERNATIONAL JOURNAL FOR ALL THOSE CONCERNED
WITH THE MANAGEMENT OF PHYSICAL ASSETS
T
his end-of-year issue focuses on one particular maintenance support technique: the
monitoring of rolling bearing condition by measuring and analysing vibration. Firstly,
Steve Lacey gives us a comprehensive review of the general principles of the technique,
and examples of its use to detect the onset and deterioration of rolling bearing defects. Louis
Morando then explains the Shock Pulse Method and why he believes it to be an appropriate
vtechnique for routine monitoring of bearing vibration, supporting his case by showing how
it has benefited the maintenance of paper mill machinery.
Now it has been said before in these pages that there are many more ways than one of
monitoring the health of an engineering system. We could measure it directly, observing
Editor:
the performance of whatever is its basic function (compressing fluid, transferring heat, etc.)
John Harris
or indirectly, observing the condition of its components (working temperatures, surface
corrosion, lubricant contamination etc.). However, it has long been my impression that the
most widely employed of all the second group of techniques is, indeed, the monitoring of vibration, especially that
of bearings. Certainly, among some of my academic colleagues this topic seems to excite more research interest
than does almost any other aspect of maintenance. I used to think that this was just because it involves using
sophisticated instrumentation and IT systems, not to mention some quite esoteric mathematics (these being
things that are highly regarded in academia). But I now accept that there may be a more cogent explanation.
Following up one of Steve Lacey’s references I came across the following extract from an interview with
T.A.Harris (no relation), a.k.a. ‘The author of the “bible” on rolling bearing technology’. Asked what was his biggest
satisfaction from having devoted almost his whole professional career to this apparently very specialised area,
he replied –
‘After working in the industry a short time, I realised that ball and roller bearings were used in every engineering
mechanism of any significance. I was working with customers who used rolling bearings in aircraft engines, electric
motors of all sizes, rolling mills, dental drills, machine tools, space vehicles, nuclear power plants, etc. So I found out the
field was not narrow; rather, it is very broad.’
So there you are. Rolling bearings (and their maintenance) are among the most critical components of our
modern industrial civilisation (and of my bike). Other than our various relationships could there be anything
more important?
Happy Christmas!
32
An Overview of Bearing Vibration Analysis
Vibration produced by rolling bearings can be complex and can result from geometrical imperfections
during the manufacturing process, defects on the rolling surfaces or geometrical errors in associated
components. Noise and vibration is becoming more critical in all types of equipment since it is often
perceived to be synonymous with quality and often used for predictive maintenance. In this article
the different sources of bearing vibration are considered along with some of the characteristic defect
frequencies that may be present. Some examples of how vibration analysis can be used to detect
deterioration in machine condition are also given.
44
Measuring Shock Pulse –
Another approach to Front Line Condition Monitoring
Downtime in a paper mill or any 24/7 facility is very expensive in maintenance costs, but even more so in its
impact on profit because of the consequent production loss. This article will explain the Shock Pulse Method
and why the technique is a good choice for front-line vibration measurement. It will then show the resulting
savings that the Hallsta Mill in Sweden realised from utilising it as the primary component of its Condition
Based Maintenance Programme. Hallsta personnel calculated the amount of this benefit when they looked at
the number of incidents in which they were able to perform maintenance in shutdowns that were planned and
not, as previously, forced.
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 31
Abstract
An Overview of
Bearing Vibration Analysis
Dr. S. J. Lacey
Engineering Manager, Schaeffler (UK) Ltd
Vibration produced by rolling bearings can
be complex and can result from geometrical
imperfections during the manufacturing
process, defects on the rolling surfaces or
geometrical errors in associated components.
Noise and vibration is becoming more critical
in all types of equipment since it is often perceived to be synonymous
with quality and often used for predictive maintenance. In this article
the different sources of bearing vibration are considered along with
some of the characteristic defect frequencies that may be present. Some
examples of how vibration analysis can be used to detect deterioration
in machine condition are also given.
Keywords: education, maintenance engineering, reliability engineering,
off-campus education, distance education, flexible learning, internet.
INTRODUCTION
R
olling contact bearings are used
in almost every type of rotating
machinery whose successful and
reliable operation is very dependent on
the type of bearing selected as well as the
precision of all associated components, i.e.
shaft, housing, spacers, nuts etc. Bearing
engineers generally use fatigue as the
normal failure mode, on the assumption
that the bearings are properly installed,
operated and maintained. Today, because of
improvements in manufacturing technology
and materials, it is generally the case that
bearing fatigue life, which is related to sub-
surface stresses, is not the limiting factor
and probably accounts for less than 3% of
failures in service.
Unfortunately though, many bearings
fail prematurely in service because
of contamination, poor lubrication,
temperature extremes, poor fitting/fits,
unbalance and misalignment. All these
factors lead to an increase in bearing
vibration and condition monitoring
has been used for many years to
detect degrading bearings before they
catastrophically fail (with the associated
costs of downtime or significant damage to
other parts of the machine).
32 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
Rolling element bearings are often
used in noise sensitive applications, e.g.
household appliance electric motors which
often use small to medium size bearings.
Bearing vibration is therefore becoming
increasingly important from both an
environmental consideration and because it
is synonymous with quality.
It is now generally accepted that quiet
running is synonymous with the form
and fi nish of the rolling contact surfaces.
As a result, bearing manufacturers have
developed vibration tests as an effective
method for measuring quality. A common
approach is to mount the bearing on a quiet
running spindle and measure the radial
velocity at a point on the bearing’s outer
ring and in three frequency bands, viz. 50300, 300-1800 and
1800-10000 Hz. The bearing must meet
RMS velocity limits in all three frequency
bands.
Vibration monitoring has now become
a well accepted part of many planned
maintenance regimes and relies on the well
known characteristic vibration signatures
which rolling bearings exhibit as the
rolling surfaces degrade. However, in
most situations bearing vibration cannot
be measured directly and so the bearing
vibration signature is modified by the
machine structure, this situation being
further complicated by vibration from other
equipment on the machine, i.e. electric
motors, gears, belts, hydraulics, structural
resonances etc. This often makes the
interpretation of vibration data difficult
other than by a trained specialist and can
in some situations lead to a mis-diagnosis,
resulting in unnecessary machine downtime
and costs.
In this paper the sources of bearing
vibration are discussed along with the
characteristic vibration frequencies that are
likely to be generated.
A
n Ovethe
rviReliability
ew of of
Bea Coal
arin
gV
ibrPlant
atiousing
n AanSAP
aly
sis Interface
Improving
Fired
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– REWOP
SOURCES OF VIBRATION
Rolling contact bearings represents
a complex vibration system whose
components – i.e. rolling elements, inner
raceway, outer raceway and cage – interact
to generate complex vibration signatures.
Although rolling bearings are manufactured
using high precision machine tools and
under strict cleanliness and quality controls,
like any other manufactured part they will
have degrees of imperfection and generate
vibration as the surfaces interact through
a combination of rolling and sliding.
Nowadays, although the amplitudes of
surface imperfections are in the order of
nanometres, significant vibrations can still
be produced in the entire audible frequency
range (20 Hz – 20 kHz).
The level of the vibration will depend
upon many factors, including the energy of
the impact, the point at which the vibration
is measured and the construction of the
bearing.
Variable compliance
Under radial and misaligning loads
bearing vibration is an inherent feature
of rolling bearings even if the bearing is
geometrically perfect and is not therefore
indicative of poor quality. This type of
vibration is often referred to as variable
compliance and occurs because the external
load is supported by a discrete number
of rolling elements whose position with
respect to the line of action of the load
continually changes with time (see Figure 1).
As the bearing rotates, individual
ball loads, hence elastic deflections at the
rolling element raceway contacts, change
Radial Load
Figure 1 Simple bearing model
to produce relative movement between
the inner and outer rings. The movement
takes the form of a locus which under radial
load is two dimensional and contained in
a radial plane, whilst under misalignment
it is three-dimensional. The movement is
also periodic with base frequency equal to
the rate at which the rolling elements pass
through the load zone. Frequency analysis
of the movement yields the base frequency
and a series of harmonics. For a single row
radial ball bearing with an inner ring speed
of 1800 rev/min a typical ball pass rate is
100 Hz and significant harmonics to more
than 500 Hz can be generated.
Variable compliance vibration is
heavily dependent on the number of rolling
elements supporting the externally applied
load; the greater the
number of loaded
rolling elements, the
less the vibration.
For radially loaded or
misaligned bearings
‘running clearance’
determines the extent
of the load region,
and hence, in general,
variable compliance
increases with
clearance. Running
clearance should
not be confused
Sraceway
with radial internal
clearance (RIC), the
former normally being lower than the RIC
due to interference fit of the rings and
differential thermal expansion of the inner
and outer rings during operation.
Variable compliance vibration levels can
be higher than those produced
by roughness and waviness of
the rolling surfaces. However,
in applications where vibration
is critical it can be reduced to
a negligible level by using ball
bearings with the correct level of
axial pre-load.
Geometrical imperfections
Because of the very nature
of the manufacturing processes
used to produce bearing
components geometrical
imperfections will always be
present to varying degrees
depending on the accuracy
class of the bearing. For axially loaded ball
bearings operating under moderate speeds
the form and surface fi nish of the critical
rolling surfaces are generally the largest
source of noise and vibration. Controlling
component waviness and surface fi nish
during the manufacturing process is
therefore critical since it may not only have
a significant effect on vibration but also may
affect bearing life.
It is convenient to consider geometrical
imperfections in terms of wavelength
compared with the width of the rolling
element-raceway contacts. Surface features
of wavelength of the order of the contact
width or less are termed roughness, whereas
longer wavelength features are termed
waviness (see Figure 2).
Width of Contact
Sball
h
Figure 2 Waviness and roughness of rolling surfaces
SURFACE ROUGHNESS
Surface roughness is a significant
source of vibration when its level is high
compared with the lubricant fi lm thickness
generated between the rolling elementraceway contacts (see Figure 2). Under
this condition surface asperities can break
through the lubricant fi lm and interact with
the opposing surface, resulting in metalto-metal contact. The resulting vibration
consists of a random sequence of small
impulses which excite all the natural modes
of the bearing and supporting structure.
Surface roughness produces vibration
predominantly at frequencies above sixty
times the rotational speed of the bearing.
Thus the high frequency part of the
spectrum usually appears as a series of
resonances.
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 33
100
Percent Film
80
60
Region of
lubricated
related
surface
distress
40
Region
of
possible
surface
distress
with
severe
sliding
Operating
region for
most
industrial
applcations
Region of
increased life
20
0.4 0.6
1
2
4
6
10
Λ
Figure 3 Percent film versus Λ (function of film thickness and surface roughness)
A common parameter used to estimate
the degree of asperity interaction is the
lambda ratio (Λ). This is the ratio of
lubricant film thickness to composite surface
roughness and is given by the expression
Λ = h (σЪ2 + σr2)0.5
where Λ
h
σЪ
σr
=
=
=
=
degree of asperity interaction
the lubricant film thickness
RMS roughness of the ball
RMS roughness of the raceway
If we assume that the surface fi nish of
the raceway is twice that of rolling element,
then for a typical lubricant fi lm thickness of
0.3µm surface fi nishes better than 0.06 µm
are required to achieve a Λ value of three
and a low incidence of asperity interaction.
For a lubricant fi lm thickness of 0.1_m
surface fi nishes better than 0.025 _m are
required to achieve Λ=3. The effect of Λ on
bearing life is shown in Figure 3.
If Λ is less than unity it is unlikely
that the bearing will attain its estimated
design life because of surface distress,
which can lead to a rapid fatigue failure
of the rolling surfaces. In general, Λ ratios
greater than three indicate complete surface
separation. A transition from full EHL
(elastohydrodynamic lubrication) to mixed
lubrication (partial EHL fi lm with some
asperity contact) occurs in the Λ range
between 1 and 3.
elements following the surface contours.
The relationship between surface geometry
and vibration level is complex, being
dependent upon the bearing and contact
geometry as well as conditions of load and
speed. Waviness can produce vibration
at frequencies up to approximately three
hundred times rotational speed but is
usually predominant at frequencies below
sixty times rotational speed. The upper limit
is attributed to the fi nite area of the rolling
element raceway contacts which average out
the shorter wavelength features.
In the direction of rolling, elastic
deformation at the contact attenuates simple
harmonic waveforms over the contact width
(see Figure 4).
The level of attenuation increases as
wavelength decreases until, in the limit, for
Discrete defects
Whereas surface roughness and
waviness result directly from the bearing
component manufacturing processes,
discrete defects refer to damage of the rolling
surfaces due to assembly, contamination,
operation, mounting, poor maintenance
etc. These defects can be extremely small
and difficult to detect and yet can have
a significant impact on vibration-critical
equipment or can result in reduced bearing
Contact Width
Ball
Raceway Waviness
Waviness
For longer wavelength surface features,
peak curvatures are low compared with
that of the Hertzian contacts and rolling
motion is continuous with the rolling
a wavelength equal to the contact width,
waviness amplitude is theoretically zero.
The contact length also attenuates short
wavelength surface features. Generally
poor correlation can exist between parallel
surface height profi les taken at different
points across the tracks and this averages
measured waviness amplitudes to a low
level. For typical bearing surfaces poor
correlation of parallel surface heights
profi les only exists at shorter wavelengths.
Even with modern precision machining
technology waviness cannot be eliminated
completely and an element of waviness
will always exist albeit at relatively low
levels. As well as the bearing itself, the
quality of the associated components
can also affect bearing vibration and any
geometrical errors on the outside diameter
of the shaft or bore of the housing can be
reflected on the bearing raceways with the
associated increase in vibration. Therefore,
careful attention is required to the form
and precision of all associated bearing
components.
Figure 4 Attenuation due to contact width
34 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
Attention due to Elastic
Deformation
An Overview of Bearing Vibration Analysis
Figure 5(a) Signal from a good bearing
life. This type of defect can take a variety of
forms, viz. indentations, scratches along and
across the rolling surfaces, pits, debris and
particles in the lubricant.
Bearing manufacturers have adopted
simple vibration measurements on the
fi nished product to detect such defects but
these tend to be limited by the type and
size of bearing. An example of this type of
measurement is shown in Figures 5(a) and
5(b) where, compared to a good bearing,
the discrete damage on a bearing outer ring
raceway has produced a characteristically
impulsive vibration which has a high peak/
RMS ratio.
Where a large number of defects occurs
individual peaks are not so clearly defi ned
but the RMS vibration level is several times
greater than that normally associated with a
bearing in good condition.
Bearing characteristic frequencies
Although the fundamental frequencies
generated by rolling bearings are expressed
by relatively simple formulas they cover a
wide frequency range and can interact to
give very complex signals. This is often
further complicated by the presence on the
equipment of other sources of mechanical,
Figure 5(b) Signal from a damaged bearing
structural or electro-mechanical vibration.
For a stationary outer ring and rotating
inner ring, the fundamental frequencies
are derived from the bearing geometry as
follows –
fc/o = fr/2 [1 – d/D Cos α ]
fc/i = fr/2 [1 + d/D Cos α ]
f b/o = Z fc/o
f b/i = Z fc/i
f b = D/2d fr [1 – (d/D Cos α)2]
where
fr = inner ring rotational frequency
fc/o = fundamental train (cage)
frequency relative to outer ring
fc/i = fundamental train frequency
relative to inner ring
f b/o = ball pass frequency of outer ring
f b/i = ball pass frequency of inner ring
f b = rolling element spin frequency
D = Pitch circle diameter
d = Diameter of roller elements
Z = Number of rolling elements
α = Contact angle
The bearing equations assume that there
is no sliding and that the rolling elements
roll over the raceway surfaces. However,
in practice this is rarely the case and due
Figure 6 Axial vibration acceleration spectrum on end cap of a 250 kW electric motor
to a number of factors the rolling elements
undergo a combination of rolling and sliding.
As a consequence, the actual characteristic
defect frequencies may differ slightly from
those predicted, but this is very dependent
on the type of bearing, operating conditions
and fits. Generally the bearing characteristic
frequencies will not be integer multiples of
the inner ring rotational frequency which
helps to distinguish them from other sources
of vibration.
Since most vibration frequencies are
proportional to speed it is important when
comparing vibration signatures that data is
obtained at identical speeds. Speed changes
will cause shifts in the frequency spectrum
causing inaccuracies in both the amplitude
and frequency measurement. Sometimes,
in variable speed equipment spectral orders
may be used where all the frequencies are
normalized relative to the fundamental
rotational speed. This is generally called
‘order normalisation’, where the fundamental
frequency of rotation is called the first order.
The bearing speed ratio (ball pass
frequency divided by the shaft rotational
frequency) is a function of the bearing
loads and clearances and can therefore give
some indication of the bearing operating
performance. If the bearing speed ratio
is below predicted values it may indicate
insufficient loading, excessive lubrication
or insufficient bearing radial internal
clearance, which could result in higher
operating temperatures and premature
failure. Likewise, a higher than predicted
bearing speed ratio may indicate excessive
loading, excessive bearing radial internal
clearance or insufficient lubrication.
A good example of how the bearing
speed ratio can be used to identify a
potential problem is shown in Figure
6, which shows a vibration acceleration
spectrum measured axially on the end cap
of a 250 kW electric motor.
In this case the Type 6217 radial ball
bearings were experiencing a high axial
load as a result of the non-locating bearing
failing to slide in the housing (thermal
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 35
Imperfections on the surface of
raceways and rolling elements, as a result
of the manufacturing process, interact to
produce other discrete frequencies and
sidebands (summarised in Table 1).
Figure 7 Photograph of Type 6217 inner ring
showing running path offset from centre of
raceway
loading). For a nominal shaft speed of
3000 rev/min the estimated outer ring ball
pass frequency, f b/o, was 228.8 Hz giving
a bearing speed ratio of 4.576. The actual
outer ring ball pass frequency was 233.5 Hz
giving a ball speed ratio of 4.67, an increase
of 2%. A photograph of the inner ring is
shown in Figure 7, showing the ball running
path offset from the centre of the raceway
towards the shoulder.
Eventually this motor failed
catastrophically and thermal loading (cross
location) of the bearings was confi rmed.
A number of harmonics and sum and
difference frequencies are also evident in
the spectrum.
Ball pass frequencies can be
generated as a result of elastic properties
of the raceway materials due to variable
compliance or as the rolling elements
pass over a defect on the raceways. The
frequency generated at the outer and inner
ring raceway can be estimated roughly as
40% (0.4) and 60% (0.6) of the inner ring
speed times the number of rolling elements
respectively.
Unfortunately, bearing vibration signals
are rarely straightforward and are further
complicated by the interaction of the
various component parts, but this can be
often used to advantage in order to detect
a deterioration or damage to the rolling
surfaces.
which is amplitude modulated at inner
ring rotational frequency. In the frequency
domain this not only gives rise to a discrete
peak at the carrier frequency (ball pass
frequency) but also a pair of sidebands
spaced either side of the carrier
Surface Defect
frequency by an amount equal to the
Frequency
modulating frequency (inner ring
Component
Imperfection
rotational frequency) (see Figure 8).
fr
Inner Raceway Eccentricity
Generally, as the level of
amplitude modulation increases so
Waviness
nZfc/i ±fr
will the sidebands. As the defect
Discrete Defect nZfc/i ±fr
increases in size more sidebands
are generated and at some point the
Outer
Waviness
nZfc/o
Raceway
ball pass frequency may no longer
Discrete Defect nZfc/o±fr;
be generated, but instead a series of
nZfc/o±fc/o
peaks will be generated spaced at the
Zfc/o
Rolling
Diameter
inner ring rotational frequency.
Element
Variation
A discrete fault on the outer
Waviness
2nfb ±fc/o
raceway will generate a series of
high energy pulses at a rate equal
Discrete Defect 2nfb ±fc/o
to the ball pass frequency relative
to the outer ring. Because the outer ring is
Table 1 Frequencies related to surface
stationary the amplitude of the pulse will
imperfections
remain theoretically the same and hence
will appear as a single discrete peak within
the frequency domain.
Analysis of bearing vibration signals
An unbalanced rotor will produce
is usually complex and the frequencies
a rotating load, so as with an inner ring
generated will add and subtract and are
defect, the resulting vibration signal can
almost always present in bearing vibration
be amplitude modulated at inner ring
spectra. This is particularly true where
rotational frequency.
multiple defects are present. However,
Likewise the ball pass frequency can
depending upon the dynamic range of
also be modulated at the fundamental
the equipment, background noise levels
train frequency. If a rolling element has
and other sources of vibration bearing
a defect it will enter and leave the load
frequencies can be difficult to detect in
zone at the fundamental train frequency
the early stages of a defect. However,
causing amplitude modulation and result in
over the years a number of diagnostic
sidebands around the ball pass frequency.
algorithms have been developed to detect
Amplitude modulation at the fundamental
bearing faults by measuring the vibration
train frequency can also occur if the cage is
signatures on the bearing housing. Usually,
located radially on the inner or outer ring.
these methods take advantage of both the
Although defects on the inner and
characteristic frequencies and the ‘ringing
outer raceways tend to behave in a similar
frequencies’ (i.e. natural frequencies) of the
manner, for a given size defect the amplitude
bearing (see later).
of the spectrum of an inner raceway defect
Raceway defect
is generally much less. The reasons for this
might be that a defect on the inner ring
A discrete defect on the inner raceway
raceway only comes into the load zone once
will generate a series of high energy pulses
per revolution and the signal must travel
at a rate equal to the ball pass frequency
through more structural interfaces before
relative to the inner raceway. Because the
reaching the transducer location, i.e. rolling
inner ring is rotating, the defect will enter
element, across an oil film, through the outer
and leave the load zone causing a variation
ring and through the bearing housing, to
in the rolling element-raceway contact
the transducer position. The more difficult
force, hence deflections. While in the load
transmission path for an inner raceway fault
zone the amplitudes of the pulses will
probably explains why a fault on the outer
be highest but then reduce as the defect
raceway tends to be easier to detect.
leaves the load zone, resulting in a signal
36 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
An Overview of Bearing Vibration Analysis
Figure 8
and this limits the effectiveness of the
envelope spectrum (see later). In the case
of cage failure the signature is likely to have
random bursts of vibration as the balls slide
and the cage starts to wear or deform and a
wide band of frequencies is likely to occur.
As a cage starts to deteriorate, for example
from inadequate lubrication, wear can start to
occur on the sliding surfaces, i.e. in the cage
pocket or in the case of a ring guided cage on
the cage guiding surface. This may gives rise
to a less stable rotation of the cage or a greater
excursion of the rolling elements, resulting in
increased sideband activity around the other
bearing fundamental frequencies, e.g. the ball
spin frequency.
Excessive clearance can cause vibration
at the fundamental train frequency (FTF) as
the rolling elements accelerate and decelerate
through the load zone, which can result
in large impact forces between the rolling
elements and cage pockets. Also, outer race
defects and roller defects can be modulated
with the FTF fundamental frequency.
Amplitude modulation (AM) (a) Amplitude modulated time signal
Amplitude
Other sources of vibration
Ac/2
fc - fm
Am/4
fc + fm
fc
Figure 8
frequency
Amplitude modulation (AM) (b) Spectrum of amplitude modulated signal
Rolling element defect
Defects on the rolling elements can
generate a frequency at twice ball spin
frequency, and also harmonics and the
fundamental train frequency. Twice the
rolling element spin frequency can be
generated when the defect strikes both
raceways, but sometimes the frequency
may not be this high because the ball is not
always in the load zone when the defect
strikes and energy is lost as the signal
passes through other structural interfaces
as it strikes the inner raceway. Also, when
a defect on a ball is orientated in the axial
direction it will not always contact the inner
and outer raceway and therefore may be
difficult to detect. When more than one
rolling element is defective, sums of the ball
spin frequency can be generated. If these
defects are large enough then vibration
at fundamental train frequency can be
generated.
Cage defect
As already shown, the cage tends to
rotate at typically 0.4 times inner ring
speed, generally has a low mass and
therefore, unless there is defect from the
manufacturing process, is generally not
visible.
Unlike raceway defects, cage failures do
not usually excite specific ringing frequencies
Contamination is a very common source
of bearing deterioration and premature
failure and is due to the ingress of foreign
particles, either as a result of poor handling
or during operation. By its very nature
the magnitude of the vibration caused by
contamination will vary and in the early
stages may be difficult to detect, but this
depends very much on the type and nature
of the contaminants. Contamination can
cause wear and damage to the rolling
contact surfaces and generate vibration
across a broad frequency range. In the early
stages the crest factor of the time signal will
increase, but it is unlikely that this will be
detected in the presence of other sources of
vibration.
With grease lubricated bearings,
vibration may be initially high as the
bearing ‘works’ and distributes the grease.
The vibration will generally be irregular
but will disappear with running time and
generally, for most applications, doesn’t
present a problem. For noise-critical
applications special low-noise-producing
greases are often used.
VIBRATION MEASUREMENT
Vibration measurement can be generally
characterised as falling into one of three
categories, viz. detection, diagnosis and
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 37
prognosis. Detection generally uses the
most basic form of vibration measurement,
where the overall vibration level is measured
on a broadband basis in a range, say, of
10 to 1000 Hz, or 10 to 10000 Hz. In
machines where there is little vibration
other than from the bearings, the spikiness
of the vibration signal indicated by the Crest
Factor (the ratio Peak/RMS) may imply
incipient defects, whereas the high energy
level given by the RMS level may indicate
severe defects.
Generally, other than to the experienced
operator this type of measurement
gives limited information, but can be
useful when used for trending, where an
increasing vibration level is an indicator of
a deteriorating machine condition. Trend
analysis involves plotting the vibration
level as a function of time and using this to
predict when the machine must be taken
out of service for repair. Another way of
using the measurement is to compare the
levels with published vibration criteria for
different types of equipment.
Although broadband vibration
measurements may provide a good starting
point for fault detection it has limited
diagnostic capability, and although a fault
may be identified it may not give a reliable
indication of where the fault is, i.e. bearing
deterioration or damage, unbalance,
misalignment etc. Where an improved
diagnostic capability is required frequency
analysis is normally employed, which
usually gives a much earlier indication of
the development of a fault and, secondly,
the source of the fault.
Having detected and diagnosed a fault
the prognosis – i.e. what the remaining
useful life and possible failure mode of
the machine or equipment are likely to
be – is much more difficult and often relies
on the continued monitoring of the fault
to determine a suitable time when the
equipment can be taken out of service, or
relies on known experience with similar
problems.
Generally, rolling bearings produce very
little vibration when they are fault free and
have distinctive characteristic frequencies
when faults develop. A fault that begins as
a single defect, e.g. a spall on the raceway,
is normally dominated by impulsive events
at the raceway pass frequency resulting
in a narrow band frequency spectrum.
As the damage worsens there is likely to
be an increase in the characteristic defect
frequencies and sidebands followed by a
drop in these amplitudes and an increase
in the broadband noise with considerable
vibration at shaft rotational frequency. Where
machine speeds are very low, the bearings
generate low energy signals, which again
may be difficult to detect. Also, bearings
located within a gearbox can be difficult to
monitor because of the high energy at the
gear meshing frequencies, which can mask
the bearing defect frequencies.
Overall vibration level
This is the simplest way of measuring
vibration and usually consists of measuring
the Root Mean Square (RMS) vibration of
the bearing housing, or of some other point
on the machine, with the transducer located
as close to the bearing as possible. This
technique involves measuring the vibration
over a wide frequency range, e.g. 10-1000
Hz or 10-10000 Hz. The measurements can
be trended over time and compared with
known levels of vibration, or pre-alarm and
alarm levels can be set to indicate a change
in the machine condition. Alternatively,
measurements can be compared with
general standards. Although this method
represents a quick and low cost method of
vibration monitoring, it is less sensitive to
incipient defects, i.e. it detects defects in
the advanced condition and has a limited
diagnostic capability. Also, it is easily
influenced by other sources of vibration,
e.g. unbalance, misalignment, looseness,
electromagnetic vibration etc.
In some situations, the Crest Factor
(the ratio Peak/RMS) of the vibration is
capable of giving an earlier warning of
bearing defects. The development of a
local fault produces short bursts of high
energy which increase the peak level of the
vibration signal, but have little influence
on the overall RMS level. As the fault
progresses, more peaks will be generated
until fi nally the Crest Factor will reduce but
the RMS vibration will increase. The main
disadvantage of this method is that in the
early stages of a bearing defect the vibration
is normally low compared with other
sources of vibration present and is therefore
easily influenced, so any changes in bearing
condition may be difficult to detect.
Frequency spectrum
Frequency analysis plays an important
part in the detection and diagnosis of
machine faults. In the time domain the
38 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
individual contributions, e.g. unbalance, to
the overall machine vibration are difficult
to identify. In the frequency domain they
become much easier to identify and can
therefore be much more easily related to
individual sources of vibration. As we have
already discussed, a fault developing in a
bearing will show up as increasing vibration
at frequencies related to the bearing
characteristic frequencies, making detection
possible at a much earlier stage than with
overall vibration.
Envelope spectrum
When a bearing starts to deteriorate
the resulting time signal often exhibits
characteristic features which can be used to
detect a fault. Also, bearing condition can
rapidly progress from a very small defect
to complete failure in a relatively short
period of time, so early detection requires
sensitivity to very small changes in the
vibration signature. As we have already
discussed, the vibration signal from the early
stage of a defective bearing may be masked
by machine noise making it difficult to
detect the fault by spectrum analysis alone.
The main advantage of envelope
analysis is its ability to extract the periodic
impacts from the modulated random noise
of a deteriorating rolling bearing. This is
even possible when the signal from the
rolling bearing is relatively low in energy
and ‘buried’ within other vibration from the
machine.
Like any other structure with mass and
stiffness the bearing inner and outer rings
have their own natural frequencies which
are often in the kilohertz range. However,
it is more likely that the natural frequency
of the outer ring will be detected due to
the small interference or clearance fit in the
housing.
If we consider a fault on the outer
ring: as the rolling element hits the fault
the natural frequency of the ring will be
excited and will result in a high frequency
burst of energy which decays and then is
excited again as the next rolling element
hits the defect. In other words, the resulting
time signal will contain a high frequency
component amplitude-modulated at the ball
pass frequency of the outer ring. In practice,
this vibration will be very small and almost
impossible to detect in a raw spectrum, so a
method to enhance the signal is required.
By removing the low frequency
components through a suitable high pass
Bearing Vibration Analysis
peaks spaced at cage speed, 2.93 Hz, which
again is consistent with deterioration in
the condition of the rollers. The 374.4 Hz
component is related to the gear mesh
frequency, with sidebands at rotational
speed, 6.56 Hz.
As previously mentioned, bearing
defects normally produce a signal which is
amplitude modulated, so by demodulating
the signal and analysing the envelope
provides a useful technique for early fault
detection. Figure 10 shows the envelope
spectrum, where discrete peaks are present
at 62.5 Hz, and its harmonics which
correspond with the roller defect frequency,
clearly showing how demodulation can be
used, in some circumstances, to provide
a convenient and early detection of
deterioration in rolling bearings.
Cage damage
Figure 9 Spectra obtained from the housing of a taper roller bearing
fi lter, rectifying and then using a low
pass fi lter the envelope of the signal is
left, the frequency of which corresponds
to the repetition rate of the defect. This
technique is often used to detect early
damage in rolling element bearings and is
also often referred to as the High Frequency
Resonance Technique (HFRT) or Envelope
Spectrum.
roller, plus a number of harmonics, i.e.
186.5 (x 3), 497 (× 8), 560 (× 9), 748 (×
12), 873 (× 14) and 936 Hz (× 15).
This would suggest some deterioration
in the condition of the roller(s), which
was confi rmed upon examination of the
bearing. The spectrum also shows discrete
The vibration spectrum shown in Figure
11 was measured on the spindle housing
of an internal grinding machine which
was grinding the raceways of bearing outer
rings. Although the machine was producing
work to the required quality the routine
vibration measurement immediately raised
some concerns regarding the condition of
the spindle.
The spindle was rotating at 19,200
rev/min (320 Hz) and the most unusual
aspect of the spectrum is the presence of
a large number of discrete peaks spaced at
140 Hz, which related to the fundamental
train frequency of the angular contact ball
bearings which had a plastic cage and were
lubricated with oil mist.
Upon examination of the bearing the
Examples of vibration spectra
Roller deterioration
Figure 9 is an example of spectra
obtained from a taper roller bearing with
a 432 mm diameter bore rotating at 394
rev/min.
The shaft was gear driven with a
drive shaft speed of 936 rev/min (2.375
reduction) giving a theoretical gear mesh
frequency of 374.4 Hz. Vibration at shaft
speed 6.56 Hz is clearly evident along with
its harmonics. Also evident in the spectra
is vibration at 62.4 Hz, which corresponds
with twice the rotational frequency of the
Figure 10 Envelope spectrum from the housing of a taper roller bearing
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 39
cage outer diameter showed clear signs of
damage with some fragments of plastic
material which had broken away, but was
still attached to the outer diameter. As a
result, the spectrum had sum and difference
frequencies related to the shaft (fr) and cage
(fc), e.g. 1740 Hz (5fr+fc).
As already discussed, the
deterioration of rolling element bearings
will not necessarily show at the bearing
characteristic frequencies, but the vibration
signals are complex and produce sum and
difference frequencies which are almost
always present in the spectra.
Figure 11 Vibration acceleration measured on the spindle housing of an internal grinding machine.
Raceway damage
High axial load
An example of a vibration spectrum
measured axially on the drive side end cap
of a 250 kW electric motor is shown in
Figure 12.
The rotational speed was approximately
3000 rev/min (50 Hz) and the rotor was
supported by two type-6217- C4 (85 mm
bore) radial ball bearings, grease lubricated.
The vibration spectrum shows dominant
peaks between 1 kHz and 1.5 kHz, which
can be related to the outer raceway ball pass
frequency. The calculated outer raceway
ball pass frequency, f b/o, is 229 Hz and the
frequency of 1142 Hz relates to 5f b/o with
Figure 12 Vibration acceleration measured axially on the DE of a 250 kW electric motor.
a number of sidebands at
rotational frequency, fr.
When the bearings
were removed from the
motor and examined the
ball running path was
offset from the centre
of the raceways towards
the shoulders of the
both the inner and outer
rings, indicative of high
axial loads. The cause of
the failure was thermal
pre-loading as a result of
the non-locating bearing
not sliding in the housing
to compensate for axial
thermal expansion of the
shaft; this is often referred
to as ‘cross location’. The
non-drive end bearing
had severe damage to the
raceways and the rolling
elements which was
Figure 13 Vibration acceleration measured radially on the housing of a Type 23036 spherical roller bearing
40 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
An Overview of Bearing Vibration Analysis
Also a number of the rollers had black
corrosion stains, which was consistent with
the vibration at cage rotational frequency,
fc=4 Hz, in the envelope spectrum (see
Figure 15).
The modulation of the time signal at
cage rotational frequency can be clearly seen
in the time signal, Figure 16.
Effect of bearing vibration on
component quality
Figure 14 Type 23036 spherical roller bearing
outer ring raceway showing black corrosion stains
Even low levels of vibration can have
a significant impact on critical equipment,
such as machine tools that are required to
produce components whose surface fi nish
and form are critical. A good example of
this is during the manufacture of bearing
inner and outer rings. One of the most
Figure 15 Envelope spectrum of the Type 23036 spherical roller bearing
consistent with the highly modulated signal
and high amplitude of vibration at 5f b/o.
The overall RMS vibration level of the motor
increased from typically 0.22g to 1.64g.
Another example of a vibration
acceleration spectrum obtained from the
housing of a Type 23036 (180 mm bore)
spherical roller bearing, located on the main
drive shaft of an impact crusher, is shown
in Figure 13. The spectrum shows a number
of harmonics of the outer raceway ball pass
frequency, 101 Hz, with a dominant peak
at 404 Hz (4f b/o) with sidebands at shaft
rotational frequency, 9 Hz.
When the bearing was removed from
the machine and examined one part of the
outer raceway had black corrosion stain (see
Figure 14).
critical operations is grinding of the bearing
raceways which have to meet very tight
tolerances of roundness and surface fi nish,
and any increase in machine vibration can
result in a severe deterioration in workpiece
quality.
Figure 17, which shows the vibration
acceleration spectrum, 0-500 Hz, measured
on the spindle housing of an external shoe
centreless grinding machine during the
grinding of an inner ring raceway, where
the typical values for out-of-roundness and
surface roughness were >4 µm and 0.3
µmRa respectively. The most distinctive
feature on the fi nished raceway was the
presence of 21 lobes which, when multiplied
by the workpiece rotational speed (370 rev/
min or 6.2 Hz), corresponded to a frequency
of 129.5 Hz. This was very close to the 126
Hz component in the spectrum which was
associated with the ball pass frequency
relative to outer raceway of a ball bearing
in the drive head motor. Also present are
harmonics at 256 and 380 Hz. The discrete
peaks at 38, 116 and 190 Hz correspond
to the spindle rotational speed and its
harmonics.
Figure 18 shows that after replacing
the motor bearings the vibration at 126
Hz reduced from 0.012g to 0.00032g and
the associated harmonics were no longer
dominant. This resulted in a dramatic
improvement in workpiece out-of-roundness
of <0.4 µm and the surface fi nish improved
to 0.19 µmRa. This demonstrates that with
some critical equipment such as machine
tools it is possible to assess directly the
condition of the machine by measuring the
resultant workpiece quality [2, 3].
Figure 16 Acceleration time signal of the Type 23036 spherical roller bearing
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 41
Figure 17 Vibration spectrum and roundness before replacing
wheel head drive motor bearings (a) Vibration spectrum on
spindle housing (b) Roundness of raceway
Figure 18 Vibration spectrum and roundness
after replacing wheel head drive motor
bearings (a) Vibration spectrum measured on
spindle housing (b) Roundness of raceway
CONCLUSIONS
The various sources of bearing vibration
have been discussed, also how each such
source can generate characteristic vibration
frequencies which can combine to give
complex vibration spectra, which at times
may be difficult to interpret other than by
the experienced vibration analyst. However,
with rolling bearings, characteristic
vibration signatures are often generated,
usually in the form of modulation of the
fundamental bearing frequencies. This
can be used to advantage, and vibration
conditioning monitoring software is often
designed to identify these characteristic
features and provide early detection of an
impending problem. This usually takes
the form of signal de-modulation and
establishment of the envelope spectrum,
where the early indications of sideband
activity, and hence bearing deterioration,
can be more easily detected.
As long as there are natural frequencies
of the bearing and its nearby structures
– which occur in the case of a localized
defect on the outer raceway, or on the
inner raceway, or on a rolling element
– the envelope spectrum works well.
However, cage failures do not usually excite
specific natural frequencies. The focus of
demodulation is on the ‘ringing’ frequency
(the carrier frequency) and the rate it is
being excited (the modulating frequency).
Simple broad band vibration
measurements also have their place, but
offer a very limited diagnostic capability,
and will generally not give an early warning
of incipient damage or deterioration.
REFERENCES
1.
Harris T A, Rolling Bearing Analysis (4th Ed),
Wiley, New York, 2001
2.
Lacey S J, Vibration monitoring of the
internal centreless grinding process, Part 1:
mathematical models. Proc Instn Mech
Engrs. Vol 24. 1990,
3.
Lacey S J, Vibration monitoring of the
internal centreless grinding process, Part
2: experimental results. Proc Instn Mech
Engrs. Vol 24. 1990
4.
Wardle F P and Lacey S J, Vibration
Research in RHP. Acoustics Bulletin.
steve.lacey@schaeffler.com
42 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
10 SIMPLE QUESTIONS TO HELP YOU CHOOSE
YOUR IDEAL VIBRATION SENSORS
Monitran has the widest range of vibration sensors available from any single suppplier.
In fact, the width and depth of our range can sometimes seem a bit daunting. That’s why
we’ve designed a handy checklist to help you find just the sensors you’re looking for.
Work through the checklist, ticking the options or filling in the answers. Then simply send it to
us by post, fax or e-mail and we’ll get back to you with our recommendations. Alternatively,
simply pick up the phone to our friendly Sales Team who will be more than happy to talk
through the form with you.
CHECKLIST
1
What do you need to do?
Vibration analysis and
condition monitoring (AC
or charge output sensors)
Continuous monitoring
and machine protection
(DC output sensor)
2
3
4
Male Studs
Female Threads
Epoxy Adhesive
Magnetic Attachment
Quickfit Mounting Plus Adaptors
Other:
7
What sensitivity, output
and range do you need?
What frequency range do you need?
Frequency Range:
8
How do you want to connect the
sensors to your monitoring system?
Top Entry
Side Entry
Sensitivity:
Output:
Range:
Automotive
Buildings and Maintenance
Heavy Industry
Mining
Paper Making
Petrochemical
Research and Development
Utilities
Wind Farms
Other:
Which cable orientation
is best for you?
What sort of mounting do you need?
6
In which industry sector
will the sensors be used?
Integral Cable
Plug and Socket
5
9
Will the sensors be used in the
petrochemical or mining industries?
Petrochemical
Mining
Will your sensors need special
protection from dust and water
ingress?
Dusty Environment
Submersion in <1m Water
Submersion in >1m Water
10 At what temperature will the sensor
be required to operate?
Minimum ambient temperature
Maximum ambient temperature
°C
°C
When you have completed
the checklist call the
MONITRAN Sales Team
on 01494 816569
Alternatively, post,
fax or e-mail it to us
and we’ll get back to
you within 24 hours
Monitran
33 Hazlemere Road
Penn, Bucks,
HP10 8AD
Telephone: 01494 816569
Fax: 01494 812256
e-mail: info@monitran.com
ME | Nov/Dec 2008 | 43
Enquire using 1696 at www.maintenanceonline.co.uk/ME
Measuring Shock Pulse
Abstract
Another approach to Front Line Condition Monitoring
Louis E. Morando
Manager, Special Projects,
SPM Instrument, Inc., Windsor Locks,
Connecticut, USA
Downtime in a paper mill or any 24/7 facility
is very expensive in maintenance costs, but
even more so in its impact on profit because
of the consequent production loss. This article
will explain the Shock Pulse Method and why
the technique is a good choice for front-line vibration measurement.
It will then show the resulting savings that the Hallsta Mill in Sweden
realised from utilising it as the primary component of its Condition Based
Maintenance Programme. Hallsta personnel calculated the amount of
this benefit when they looked at the number of incidents in which they
were able to perform maintenance in shutdowns that were planned and
rule in many facilities. That is, around 80%
of the plant needs to be monitored without
recourse to large amounts of data collection
and to the sophisticated techniques of
vibrational spectra analysis. You could then
utilise such analysis only on the 20% of the
plant that needs it. And indeed, for those
items of equipment that are so critical that
periodic monitoring is not enough then
continuous vibration monitoring needs to
be considered.
The Shock Pulse Method (SPM) is the
front line technique that the Hallsta paper
mill (located just north of Stockholm in
Sweden) has chosen to quickly manage
input of information on the condition of its
800 rolls, with their 4,000 machines and
6,000 measurement points. With just eight
inspectors, they need a quick method to
know whether bearings need to be greased
or not, or whether damage is present and
needs to be monitored more frequently.
not, as previously, forced.
WHAT IS SHOCK PULSE?
INTRODUCTION
C
ondition monitoring should always
start with a list of machine faults,
specific for each machine. Only if
you know exactly what you expect from
the monitoring method can you apply it
efficiently and correctly. Otherwise there is
a danger that you will simply be collecting
data. And data is of no use unless it is
converted to useful information that you
can act upon to realise your true goal of
maintaining plant equipment in good
working order.
When we look for the rotating
component that gives us the most concern,
it usually comes down to the bearing.
I think it is fair to say that 70-80% of
rotational problems are bearing related.
Whether the causes are due to under or
over lubrication, contamination, installation
faults, secondary forces or just plain fatigue,
it is the operating condition of bearings
that is the thing that we most frequently
wish to know. So it is very important to
determine the best technique for identifying
your particular bearing problems. The
other rotational problems certainly need
to be identified as well, so again, we need
to choose the most cost effective, efficient
technique to accomplish that.
How do you run a cost efficient,
effective Condition Based Monitoring
programme? You start by selecting the
appropriate technique for the application
and for the type of answers needed. As a
general rule, you can apply the 80/20 Pareto
44 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
What we loosely call ‘machine vibration’
is a very complex form of movement that
has many different causes and that can be
described and measured in many different
ways. Vibration exists in all machines with
moving parts because some of the force
which makes the machine work is directed
against the machine structure and tries to
shift it from its position. Thus, vibration is
normal up to a degree, and all machines are
constructed to withstand a certain amount
of vibration without malfunction. In order
to use vibration monitoring to diagnose
machine condition, we have to –
쐍 find a suitable way of
measuring vibration,
쐍 decide what normal vibration
is, and what excessive vibration
is for any particular machine.
All vibration measurement starts with a
time record, a registration of vibration over
a length of time. A transducer converts the
Improving
Another appthe
roacReliability
h to Front Liof
ne aCoCoal
nditioFired
n MonPower
itoringPlant using a SAP – REWOP Interface
Figure 1
movement into an electric signal which an
instrument quantifies, displays and stores.
The signal can then be evaluated in terms
of ‘good’ (i.e. the equipment monitored is in
satisfactory condition) or ‘bad’ ( it isn’t, or
soon won’t be).
One way of looking at vibration is to
defi ne the type of force which causes it.
Most industrial machines are rotating, so
the main force is rotational, operating on
masses which are imperfectly balanced.
This accounts for approximately 99% of the
total vibrational energy. Rotational forces
are continuous and cyclic – the force does
not stop (while the machine is running
under power) and the movement is repeated
once per revolution of a part. About 0.9%
of machine vibration is due to shock.
Shock forces are not continuous but can
be repeated, either at regular or irregular
intervals. The remaining small amount
of vibration, about 0.1%, is attributed to
frictional forces.
Even bearing damage can be detected
through vibration analysis. A bearing
produces a group of peaks in the vibration
spectrum, caused by the rolling elements
passing, at different speeds, over the inner
race and the outer race, and by spinning
around their axes. A further peak is caused
by cage rotation. Given the small mass of
the bearing in relation to the large mass of
the machine, these peaks normally have
very low amplitudes and are often difficult
to detect in a spectrum before severe
damage occurs.
A shock pulse transducer contains
a reference mass (m) and responds with
a dampened oscillation when hit by a
shock wave. Attached to the reference
mass is a piezo-electric crystal which
produces a voltage when compressed by
the movement of the reference mass. This
voltage is proportional to the amplitude of
the oscillation and thus to the energy of
the shock wave. The principle is the same
as used in accelerometers for vibration
measurement. There is, however, an
important difference.
When a mass is excited at its resonance
frequency, it will oscillate with much greater
amplitude than at any other frequency.
For vibration measurement, one normally
stops measuring far below the resonance
frequency of the transducer. On the other
hand, shock pulse meters are mechanically
and electrically tuned to operate exclusively
at their resonance frequency of 32 kHz
(fm), where the resulting signal is strongest.
This gives us a very sensitive transducer
for shocks only, but which will not react to
‘normal’ machine vibration frequencies.
When a ball hits a damaged area in
the raceway, it produces a shock wave.
Shock waves are ‘transients’ or shortlived waves starting with relatively high
amplitude that quickly dampens out. In a
time record displayed by an oscilloscope
these transients are often clearly seen,
superimposed on the continuous wave
produced by shaft rotation (see Figure 1).
When the distance between transients is
constant and corresponds to the ball pass
frequency, this is clear evidence of bearing
damage.
In the spectrum, however, peak
amplitude is determined by the energy
content of the vibration at any given
frequency. In relation to the energy at the
shaft frequency, the energy of the shocks
produced by the damaged bearing can be
negligible. Thus, the ball pass frequency line
has low amplitude and is easily lost among
the ‘noise’, as shown in Figure 2. In the area
around the resonance frequency we can
record a time signal, which clearly shows
Figure 2
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 45
Figure 3
the transients produced by the damaged
bearing. Each shock is a single event,
The dBi value is calculated once the
RPM and shaft diameter have been input
into the Tester. This becomes the starting
point for the 0-60 scale.
Many years ago, SPM took the Shock
Pulse technology and developed it into the
Shock Pulse Method. Through actual testing
in bearing test labs, empirical data was
developed based on the bore diameter and
rpm. With this information a dBi value is
determined, which positions the normalised
condition colour alarm scale onto the
dynamic range of the shock pulse transducer.
This enables users to utilise a standardised
alarm scale, regardless of the rpm or bearing
bore diameter (see Figure 3). The dBm is
the maximum value, the measured value
of the strongest pulses detected during
the measuring interval. While the bearing
surfaces are undamaged, the difference
between dBm and dBc (decibel level Carpet)
is small. A high dBm and a large difference
between dBm and dBc are caused by surface
damage or foreign particles between rolling
element and raceway.
as dBc. The dBc is measured in the time
wave signal of the shock pulse transducer.
The fi ltered transducer signal reflects the
pressure variation in the rolling interface
of the bearing. When the oil fi lm in the
bearing is thick, the shock pulse level is low,
without distinctive peaks (the green area in
WHAT IS THE SHOCK PULSE
METHOD?
Due to the sensitivity of the Shock
Pulse Method, bearing lubrication condition
is measurable through the signal monitored
Figure 4
46 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
Figure 4). The level increases when
the oil fi lm is reduced, but there are
still no distinctive peaks (the yellow
area in Figure 4). Damage causes
strong pulses at irregular intervals
(the red area in Figure 4).
In 2002, SPM expanded the
SPM Method by performing a
Fast Fourier Transform (FFT) on
the same 32 kHz signal utilised,
which gave the capability to
conduct a more in-depth analysis.
By identifying the different
bearing frequencies (symptoms)
we can now see the matches of
those frequencies within the
SPM Spectrum. Likewise, typical
symptoms such as imbalance or
looseness can also be introduced for
more accurate pattern recognition.
The x-axis of the SPM Spectrum is
scaled in Hz. The y-axis is in SD
(Shock Distribution units). The
amplitude in the SPM spectrum
should be used in conjunction with the
SPM values. A new damage can cause
high SD readings and an older more severe
damage can have lower SD values. Primarily
the SPM Spectrum is used for pattern
recognition. It is known, but not quantified,
that the delta (the difference between high
Another approach to Front Line Condition Monitoring
Figure 6a
Figure 5
peaks and average level) in a spectrum is
related to the bearing status.
Figure 5 shows a typical Shock Pulse
Bearing Condition chart. The x-axis
represents the time frame. The y-axis
is signal strength intensity divided up
as a Green-Yellow-Red condition code.
As explained earlier, the Alarm level is
determined by the shaft diameter and RPM
that is programmed into the instrument
and/or the PC software. That defi nes the
baseline, and from there the Green/Yellow/
Red divisions are further defi ned. On the
chart we see the readings in the Green zone
until about March 2002. Then they take off
into the Yellow then the Red zones. Plus we
see the development of a large delta (dBm –
dBc), which also indicates bearing damage
in progress.
Refi ners (Figure 6a) are critical pieces
of equipment in the paper making process.
They are the part of the process that breaks
down the cellulose fibres, helping them
stick to one another in the paper web. With
a series of rotating serrated metal disks,
refi ners ‘beat’ the pulp for various lengths of
time depending on its origin and the type of
paper product that will be made from it.
Figure 6b is an on-line history
identifying a bearing deteriorating into
the Red zone. It identifies damage in
progression, then bearing replacement and
fi nally new lower readings as a result of
the replacement. This was accomplished
using only the shaft diameter and rpm.
A subsequent SPM Spectrum (Figure 6c)
measured at the same location identifies the
problem area as the inner raceway (Figure
6d). The pattern displays as an inner race
defect with sidebands. If the philosophy
of front line condition monitoring is to
be adopted, shock pulse measurements
would be utilised as the fi rst stage of
identifying anomalies. Because the shock
pulse transducer is ‘seeing’ only the bearing
signal, it makes the analysis of bearing
condition easier to see, and provides an
earlier call. With this technology, when
Figure 6b
vol 23 no 6 maintenance & asset management | Nov/Dec 2008 ME | 47
Figure 6c
saturation, the bearing call
can be made more easily.
SHOCK PULSE AT
HALLSTA
Figure 6d
the shock values rise and the delta (the
difference between dBm and dBc) increases
over time, it is a prime indicator of
progressive bearing damage. And, by using
the SPM Spectrum, bearing problems can
be clearly identified from secondary
signal sources. The matching of
symptoms (to bearing components)
makes the decision-making process
smoother.
In the SPM Spectrum (Figure 6c)
we carry out an FFT on the unique
Shock Pulse signal that is developed
only from the compression waves
being generated by the operating
bearing. The individual frequencies,
or symptoms, are pre-defined, and
we simply match the symptoms with
the signal patterns of the components
that caused the output of the Shock
Pulse Method to go into the Red zone.
The software identifies the matches
and the y-axis (shock distribution
scale) identifies which symptom is
generating the most shocks.
Between the SPM Method
identifying the bearing and the SPM
Spectrum identifying the bearing
component with the greatest shock Figure 7
The Hallsta mill
utilises the SPM Method
and the SPM Spectrum.
It produces over 785,000
tons per year of magazine,
book, office and newsprint
paper. Hallsta personnel
compiled data from 1993–
1999 on over 2,326 pieces
of machinery in their facility, and their
average warning times are shown in Figure
7. Because of the extended warning before
failure, 100% of replacements were able to
be completed during a scheduled shut-
48 | Nov/Dec 2008 ME | maintenance & asset management vol 23 no 6
down. It was calculated
that this worked out to be
an $800,000 contribution
to profit per inspector, or
$6,400,000 in total. The
Figure shows the 95%
confidence level for the
various average pre-warning
times.
When the bearing
condition fi rst goes from Green to Yellow
and lubrication correction does not reverse
the trend, these values represent the average
warning time for bearing replacement.
With this knowledge, they now use these
average values to determine the corrective
replacement action and the timing of
the replacement. The main arguments
for condition based monitoring are the
considerable cost reductions achieved
by reducing the time it takes to make a
necessary repair. A planned replacement
means less waiting time and less repair
time. When you also add in the saving
of the cost of secondary damage and lost
production that could have resulted from a
breakdown it is easy to understand why an
effective CBM programme is so beneficial.
loumorando@spminstrument.com
Enquire using 1697 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 49
ENERGY&
ENVIRONMENT
STEAM TRAPS
Drastic increases in fuel prices and increased
concern about carbon footprints means the
pressure is on to reduce energy use and cut
fuel bills. Rick Plummer, UK Engineering
Manager for Spirax Sarco explains how a
focus on steam traps can raise the energy
efficiency of steam systems.
Steam trap surveys reveal
£28,000 in potential
energy savings per site
S
team systems are highly reliable and can drop
down the list of priorities when it comes to
applying finite maintenance resources. This can
mean that steam systems do not always run at their
full potential. For many steam system operators, a new
focus on their steam trap population is all that is needed
to create substantial energy efficiency gains with short
payback times. A steam trap survey will help to keep a
system running smoothly and will almost certainly reveal
impressive savings through reduced fuel consumption,
fuel emissions, water and effluent charges.
A survey will also give an estimate of the potential
financial gains through upgrades – providing
information to help justify maintenance expenditure.
For example, an analysis of 50 recent steam trap
surveys revealed potential annual energy savings of
£28,400 per survey on average. The average payback
time, including the cost of replacement products and
their installation, is about two months.
A survey will encompass the location and tagging
of all steam taps in the system, an inspection of each
steam trap’s installation and suitability, and ultrasonic
and temperature testing. An evaluation report will
be written, detailing a plan of work and equipment
specification for replacing inappropriate and failed
components, correcting faulty installation and adding
new equipment to improve the system’s performance.
The proposal should include full costings, scope and
schedule of work and payback calculations.
A new focus on the steam trap
population is all that is needed
to create substantial energy
efficiency gains
payback of less than nine months after investing in a steam
trap survey and undertaking the resulting remedial work.
The site has more than 550 steam traps, but there hadn’t
been a systematic trap survey for over five years. The site’s
environmental compliance manager therefore decided to
carry out a full survey in light of the company’s commitment
to energy efficiencies and improvements, but rather than
perform the work in-house it was decided to buy in the
necessary steam system expertise.
Engineers were on site for 10 days. They surveyed 559
traps, of which 75 were found to need maintenance to
improve their energy efficiency. As a result of the survey’s
findings, Heinz now intends to prevent possible future losses
by adopting a planned approach to steam trap maintenance,
including bringing in experts to carry ou t annual surveys from
now on.
The right trap for the job
Ensuring correctly specified steam traps is vital for
maximising the effective heat transfer and energy efficiency
of any steam system. Around 98% of steam applications place
varying loads on traps. They may involve a fluctuating steam
demand, for instance, or changing external factors such as
ambient temperature. The condition of the steam itself may
also vary, and even a process that normally demands a fairly
steady load will result in a range of flow rates, temperatures
and pressures, depending on whether the equipment is
starting up, operating normally or going through a cycle of
operations.
There are a variety of steam traps available for such
variable applications, which can generally be divided into
three groups.
쐍 Thermostatic traps sense a temperature
difference between steam and sub-cooled
condensate or air/steam mixtures. For example
bimetallic traps and balanced pressure traps.
쐍 Mechanical traps sense a density difference
between condensate and gases. Examples
include float traps and inverted-bucket traps.
쐍 Thermodynamic traps sense the difference
between the dynamic pressures of condensate
at lower velocities and high-velocity flash steam.
In systems with continuous demand a user may
also consider fixed-orifice traps as a further option,
although these may struggle to cope with variable
load conditions.
Picking the right trap for the job
is not always straightforward and it’s
often worth asking the opinion of a
reputable supplier. For example, for
batch processing applications which
Achieving the savings
involve a lot of starting and stopping
there is likely to be a lot of air in the
One site that has benefited from a survey is the
steam space. A balanced pressure
Heinz factory in Wigan, the largest food factory in
thermostatic trap would be a good
Europe. The 55-acre site produces canned soups, baked
choice in this instance because it
beans, pasta and puddings for the UK and continental
will discharge air freely, whereas an
European market, and its on-site energy centre
inverted-bucket trap might struggle to
generates up to 140 tonnes of steam per hour to keep
cope
because bucket traps have only a
the canning lines running.
A steam trap survey will help to keep a system running
limited capacity for air venting.
Energy savings have enabled Heinz to realise a
smoothly and will almost certainly reveal impressive savings
50 | Nov/Dec 2008 | ME
Due to varying loads from steam
applications there are a wide
variety of steam traps available
=dia^cZ/
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Wellman Robey Limited. Newfield Road, Oldbury,
West Midlands, B69 3ET. www.wellman-robey.com
Fax: 0121 543 0070 Email:ME
info@wellman-robey.com
| Nov/Dec 2008 | 51
Enquire using 1698 at www.maintenanceonline.co.uk/ME
Italica 2711013
OEKH8E?B;H>EKI;
FKPPB;IEBL;:$$$
ENERGY&
ENVIRONMENT
EMISSIONS CONTROL
The Government has committed the UK to cutting greenhouse
gas emissions by 80% by 2050, putting pressure on industries to
change bad habits. But how do industries not typically associated
with curbing carbon emissions, such as manufacturing and
engineering, change their ways? Setting an example of how such
companies can actively reduce their emissions is InterfaceFLOR,
a 2008 and 2002 winner of the prestigious Queen’s Award for
Enterprise in the Sustainable Development category.
Curbing the Carbon
to Cool Climate Change
Mission Zero
D
uring the mid-nineties, leading
carpet tile manufacturer
InterfaceFLOR was one of the
first companies to publicly commit to
tackling climate change. Ray Anderson,
the company founder and chairman,
established Mission Zero – “the company’s
promise to completely eliminate the negative
impact it may have on the environment by
2020” says Lindsey Parnell (left), President
and CEO of InterfaceFLOR in the EMEAI region. This vision
laid down the gauntlet for the company to change itself into
a new kind of industrial company - one that could, in time,
rightfully claim to be truly sustainable as well as successful.
Mission Zero underlines the company’s commitment
to consider the environmental impact of every creative,
manufacturing and building decision it makes. Over the last
thirteen years, Interface has proven that the company can “do
well by doing good”, and that by being more environmentally
conscious this in turn benefits the bottom line of the
organisation. The Mission Zero initiatives have resulted in
cumulative avoided costs of $372 million US dollars globally.
Eliminating Emissions
The company is actively working to reduce emissions
via energy efficiency programmes and increasing the use of
renewable energy. All of its manufacturing facilities in Europe
operate on 100% renewable electricity and 27% of Interface
Inc.’s global consumption is from sustainable sources such as
wind turbines, landfill gas, and small-scale hydro resources.
One other way InterfaceFLOR’s European facilities are
tackling their emissions is by introducing lean manufacturing
which uses Overall Equipment Effectiveness (OEE) as a
benchmark and tools such as Total Productive Manufacture
(TPM) and Process Flow Analysis to measure, address and
improve all areas of the factory process. OEE has been
implemented at all of the company’s manufacturing
facilities, including its factory in Shelf, Halifax where the OEE
52 | Nov/Dec 2008 | ME
has improved year on year since it was introduced in 2004,
recording a 10% total improvement.
Business Improvement Team (BIT)
BIT activity boards, are used to stimulate sustainable
projects on the shop floor at Shelf. These have resulted in a
series of improvements throughout the production site across
all departments. Areas covered include improved material use,
eg yarns, samples and pre-coat, as well as improved production
times, including changeover time reduction. Linked to this, the
company rewards shop floor employees based on material
usage, labour variance and the energy they have saved rather
than on output.
One of the initial results from the lean manufacturing
implementation has been the identification of a bottleneck
within the Shelf facility’s packaging division, leading to
unacceptable levels of downtime. By implementing tools
such as OEE and TPM, downtime within this unit was
reduced by 71%.
Manufacturing facilities such as those in Shelf and
Craigavon, Northern Ireland have also had new systems
installed to prevent energy from being wasted. These include
the ‘intelligent conveyor systems’ that only operate when
there is something to move, smart lighting, which switches
on only when a room is in use and Variamatic voltage systems,
which allow lighting to operate on a lower voltage than
normal. InterfaceFLOR’s facility in Shelf also incorporates
a Building Management System that centralises control
of heating and collects energy sub-meter readings every
thirty minutes. This allows analysis and rapid reduction of
unnecessary energy use. As a result of all of its efforts, the
company has already achieved an 82% reduction in Net
Greenhouse Gas Emissions.
InterfaceFLOR
understands that around
75% of the lifecycle
emissions of its products
can be attributed to
the creation of the raw
materials rather than the
actual manufacturing
process itself. The
company also has a clear
policy on offsetting
emissions – only
once emissions have
been reduced to their
irreducible minimum
should offsetting be
considered. In 2002,
InterfaceFLOR introduced Cool Carpet™ a service that allows
consumers to purchase a ‘climate neutral’ product by paying
a small premium on the purchase price and thus offset its
related life-cycle emissions. The company has also introduced
its Evergreen carpet leasing system which allows customers to
choose from the its complete range of products and, in return
for a monthly leasing charge, InterfaceFLOR undertakes to
supply, install, maintain and replace all its products.
By doing so, the company has shown that it is possible
for manufacturing and engineering companies not only to
control their emissions but to also use them while benefiting
the environment and business at the same time.
For ALL your temperature
measurement applications...
Thermal profiling
Process thermal imaging
Portable infrared thermometers
Continuous spot temperature measurement
Tel.: +44 (0) 1246 417691
Email: land.infrared@ametek.co.uk
www.landinst.com
An
Enquire using 1699 at www.maintenanceonline.co.uk/ME
Company
...providing temperature
measurement solutions to
industry for over 60 years
Enquire using 1700 at www.maintenanceonline.co.uk/ME
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Enquire using 1701 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 53
PR0DUCT
REVIEW
ENERGY&
ENVIRONMENT
Three New NHS Contracts in 3 Days Enersys Battery
unphy has achieved a new in-house record for NHS contract
Monitoring Goes
signings. In 3 days, Sunderland & Burton Hospitals, and
D
Wireless
Derrisford Hospital in Plymouth, recently signed orders for
Dunphy burners, as part of their upgrades of steam and heat
provision, and
bring Dunphy’s
total of new
NHS contract
signings in
recent months
to 31. Dunphy’s
patented
and unique
axial air flow
burner design
delivers a tried and tested solution for hospitals focused on
reliably maintaining lowest cost energy supplies across a 24/7
and 365 day variable operating load. The new touchscreen digital
combustion control system, shown below, is also proving a
winner with healthcare engineers.
Sharon Kuligowski t: +44 (0)1706 649217 sharon.kuligowski@
dunphy.co.uk or enter 1723 at www.maintenanceonline.
co.uk /ME
Team Strenghtened at Exide
E
xide Technologies (CMP Batteries) has made two new
appointments to strengthen its service to customers. Richard
Jones, who has many years’ experience within Industrial Sales,
has been appointed as Senior Key Account Manager and Jon
Wells, who has worked for one of
Exide’s customers for the last seven
years, takes up the role of Technical
Projects Manager. Both will be based
at Exide Technologies’ traction battery
manufacturing plant in Bolton.
Richard has extensive experience
Richard Jones
of the MoD, the railway sector and
nationalised industries – all sectors that will be relevant to
Exide. Jon’s knowledge of the battery
industry will be invaluable as he works
in a management role helping major
customers to develop large materials
handling power projects.
t: +44 (0)1204 661460 elaine.mcleod@
eu.exide.com or enter 1724 at www.
maintenanceonline.co.uk /ME
Jon Wells
Enquire using 1702 at www.
maintenanceonline.co.uk/ME
54 | Nov/Dec 2008 | ME
E
nerSys Motive Power has launched a
wireless battery monitoring device,
Wi-IQ, which can be fitted to all motive
power batteries. Used in conjunction with
Wi-IQ Report software, it helps warehouse
management staff to keep on top of fleet
battery management by enabling reports to be produced
by battery, by truck family or by battery condition, depth
of discharge or other diagnostic indicators. By attaching
the USB wireless key to a laptop computer loaded with the
Wi-IQ Report software program, an entire battery room
can be monitored.
Karen Smith t: 0161 727 3800 karen.smith@uk.enersys.
com or enter 1726 at www.maintenanceonline.co.uk /ME
Steam Trap will offset
Power Rises
A
further addition to Gardner
Energy Management’s
growing range of award winning
venturi steam traps, the GEM
Sapphire, has been specifically developed for screwed
pipework applications. Removing the need for steam
trap surveys, regular maintenance and replacement
traps, the highly efficient Sapphire has no moving parts
to fail open (thereby wasting steam and energy) or jam
shut (risking water hammer and system failure). Instead
it uses the patented venturi orifice design to effectively
drain condensate from the steam.
Available in five sizes ranging from 15-50mm, it is
manufactured from corrosion resistant stainless steel
and has a 10-year guarantee.
t: +44 (0)117 917 7010 f: +44 (0)117 917 7011
enq@gemtrap.co.uk or enter 1725 at www.
maintenanceonline.co.uk /ME
Twenty four Hospitals in
24 Months
O
ver the past twenty four months no less than
twenty four hospitals throughout the UK have
taken delivery of Wellman Robey boilers. Each
installation varies in size and output for steam and hot
water; however the criteria for selection has remained
constant;
that being “to
provide the most
economical
and efficient
plant capable
of meeting all
foreseeable
emissions
legislation”.
Wellman Robey is now firmly established as the
market leader in this particular sector, borne out by the
string of recent NHS Hospital successes.
t: +44 (0)121 543 0000 Info@wellman-robey.com or
enter 1727 at www.maintenanceonline.co.uk /ME
Downtime through loss of compression is bad enough. But when
your back-up compressors also fail and your existing supplier has
no answer, losses can escalate. That’s where
Speedy Power come in.
Technic
al
Handb
• UK’s largest and newest fleet of
ooks
now avai
lable for
compressed air equipment
compre
pum
ss
• 100% oil free options
• 24/7 nationwide hire and support
ors,
ps an
Call now d generators.
quoting
MESEP
for your
T
free cop
ies.
01942 72
3 700
• Experienced and knowledgeable staff
So, in case of emergency, call:
0845 307 0777
www.speedyhire.co.uk/compressors
73239 AUG08
Enquire using 1703 at www.maintenanceonline.co.uk/ME
BOILER OPERATOR
TRAINING
COURSES
LEADING TO QUALIFICATION CERT I.B.O.
• TO RAISE SAFETY AWARENESS
• TO INCREASE EFFICIENCY
• TO PROTECT THE ENVIRONMENT
ENDORSED BY:
GASTEC & CEA
Please contact us for further information
on range of couses and dates available.
Web: www.byworth.co.uk
Tel: 01535 665225
Email: training@byworth.co.uk
Enquire using 1704 at www.maintenanceonline.co.uk/ME
Enquire using 1705 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 55
SITE, BUILDINGS &
WORKS M A N AG EM EN T
COMPRESSED AIR
From model engines to flight simulators paint
spraying to patterns of nature, compressed air has a
vast assortment of applications around the Science
Museum in London. An Atlas Copco variable speed
drive compressor supplies the air needed to bring
science to life for its 200,000 monthly visitors.
Atlas Copco brings
science to life with
compressed air
C
Kinetic art in the Wellcome Wing
56 | Nov/Dec 2008 | ME
Science Museum compressor room
ompressed air is used in the Museum’s
mechanical workshops and for cleaning
and paint spraying. It also powers exhibits,
interactive displays and sculptures – activating them
at the press of a button.
Furthermore, the Wellcome Wing, which
contains contemporary science and technology
of the future, uses compressed air in the ‘kinetic
art’ display. These dangling exhibits move up and
down and blow jets of air onto the heads of people
passing underneath. Air also powers the Pattern Pod,
a hands-on gallery created for 5-8 year olds, forming
shapes that represent patterns occurring in nature.
Compressed air provides the motive power
also for the interactive Energy Gallery’s thoughtprovoking games and exhibits, including the
braking system for giant spinning drums. It is also
essential for the state-ofthe-art SimEx simulator ride,
driving immersive air, water
and seat vibration effects,
and the feel of a dinosaur’s
breath on visitors’ necks.
The Atlas Copco
compressor is visible to the
Museum’s visitors through
a specially constructed
door. They can see both the
compressed air installation
and associated heat recovery system that provides
‘green’ hot water (at 60ºC) for the Wellcome Wing
basement toilets and the Deep Blue restaurant heat is naturally generated as air is compressed by
the screw element of the unit. The heat exchanger,
located on the compressor, then takes the heat
out of the compressed air system but, instead of
sending it to atmosphere, re-uses it as hot water for
the selected locations, thus saving energy for the
Museum.
The GA50 W VSD (water-cooled variable speed
drive compressor) was installed by Atlas Copco’s
distributor, Air Solutions Ltd, who also carried out
the pipework fitting. The VSD, together with Atlas
Copco GA 22 standard screw compressors, supplies all
the compressed air for the museum. It is distributed to
the points of use in a network of steel pipes more than
one kilometre long. The system also includes an Atlas
Copco FD170 refrigerant dryer and an air receiver. A dry
air supply is important in order to protect the valves
in the interactive exhibits from moisture. Because it
blows air onto people’s heads, the kinetic art display is
particularly sensitive to contamination, so an oil filter
has been installed at point of use.
The Pattern Pod uses compressed air to show the patterns
that occur in nature.
A VSD is an environment-friendly solution as it uses
up to 35% less energy than an standard air compressor
by running at different speeds to match demand.
The VSD compressor operates seven days a week
throughout the year, catering for frequent evening
events as well as daytime demand. Between 10 and
2 bar air pressure is needed,
depending on the application.
Commenting on the
importance of the compressor
installation to the efficient
operation of the exhibits,
Gary Edgerton, Mechanical
Services Manager, said, “I am
very satisfied with the way the
Atlas Copco VSD is running.
Its energy-saving capacity
and heat recovery features fit
well with our environmental
activities.”
Planned
Maintenance &
Forecasting
A comprehensive business system for
facilities and maintenance management
Helpdesk
& Work
Management
UltraSys is an extremely powerful software system which, due to its unique configurability, makes it a
market leader. UltraSys has been designed by engineers who realise no two environments are
Stores
Management
identical. For this reason, UltraSys allows users to configure not only the manner in which the
software functions but also how that data is presented to different users within the same
organisation. It has continually evolved over the last 25 years making it so functionally rich
Purchasing
that it can handle just about any requirement. In addition, all aspects of all jobs can be
costed and charged making the financial aspect of the system very powerful.
Irrespective of whether the job involves repairs to a complex piece of
Billing Finance
& Payroll
t Manage Hard &
Soft Services
t Manage Multiple Sites
and Companies on one Database
t Reduce Downtime
production equipment or setting up a room providing tea and biscuits,
every aspect can be recorded and quantified.
Clients &
Contracts
Personnel
t Better Resource Management
t Extend Asset Life
t Improve Service Levels & Customer Satisfaction
Utilities
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Find out how UltraSys could benefit your organisation. Contact us: 0121 236 4622 sales@mtas.co.uk
Enquire using 1706 at www.maintenanceonline.co.uk/ME
Total solutions
for welding workshops
Welding fumes are dangerous.
Nederman has worldwide experience of protecting
personnel and environment, and improving workplace
efficiency. Nederman solutions comprise from single
products to complete systems including design and
planning, installation, maintenance, and service.
• Low vacuum extraction systems
• On-torch high vacuum extraction systems
• Mobile and portable fume extraction and filter units
• Central vacuum/filter systems
Nederman Ltd
Unit 91 Seedlee Road
Walton Summit Centre, Bamber Bridge Preston
Lancashire PR5 8AE
Telephone 01772 334721, Fax: 01772 315273
Email: info@nederman.co.uk
Web: www.nederman.co.uk
Enquire using 1707 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 57
Roof Access
for short duration roof maintenance and
bespoke solutions
Bespoke walkways
Tailored for your specific roof
access requirements.
Suitable for flat and pitched roofs.
Free standing edge protection
Lightweight aluminium construction
providing superior aesthetics
and durability.
Valleywalk, Boardwalk,
Roofwalk
For all your short duration roof
maintenance access requirements.
Lightweight, portable, suitable for
fragile roofs.
For all your access requirements contact:
info@easi-dec.com
01767 691812
visit our website www.easi-dec.co.uk
or call Rob on 01767 691812
Enquire using 1709 at www.maintenanceonline.co.uk/ME
‘ACE’ Industrial Air Curtains
Protect open doorways
Resist external winds
Maintain temperature
Don’t obstruct traffic
Don’t damage goods
Don’t block vision
Minimal maintenance
For more details contact Terry McNally direct on:
01440 705503 or terrymcnally@btconnect.com
www.aircurtains.co.uk
Air Curtain Engineering Ltd
Unit 2, Abrac Works, Albright Industrial Estate, Ferry Lane, Rainham, Essex RM13 9BU
Enquire using 1708 at www.maintenanceonline.co.uk/ME
58 | Nov/Dec 2008 | ME
Enquire using 1710 at www.maintenanceonline.co.uk/ME
SITE, BUILDINGS &
WORKS M A N AG EM EN T
When is a door not a door?
When it’s ajar.
An oldie but a goodie and one which succinctly
reflects the tension facing the role of doors
within buildings that serve the twofold purpose
of separating adjacent areas while also allowing
access between them. Primarily this tends to be
areas of different temperature but it can also be
as a means of preventing contamination from one
area to another. A door may be highly efficient at
any of the above but only when kept closed. The
more traffic between different areas within a
building or factory, the more time a door is spent
open, therefore reducing the effectiveness of what
it is trying to achieve.
Air Curtains:
An open & shut case?
T
Terry McNally,
Technical Manager,
Air Curtain
Engineering
raditional solutions have included roller shutter and
fast acting doors as well as plastic strip curtains, but
each has inherent problems. Roller shutter doors may
be necessary for security but take considerable time to open
and close with even fast acting doors in high traffic volume
areas spending considerable time open. Plastic strip curtains
are prone to scratching and wearing and can damage goods
as well as people passing through them. Pedestrian apertures
are often cut into them which eases traffic issues but at the
expense of escaping heat/cooling. Furthermore, when used
on external doors, wind pressure can cause the bottom
section of the curtains to lift allowing a considerable amount
of unwanted cold or hot air into the building.
A more recent innovation, air curtains are increasingly
being used on their own and in conjunction with fast acting/
roller shutter doors to minimise energy loss while retaining
the integrity of the environmental conditions the doors
are designed to protect. Yet according to Terry McNally,
Technical Manager of Air Curtain Engineering Ltd, companies
are at risk more than ever before of not getting the best
results from their investment in air curtain technology.
McNally should know, with over 40 years personal experience
in the business, twenty five with Air Curtain Engineering Ltd.
“Putting it simply, the market is increasingly full of poorly designed,
poorly built, inefficient solutions which rarely ideally fit the exact
requirements of the customer.”
For this reason, Air Curtain Engineering treats every
customer requirement as a unique problem requiring a
unique solution. McNally again, “It’s tempting on one level to
buy an out-of-the-box air curtain solution that is suitable for a
range of door sizes but the reality is every door and every working
environment is subtly different. It’s a simple fact that an air curtain
with a fixed fan output can’t operate at maximum efficiency over
a range of door sizes. At one end it will be only just strong enough
to cover the door space and be very susceptible to gusts of wind
or changes in air pressure while at the other, it may well be too
strong which can cause draughts.”
With energy prices going through the roof, it makes
more sense than ever for a company to ensure that it’s only
using the exact amount of energy required to maximise the
energy efficiency of an air curtain.
It is for this reason that McNally recommends the starting
point of any investment in an air curtain to be a proper
on-site survey. “Two customers may each have a 3 metre door
but completely different amounts of space around the door as
well as a range of other internal considerations meaning that
each customer requires a totally different solution.” McNally
also recommends that customers obtain a full specification
about any solution and more importantly, a guarantee of
performance. As he explains, “On the face of it, one air curtain
unit can look very similar to another yet offer a world of difference.
One may contain several smaller fans running at a higher rpm
while another may have just one fan operating at a lower rpm.
One may contain a heating element while another may make
use of existing ambient temperature differentials.” He also points
out that acoustic properties and noise operating levels, often
overlooked, can create significant workplace discomfort as
well as introducing potential Health and Safety issues. “Double
check any noise ratings and ask at what distance the noise ratings
apply. 65 dB(A) at 5 metres sounds a lot louder if in reality people
are only 3 metres away.”
Last but not least, it should be possible to determine
fairly accurately what payback period you should expect.
McNally closes with this advice, “If your supplier can’t estimate
how long your payback period is, then ask why. If the supplier has
done their job properly and designed and supplied a solution to
your exact requirements, they will be able to estimate how much
energy you could be saving.”
ME | Nov/Dec 2008 | 59
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SALES AERZENCOUKWWWAERZENCOUK
Enquire using 1711 at www.maintenanceonline.co.uk/ME
01234 841468 info@casellacel.com
www.casellacel.com
Think Environment Think Casella
Enquire using 1712 at www.maintenanceonline.co.uk/ME
FREE!
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Environmental Noise Roadshow
Newcastle - Wednesday, 12th November ‘08
Noise & Vibration Legislation Seminar
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Peterborough - Thursday, 29th January ‘09
COSHH & Air Sampling Road Show
Harrogate - Thursday, 28th May ‘09
dosemeter. With a rugged, durable metal case
and no cables, controls or displays, it is your ideal
tool for the Noise at Work Regulations.
Castle Group Ltd
Technical instruments for Health & Safety at work and in the environment
t: 01723 891655
For further information, why not contact us: +44 (0) 1723 584250
e: sales@cirrusresearch.co.uk
See our website for further
dates and venues:
w: www.cirrusresearch.co.uk
Enquire using 1714 at www.maintenanceonline.co.uk/ME
60 | Nov/Dec 2008 | ME
www.castlegroup.co.uk
Enquire using 1713 at www.maintenanceonline.co.uk/ME
SITE, BUILDINGS &
WORKS M A N AG EM EN T
It’s heading towards two years since the updated Control
of Noise at Work Regulations came into force. Technically
speaking it stipulates that 80 decibels is now the level at
which employers must assess the risk to worker’s health
and provide them with information and training while 85
decibels represents the daily or weekly average exposure
above which an employer must provide hearing protection
and hearing protection zones.
Prevention
is better than protection
A
James Tingay
Cirrus Research
ccording to James Tingay of Cirrus Research, a
leading designer and manufacturer of noise
measurement instruments, this means that a whole
new range of working environments and practises are
now recognised as potentially contributing to hearing
damage of workers. These include workshops, production
lines, maintenance areas, on and off-site activities, and even
office environments. “The real danger of noise induced hearing
damage”, according to Tingay, “is that in the vast majority of
cases, especially at the noise levels now being addressed by the
current regulations, it is a creeping, silent threat which is often
noticeable only when it is too late.”
While the human ear does have a limited ability to
protect itself against short term excessive noise levels,
referred to as a Temporary Threshold Shift, long term damage
is precisely that – long term, and irreversible.
In Tingay’s considerable experience, the most overlooked
affects of hearing damage tend not to be the physical but the
psychological. “Damage to your hearing can affect everything
from your moods, your sleep, even your ability to communicate
with friends and family. Not only can this massively affect self
confidence, it can also affect your ability to continue to safely work,
or work at all.”
NOISE PREVENTION
So why is it that hearing damage is still such an issue
in so many workplaces? The answer is a depressing lack of
education and concern for the welfare of many workers
combined with an over reliance on Personal Protection
Equipment (PPE). Tingay provides a typical example. “Take
the case of the workman using a pneumatic drill to dig up a road.
He is wearing the correct PPE as the user of the drill must, but the
worker standing right next to him using a brush or shovel all too
often isn’t because using a shovel or broom doesn’t require PPE.
That worker’s hearing is still going to be damaged.” It’s the same
for workers working in close proximity to air ratchets or other
tools and equipment with high noise levels. Tingay’s most
frustrating examples however is the manager or supervisor
who makes frequent trips to the shop floor and doesn’t wear
his own PPE. “Not only is he putting his own hearing at risk he’s
sending out a very clear message to those being told to wear PPE
that he doesn’t really see it as important.”
It might sound like stating the obvious but it’s a truth
that is often overlooked – it’s not the use of the tool that is
the cause of hearing damage, it’s the closeness of the ear to
the source of the noise. Which is why for Tingay the issue
of noise related hearing damage needs to be treated at
source because prevention is always better than cure and
with hearing damage, there is no cure. In a great many cases,
dealing with the cause and not the symptoms of excessive
noise is also less expensive and more practical. It may be
just one machine within an entire working environment
that causes a noise issue that affects everyone around it. Far
better says Tingay to identify this and then build an acoustic
enclosure or re-site it, or even potentially replace the machine
in question. “Remember and understand what it is you are trying
to achieve – and that is the reduction of noise. Measure it, identify
the problem, and wherever possible, take any action at source
with PPE used as an appropriate secondary measure.”
Looking
forward, Tingay
advises employers of
another reason why
accurate noise level
measurements will
become increasingly
important. “As the
UK becomes more
litigious, we would expect to see more workers making injury
claims against employers concerning hearing damage. Given the
gradual nature of hearing damage, this could have been caused
a previous job or simply as a result of social activities including
listening to MP3 players at too high a volume. By providing
hearing level tests for employees as well as properly audited
noise levels for the work environment, companies will be able
to protect themselves from false claims of hearing damage by
demonstrating that such damage could not have been caused as
a result of the employee’s working environment.”
ME | Nov/Dec 2008 | 61
SITE, BUILDINGS &
WORKS M A N AG EM
EN T
EMISSIONS
Motivation:
Giving the best to and
getting the best from
your workforce
‘When the going gets tough, the tough get going’
M
otivational, cliché, a hit song for Billy Ocean in 1985
or all of the above? While few of us may be able to
summon up Billy Ocean’s enthusiasm for the phrase,
the reality is that for most of us, things are getting tough and
may well get tougher. And it’s at times like this when the
absence or presence of motivation can make all the difference,
at a personal and company level. I found myself thinking on
some of my more positive motivational memories recently:Christmas bonuses, promotion opportunities honoured,
finishing work an hour early on a Friday, and a genuine thank
you from a customer or a manager. I also remembered the
relief at being kept on in a job when things for the company
were tough and working perhaps harder than ever to play my
part to get us all through and out the other side.
Dr Marek Szwejczewski,
Cranfield School of Management
Henry Noteman,
Operations Manager for Integrated HR
Some long, some short term but each with the common
ingredient of making me feel like my work, and more
importantly, my person was valued. And now more than ever,
is the time to ensure that you and your workforce is motivated.
So says Dr Marek Szwejczewski of Cranfield School of
Management and it is his belief that there are a number of
reasons why we should remain optimistic. He also identifies
steps that employers can take to get through even the most of
the challenging economic climate.
62 | Nov/Dec 2008 | ME
For Szwejczewski, it’s all about people. “The skills needed
to work within both the Maintenance and Engineering industries
are unique and often specialist. In my opinion, it is the people and
their skills that hold the key to the survival of many engineering
companies. However, if those skills are not developed and stretched,
and new skills learned, an organisation and its people can
stagnate.” This view is shared by Henry Noteman, Operations
Manager for Integrated HR, an HR consultancy with many
years experience in the manufacturing and engineering
sector. “Successful staff motivation is when employees feel valued
and challenged. They need to feel they are making a difference
and that their efforts are recognised and appreciated by senior
management.”
Looking at the current economic situation, Noteman
stresses the need for management to look to the long term.
“Those that react on a short-term basis and seek to reassure
through quick fixes, such as seasonal bonuses, will suffer in the
long run as inconsistency emerges. Honesty is always the best
policy and this, coupled with long-term thinking, will enable staff
to feel that they are part of the solution rather than part of the
problem.” Another reason to think of the long term is precisely
because that is what most workers are themselves thinking of.
Noteman again, “In turbulent markets, staff seek job security and
contemplate their long-term prospects. To reflect this it is important
for managers to consider employee motivation over a longer time
frame. By doing so, they stand a far better chance of retaining their
best people, maintaining productivity and emerging from the
downturn unscathed.”
“...Honesty is always the best policy and this, coupled with
long-term thinking, will enable staff to feel that they are
part of the solution rather than part of the problem.”
Szwejczewski agrees and identifies staff training and
development as one of the most effective means of giving
the best to and from staff in the short, medium and long term.
“We recently conducted some research into manufacturing plant
performance, and found that the companies with the highest
performance levels were also the ones who invested the most in
employee training. In this current climate, competition is fierce, and
companies need to maintain this high level of performance in
order to keep their heads above water.” He continues, “Developing
your staff will also help you keep them. Offering training and
development incentives could mean the difference between
a valued member of staff leaving you for a ‘stronger-looking’
competitor or staying to help pull your business through to the
other side.”
Szwejczewski acknowledges that when budgets are
already constrained, it can be hard to justify further investment
in staff. Yet in his considerable experience, it remains his view
that putting money into staff training is a smart investment.
“One CEO I’ve worked with said that the amount the company
spent on training was more than offset by the resulting reduction
in scrap and reworking.”
So take heart says Szwejczewski. “In the short term, you will
have employees that are more motivated and who work harder,
faster, longer. They will bring back with them ideas and inspiration
from other industries about how your organisation would
innovate. In the longer term, they will become your company’s
greatest advocates, best managers, most creative thinkers and
ultimately, people that deliver back far, far more than your initial
investment in them.”
Enquire using 1715 at www.maintenanceonline.co.uk/ME
Anti-slip Fibreglass Floor Grating
Applications:
Benefits:
Industrial flooring
Stairs
Walkways
Platforms
Assembly lines
Wash bays
Work stations
Anti-slip surface
High strength
Easy installation
Lightweight
Corrosion/fire resistant
Impact resistant
Zero maintenance
Dura Tread has one of the highest
degrees of slip-resistance ever
measured for a walking surface
Tel: +44 (0) 1255 423601 - Fax: +44 (0) 1255 435426
www.duracomposites.com - info@duracomposites.com
Dura Composites, Unit 14 Telford Road, Clacton-on-Sea,
Essex CO15 4LP, UK
Enquire using 1716 at www.maintenanceonline.co.uk/ME
Enquire using 1717 at www.maintenanceonline.co.uk/ME
ME | Nov/Dec 2008 | 63
PR0DUCT
REVIEW
New
Oil Water
Separators
T
he new Owamat 11 from Beko
can be used on compressors
up to 230 m3/hr capacity - around
double that of the existing
Owamat 10, which still remains
in the product line-up – and
offers a cost-effective solution for
condensate treatment in one of the
most popular compressor size ranges.
Owamat is an oil-water separation system
for dispersed condensates which has undergone
a complete re-engineering. Benefits of the
new improved range include smaller footprint,
greater separation efficiency, and the ability to
treat some synthetic oils – a feature not possible
with carbon bag based separators.
Ruth Goodison t: +44 (0)1527 575778 info.uk@
beko.de or enter 1741 at
www.maintenanceonline.co.uk /ME
Quality Partnership
W
hen you take the noted manufacturer
Seetru – the leading name in relief valves
and liquid level gauges – and link them to storage
specialists Lista then you really do have the
optimum business
partnership.
So when
it comes to
compatible
storage solutions,
Seetru’s Production
Engineer, Mike
Marshall, invariably
looks toward Lista. Seetru currently have three
variations of height and width of Lista static
deep drawer cabinets, all neatly located within
the workshop office. These units offer numerous
unique features including a patented locking
system for quiet handling; exactly matched
partioning materials for ideal volume capacity;
rounded and recessed handles and anti-tilt
technology for maximum safety and eco-friendly
coating for more impact and resistance.
t: +44 (0)1908 222333 info.uk@lista.com or enter
1747 at www.maintenanceonline.co.uk/ME
SITE, BUILDINGS&WORKS
MANAGEMENT
Success at Italy’s largest
Pumped Storage Plant
J
ames Walker’s HydroSele® S has proved
its superb sealing efficiency by running
maintenance free for over two years at ENEL’s
massive Entracque pumped-storage hydroelectric
scheme in Italy. It replaced a troublesome
mechanical seal that had to be changed
frequently on the plant’s Unit 9 turbine - a costly
exercise that created an unacceptable loss of
generating capacity.
James Walker & Co Ltd is a member of the
James Walker Group. This global manufacturing
group operates through two strategic business
units: Sealing Products & Services, and Rail Systems
& Products.
It has 50
production,
engineering,
distribution
and customer
support sites
worldwide
and sells in over 100 countries.
Ian Anderson (PR195), t: +44 (0)1483 746315
jwsalesleads@jameswalker.biz or enter 1746 at
www.maintenanceonline.co.uk
Atlet support proves fruitful
C
hilled distribution
specialist Langdons
chose Atlet to deliver
a ‘complete handling
package’ for operations at
Gerber Juice Company’s
Bridgwater distribution
centre run by Langdons. A
fleet of warehouse trucks
was supplied to a precise
specification and Atlet also designed and built the
battery management and handling systems.
“We looked at other suppliers but the support
we have received from Atlet over years swayed our
decision,” says Chris Murt, Langdons Operations
Director, “Backup from Atlet has been excellent. When
the chips are down they’ve always sorted us out.”
Paul Forster, Atlet t: +44 (0)1844 215501
f: +44 (0)1844 219220 or enter 1755 at
www.maintenanceonline.co.uk/ME
Cost-Effective Reverse Osmosis
E
LGA Process Water has announced two new models in their market-leading maxiRO range of
reverse osmosis units. The new models, the maxiRO 14-4000 and maxiRO 14-5000 deliver 4m3/h
and 5m3/h respectively and extend the maxiRO range into large commercial and industrial systems.
Like other models in the maxiRO range, the new models use low pressure membranes which
remove up to 98% of dissolved inorganics and over 99% of large dissolved organics, colloids
and particles whilst low operating pressures – generally below 14bar – keep operating costs
to a minimum. Competitively priced to appeal to the commercial and industrial user of
boiler make up, cooling and process water, these RO units are self-contained, compact and
designed to blend into the modern plant room environment.
t: + 44 (0)1628 897000 sales.uk@veoliawater.com or enter 1743 at www.
maintenanceonline.co.uk/ME
64 | Nov/Dec 2008 | ME
New Spill Doctor™
Don’t leave anything to chance
when it comes to leaks & spills the new addition to Empeezy’s
Spill Doctor™ family enables you
to respond quickly to incidents,
such as leaking drums/IBC’s or
burst pipes on fuel/chemical
delivery tanks.
Although this kit has been
designed to be strategically
placed in spill sensitive locations it
is fitted with fork pockets to allow easy transport
to other areas if required.
Available in 3 versions - Maintenance, Oil
Selective & Chemical - each one is packed with
a variety of sorbent products providing total
capacities of up to 241ltr making them an ideal
choice to form part of your site contingency plan.
t: +44 (0)1506 430309 advice@empteezy.co.uk
or enter 1744 at www.maintenanceonline.co.uk
Knee & Elbow Protection
앫 Comprehensive range to suit every application
앫 Ergonomic design
앫 Comfortable and secure fit
앫 Reliable protection
앫 Tough and hard wearing
앫 Manufactured to the
highest standards
from selected quality
materials
앫 CE marking throughout
앫 NATO Stock No:
22c 8415-99-8873869
Contact: Gotec Trading Limited
Boulton Road, Pin Green
Stevenage, Herts SG1 4QL
t: 01438 740400 Fax: 01438 740005
or enter 1745 at www.maintenanceonline.co.uk/ME
A High-Speed Door Solution
Klimate Doors have supplied and installed an Ardent
high speed door at Lloyds Animal Feeds mill. The
need to control the build up of wind through the
extended loading bay and maintain a hygienic working
environment led to the decision to install the Ardent
door. With adjustable
opening and closing
speeds of up to 2 metres
per second, depending
on the size of the door,
the fast acting operation
of the Ardent range is
attractive as the doors can
prevent the influx of wind.
Mark Roberts from Lloyd’s commented: “We chose
Klimate due to their ability to provide a quality product at a
reasonable price and we have not been disappointed”.
Lisa Harrison t: 0870 607 5050 lisa.harrison@
bidgroup.co.uk or enter 1742 at www.
maintenanceonline.co.uk /ME
Anglia Composites Ltd
COMPOSITE SAFETY SOLUTIONS
TEL: 01787 377 322
COMPOSITE STRUCTURES FROM ANGLIA COMPOSITES
Composite structures made to order from our high quality fibreglass
pultruded structural profiles. We are able to manufacture platforms,
walkways, ramps, handrails, ladders, stairs and many other
structures. Built and installed to your exact requirements and to
British Standards (BS5359) by our own skilled craftsmen. A
complete CAD design and build service is available.
Our structures will never rot or rust and require zero maintenance.
They are also thermally stable, fire resistant and non-conductive.
We offer a nationwide installation service to all customers.
FIBREGLASS GRATING FROM ANGLIA COMPOSITES
Our grating is Class 1 fire resistant to BS 476. Our
entire range of products are made with high
quality resins and contain fire and UV inhibitors.
Our fibreglass products are corrosion resistant
over a wide pH range both acidic and caustic. This
is achieved by the use of premium grade resins.
Fibreglass grating allows repeated deflection without causing permanent damage or deformation.
Deflection, fire and chemical data available.
Our gratings have a tough quartz grit surface to
give amazing slip resistance. You are guaranteed
a long life with Anglia Composites gratings.
DRUM BUNDS
TREAD COVERS
Drum bunds from
stock. Single, double,
4 drum, IBC bunds with
or without keg facility.
Thousands of tread covers
in stock. Any size of tread
cover cut to order.
Amazing slip resistance.
Nationwide installation.
SAFETY GATES
GRP PLATE
All gates are double bar
gates and conform to
ISO 14122. Gates are
available in a wide
range of sizes to fit any
opening.
Plate in stock in various
sizes and colours. Any
colour plate can be
made to order.
Enquire using 1718 at
www.maintenanceonline.co.uk/ME
Anglia Composites Ltd - Unit 5 Stour Valley Business Centre
Brundon Lane - Sudbury - Suffolk - CO10 7GB
Tel: 01787 377 322 - Fax: 01787 377 433 - Email: info@angliacomposites.co.uk
ME | Nov/Dec 2008 | 65
Visit our web site for further information - www.angliacomposites.co.uk
PR0DUCT
REVIEW
On Site Line Boring Service;
Perfectly Aligned
M
&A Engineering continue to provide and
enhance a precision, on-site, line boring
machining service for maritime operators,
ship repair yards, energy companies, steel
manufacturers, petro-chemical producers and
OEM’s throughout the world. The company offers
a design-and-build facility from its base in South
West Wales, and mobilisation of engineers and
equipment to any part of the globe at minimal
notice.
Services include on-site boring, turning,
milling, hydraulically controlled bolt tensioning,
and optical alignment surveying, all covered by
Lloyds ISO 9001 certification.
Jon Mortimer +44 (0)1646 698192 jon@
mandaengineering.co.uk or enter 1748 at www.
maintenanceonline.co.uk/ME
Decorative Resin Floors
R
eepol Chemical Building Products
manufactures a range of decorative coatings
to restore worn concrete floors and turn them into
attractive working environments. The company’s
range of epoxy resin systems provides users with
hard-wearing, anti-slip operating surfaces. Excellent
design aesthetics can be achieved using a number
of options including contrasting colour schemes,
flecked-effect finishes, boundary lines and safety
markings. Corporate logos can be embedded as
floor-painted motifs.
Site managers contemplating a restoration
project are invited to request a free site survey and
technical assessment.
t: +44 (0)1952 588575 sales@reepol.com or enter
1754 at www.maintenanceonline.co.uk/ME
SITE, BUILDINGS&WORKS
MANAGEMENT
Mykal make Degreasing Choices Simple
M
ykal Industries have re-launched their definitive guide to industrial degreasing
with the release of their latest ‘Safe Solutions for Industrial Degreasing’
Catalogue, which covers every aspect of industrial degreasing, ranging from simple
maintenance products to sophisticated process degreasing solutions. It has been restructured and includes new products such as Epoxy Resin Cleaner, Electrical Power
Wipes and the heavy-duty Graffiti Remover-Plus, alongside the top selling De.Solv.It
and Aquasolv brands.
Marketing Manager, Matthew Dent, comments; “Degreasing is a huge market and a daily part of life for
many businesses. We can offer degreasing solutions ranging from wet wipes aerosols to high-tech degreasers and
Special Blends for PU and adhesives”.
To get your copy of the new catalogue telephone +44 (0)1933 402822 or email enquiries@mykal.co.uk or
enter 1750 at www.maintenanceonline.co.uk/ME
Help in the fight against
Meth
B
ritish engineering
company Smith
Flow Control (SFC) is
helping to eliminate
methamphetamine
labs in the state of
Iowa and across
the United States by cutting off the illegal supply of its
primary ingredient - anhydrous Ammonia (NH3).
NH3, a fertiliser stored in large nurse tanks on
farmland, is vulnerable to thieves, who steal it to
manufacture the highly addictive drug crystal meth.
Tanks-A-Lok, supplied by SFC, is locking off the tanks
to prevent unauthorised access and theft. The locks
are made of hardened steel and there are 3 models
available to fit the host valve. Access to the valve is only
permitted by inserting the correct coded key. The lock
is resistant to any other attempts to remove it and, once
secured, nurse tanks can be left unattended.
t: +44 (0) 1376 517901 sales@smithflowcontrol.com
or enter 1751 at www.maintenanceonline.co.uk/ME
Steelcoat Protection
on Runcorn Bridge Cable
Stays
W
inn & Coales Denso
Steelcoat 400 System
is being used to protect the
cable stays on the Runcorn
Silver Jubilee Bridge over
the Mersey, giving a longer
life than the previous paint
coatings, with a subsequent
saving on labour costs. The
peak height of the bridge is
86m and the longest cable
stays are 45m. The Steelcoat
System consists of: Hi-Tack Primer, Hi-Tack Tape,
uv-resistant Ultraseal Tape, followed by a final
two coats of acrylic topcoat.
Winn & Coales, a developer and producer
of leading anti-corrosion and sealing products,
recently commemorated their 125th anniversary.
t: +44 (0)20 8670 7511 mail@denso.net or enter
1752 at www.maintenanceonline.co.uk/ME
Easy Connection without Crimping
T
he new AxiClamp cable termination system
from Multi-Contact offers the reliability of crimp
connections but with the advantage that they can
be easily disconnected if required. The body of the
connector has a solid metal cone which clamps the
copper cable strands against an internal taper on
the metal sleeve. When screwed tightly together,
the resulting connection provides excellent long
term contact resistance equivalent to crimping.
The connectors are designed for the electrical
and mechanical
connection of copper
cables ranging from
6 to 300 mm2, class
5 and 6 according to
DIN VDE 0295, IEC 60228. They are vibration tested
to DIN EN 60068-2-6, 10g, 10-500 Hz.
Linda Kelly, t: +44 (0) 1908 265544 l.kelly@
multi-contact.com or enter 1749 at www.
maintenanceonline.co.uk/ME
Reducing Insulation Costs in Clean Environments
T
-Tubes, from Zotefoams, is an FM 4910 approved, advanced insulation system specially developed for
stainless steel process lines in clean environments. It comprises pipe insulation for a wide range of sizes
and custom moulded components to insulate joints and fittings and offers
savings in installation and long-term ownership costs.
Each component in the system is thermoformed from closed cell,
cross-linked ZOTEK® F PVDF foam. The closed cell nature of the foam inhibits
moisture and vapour ingress while thermoforming provides a durable,
cleanable, puncture resistant skin. For these reasons, it does not require
expensive PVC jacketing that many of the competing open-cell or fibrous
insulants need, and the dust-free nature of the ZOTEK F foam means that
T-Tubes can be cut to size without compromising clean environments.
Fabrice Lacroix t: +44 (0)20 8664 1600 fl@zotefoams.com or enter 1753 at www.maintenanceonline.co.uk/ME
66 | Nov/Dec 2008 | ME
INDUSTRIAL SEARCH ENGINE
ACOUSTIC EMISSION
Holroyd Instruments Ltd
www.holroyd-instruments.com
ASSET MANAGEMENT
KNOWLEDGE
The Woodhouse Partnership Ltd
www.twpl.com
BALLSCREWS REPAIR/
REPLACEMENT
Jena Rotary Technology Ltd
www.jena-tec.co.uk
BENCHMARKING
MCP Consulting & Training
www.mcpeurope.com
BOILERS
Beamont Hire - Boilers
www.beaumonthire.co.uk
Wellman Robey Ltd
www.wellman-services.com
BOLT SECURING SYSTEMS
Nord-Lock Ltd
www.nord-lock.com
COMBUSTION
The Combustion Engineering Association
www.cea.org.uk
COMPRESSSORS
British Compressed Air Society
www.bcas.org.uk
Donaldson Ultrafilter
www.donaldson.com
Gardner Denver Ltd
www.gardnerdenver.com
Xetec Ltd
www.xetec.co.uk
CONDITION MONITORING
EQUIPMENT/SERVICES
Artesis
www.artesis.com
Corus Northern Engineering Services
www.corusnes.com
Institution of Diagnostic Engineers
www.diagnosticengineers.org
Kittiwake Developments Ltd
www.kittiwake.com
PCB Piezotronics Ltd
www.pcbpiezotronics.co.uk
Pruftechnik Ltd
www.pruftechnik.co.uk
Schaeffler (UK) Ltd
www.schaeffler.com
CRANES
Hansen Transmission
www.hansentransmissions.net
HOSE & COUPLINGS
Dixon Group Europe Ltd
www.dixoneurope.co.uk
INDUSTRIAL CONTROLS
Asco Numatics
www.ascojoucomatic.ltd.uk
INFRARED TRAINING
Institute of Infrared Training
www.infraredinstitute.com
INTERNET ENABLED MAINTENANCE
Accent Software
www.helponline.org
LASER ALIGNMENT
Pruftechnik Ltd
www.pruftechnik.co.uk
KONECRANES UK
www.konecranes-uk.com
LEAK DETECTION EQUIPMENT
DRY ICE BLASTING
Alpine Components
www.alpine-components.co.uk
Clean Surface Ltd
www.cleansurface.co.uk
IceTech A/S
www.icetech.dk
LIQUID STORAGE
Empteezy Ltd
www.empteezy.co.uk
DUCTING/PIPEWORK/VACUUM
SYSTEMS
LOADING BAY EQUIPMENT &
INDUSTRIAL DOORS
Jacob (UK) Ltd
www.pipe-systems.net
Stertil Stokvis
www.stertiluk.com
ELECTRICAL MAINTENANCE
LUBRICANTS & LUBRICATION
SOLUTIONS
Aucotec Ltd
www.engineeringbase.com
COMPRESSSOR HIRE
ELECTRICAL TEST EQUIPMENT
Speedy Compressors
www.speedyhire.co.uk/compressors
Alpha Electronics (Southern) Ltd
www.alpha-electronics.com
COMPUTERISED MAINTENANCE
MANAGEMENT
EQUIPMENT RENTAL/HIRE
Cayman Venture Ltd
www.cayman.co.uk
FSI (FM Solutions) Ltd
www.fsi.co.uk
Idhammar Systems
www.idhammarsystems.com
Qube Global - Planet FM
www.qubeglobal.com
Real Asset Management Plc
www.realassetmgt.co.uk
Service Works
www.swg.com
Shire Systems Ltd
www.shiresystems.co.uk
SoftSols (EMEA) Ltd
www.softsolsgroup.com
Tempus MTAS Ltd
www.mtas.co.uk
GEAR BOX REPAIRS
Direct Instrument Hire
www.instrument-hire.co.uk
Inspectahire Instrument Co Ltd
www.inspectahire.com
EVENTS
easyFairs® MAINTEC 2009
(17-19 March 2009, Birmingham)
www.easyfairs.com/maintecuk
Maintenance North West
Conference, Exhibition,
Workshops, Seminars
2 June 2009
www.maintenanceonline.co.uk
Railtex Exhibition
10-12 March 2009, London
www.railtex.co.uk
ATS Electro-Lube (UK) Ltd
www.ats-electro-lube.co.uk
Millers Oils Ltd
www.millersoils.co.uk
Shell Lubricants
www.shell.com
Sovereign Lubricants
www.sovereign-omega.co.uk
Wymark Ltd
www.wymark.co.uk
MACHINING & POWER PLANT
MAINTENANCE
RWE Power International
TSG Ferrybridge
www.tsg.rwepi.com
MAINTENANCE CONSULTANCY
Mainnovation
www.mainnovation.com
NOISE
Cirrus Research
www.cirrusresearch.co.uk
FLEXIBLE CABLES
Igus
www.igus.co.uk
For the Maintenance Forum, Maintenance Directory,
Courses and Maintenance books
Enter the relevant enquiry number at www.maintenanceonline.co.uk/ME for more information from advertisers
INDUSTRIAL SEARCH ENGINE
NOISE AND VIBRATION
INSTRUMENTATION
STRATEGIC MAINTENANCE &
ENGINEERING SERVICES
SKF Condition Monitoring Centre
www.skf.com/cm/microlog
J&P Group
www.jandpeng.co.uk
PUMPS
TEMPERATURE, SENSING &
MEASUREMENT
Hayward Tyler
www.haywardtyler.com
RELIABILITY AND MAINTENANCE
MANAGEMENT CONSULTANTS
Labfacility Ltd
www.labfacility.co.uk
THERMAL IMAGING SURVEYS
GE Energy
www.gepower.com/prod_serv/products/
oc/en/reliability_impl.htm
Thermaltec Ltd
www.thermaltec.co.uk
SENSORS
Flir Systems Ltd
www.flir.com
Fluke (UK) Ltd
www.fluke.com
Land Instruments International
www.landinst.com
Hansford Sensors Ltd
www.hansfordsensors.com
SPINDLE REPAIR/REPLACEMENT
Jena Rotary Technology Ltd
www.jena-tec.co.uk
THERMOGRAPHY
Metrum Information Storage Ltd
www.metrum.co.uk
Radir Infra-Red Systems
www.radir.com
Testo Ltd
www.testo.co.uk
Thermoteknix Systems Ltd
www.thermoteknix.com
UK Thermography Association
www.ukta.org
TRAINING
MCP Consulting & Training
www.mcpeurope.com
Oakley Services Ltd
www.oakley-services.co.uk
Reliability Maintenance Solutions
www.rms-training.com
For the Maintenance Forum, Maintenance Directory,
Courses and Maintenance books
ADVERTISING GIFTS
BLOWERS/COMPRESSORS
Blowers, Compressors
& Vacuum Boosters
Repair and Hire
SPECIALIST SERVICES DIRECTORY
TO ADVERTISE, CALL 01252 783111
AERZEN MACHINES LIMITED
+44 (0)208 502 8100
sales@aerzen.co.uk
www.aerzen.co.uk
ME Enquiry No.1006
AIR CONDITIONING HIRE
ASSET MANAGEMENT
BALANCING
ME Enquiry No.1720
ME Enquiry No.1020
Tell
advertisers
you saw
them in
AIRCON
Portable air conditioning
HIRE
THE ALL NEW
7.5KW AIRCON
OPERATES ON A
13 AMP SOCKET
www.watkinshire.co.uk
hire@watkinshire.co.uk
FREE
PHONE
0500 526696
ME Enquiry No.173
ME Enquiry No.172
Enter the relevant enquiry number at www.maintenanceonline.co.uk/ME for more information from advertisers
BOILER HIRE
BOILERS
BOOKS
CMMS
Call Darrell
or Meryl on
Qube Global Software - Planet Division
01252 783111
Tel:
Fax:
01932 334700
01932 355654
Email:
Web:
planet@qubeglobal.com
www.qubeglobal.com
Planet FM Enterprise from the Planet division of Qube Global
Software, provides a single, integrated alternative: a suite of
functionally rich modules that are tightly linked to deliver best-ofbreed functionality. The software suite addresses the full spectrum
of FM services, from property management and maintenance, to
consolidated help desks and state-of-the-art mobile solutions.
to advertise in
Flexible, responsive and easy to use, Planet FM Enterprise can be
easily tailored to suit specific business processes and working
practices and offers standard interfaces to link into financial and
procurement systems.
Planet FM Enterprise software provides a detailed, end-to-end view
of facilities management processes in real time and the flexibility to
adapt to organisational or operational changes of the future.
Planet has over 25 years of innovative CAFM
and CMMS solutions to over 700 customers.
To find out more visit:
www.qubeglobal.com
ME Enquiry No.181
BOILERS
ME Enquiry No.826
BOILERS
BOILERS
ME Enquiry No.1112
ME Enquiry No.1312
BOOKS
STEAM
CMMS
TM
Concept
Giving you the right
CMMS tool for the job
ConceptTM, includes:
Helpdesk Asset Management
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Property & Estates Management
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process automation
Digital Dashboard Etc.
Europes Leading Supplier
of
Steam boilers from
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Let us help change your world.
Tel: +44 (0)1708 251900 or visit
www.fsi.co.uk
ME Enquiry No.177
ME Enquiry No.1158
ME Enquiry No.185
BOILERS
CASES & FOAM PACKAGING
CMMS
QFM – Advanced CMMS
Trailerised, Containerised &
Static Steam Boilers
MANUFACTURE
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• Industrial Steam &
70kw up to 3000kw
• Long Term &
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HEAT FOR HIRE
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water boiler rental
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email:sales@polyformes.co.uk
www.watkinshire.co.uk
CMMS
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10 000 organisations rely on
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(next day delivery)
ME Enquiry No.176
ME Enquiry No.188
• Service Contracts
• Boiler Operator
Tel: 01535 665225
Email: sales@byworth.co.uk
Web: www.byworth.co.uk
ME Enquiry No.848
Contact: Stella Knights T: 020 8780 6222
info@swg.com www.swg.com
ME Enquiry No. 1313
OPERATIONAL
OPERATIONAL
SUPPORT
SUPPORT
Training
Beaumont Hire Limited
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Romsey, Hants SO51 7JF
Tel: 01794 522266 Fax: 01794 522007
Email: hire@beaumonthire.co.uk
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Tool control
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Tel:01525 852444
BOILER HIRE
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Heating boilers from
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Full
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Latest technology
Why pay more?
Call 023 8022 4111 now for your
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hire@watkinshire.co.uk
FREE
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ME Enquiry No.243
shiresystems.co.uk
ME Enquiry No.183
ME Enquiry No.189
Enter the relevant enquiry number at www.maintenanceonline.co.uk/ME for more information from advertisers
CMMS
CONDITION MONITORING
DRUM HEATERS
Make complex
stuff simple.
AVAILABLE FROM STOCK
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Affordable and easy to use
maintenance software
• Browser-based
• Fresh innovative design
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It’s maintenance. Managed.
TEL: 01799 523177
FAX: 0199 513714
sales@holroydcomponents.com
www.holroydcomponents.com
To discover more agile maintenance management
visit www.getagility.com or call 01924 200344
www.drum
ME Enquiry No.190
CONDITION MONITORING
Tell
advertisers
you saw
them in
ME Enquiry No.196
CONDITION MONITORING
FLEXIBLE CABLES
Ask us about our money
back guarantee
igus® (UK) Limited
51A Caswell Road
Brackmills Ind. Estate
Northampton
NN4 7PW
eatersuk.com
ME Enquiry No.200
Phone 01604-677240
Fax 01604-677242
sales_uk@igus.co.uk
ME Enquiry No.1445
DRUM HEATERS
ELECTRICAL TESTING
FLUID POWER TRAINING
Electrical
Distribution
Information
System
Breaking the law?
ME Enquiry No.1007
ME Enquiry No.201
CONDITION MONITORING
DRY ICE CLEANING
Pioneering technology giving you
fast & effective Condition Monitoring
– affordable, field proven, rugged & compact
What more do you
need from a CM tool!
IceTech UK machines
ideal for bearings, pumps, fans, motors,
gearboxes, mixers and other
rotating equipment
down to 0.25rpm
find the PROBLEMS
before they
find YOU!
01629 822060
www.holroyd-instruments.com
ME Enquiry No.1014
ME Enquiry No.197
CONDITION MONITORING CONSULTANTS
Electrical Distribution Information System
You certainly could be if you
are responsible for a
commercial building and
there is an accident and you
don’t have a current
electrical test certificate!
Fact 1
UK law requires that the electrical
infrastructure in all commercial
buildings is tested in accordance with
National Standards & BS7671
Fact 2
Faulty electrical wiring causes more
accidental fires in the UK each year
than anything else
EDIS is the only online
enterprise system designed
specifically to help you
manage your electrical test
certificates and make them
available at a moments
notice.
Tel: 01909 504 709
Fax: 01909 504 774
e-mail: enquiries@nfpc.co.uk
www.nfpc.co.uk
ME Enquiry No.207
GUTTER LINING
BENEFITS
1 EDIS saves unnecessary testing
& saves you money year on year
2 EDIS stores your test certificates
and makes them instantly available
3 EDIS ensures that electrical
contractors always follow approved
procedures
4 EDIS is environmentally friendly
saves wasting tons of paper
and,
5 if used properly, EDIS will help
to save you from prosecution in
the event of a serious accident
Tel: 0114 243 0555
www.icetech.dk
For more details visit
www.electricalcertificates.co.uk
and log in as a guest or email
info@cobweb-is.co.uk
ME Enquiry No.202
ME Enquiry No.1023
ME Enquiry No.1009
DUST CONTROL
EQUIPMENT RENTAL/HIRE
HEALTH & SAFETY
THE COMPLETE EX
EQUIPMENT INSPECTION
& ASSET MANAGEMENT
SERVICE
Dust extraction
Manufacture
Installation
Service
Nordfab clipped
ducting
to advertise in
Industrial Hydraulics Maintenance
Mobile Hydraulics
Power Pneumatics and Control
Hydraulic System Design
Pumps and Pump Control Systems
Hydraulic Trouble Shooting
Contamination Management and Oil Analysis
Bespoke Courses – Plant Specific and On-Site
CETOP BFPA - Industry Standard Qualifications
Electrical/Electronic Control
Siemens STEP 7
Electro-hydraulics
EDIS meets the data
recording requirements of
BS7671 and is designed for
large or small estates and
can be used to manage
many thousands of
distribution boards
Call Darrell
or Meryl on
01252 783111
THE UK’S PREMIER CENTRE FOR TRAINING AND
EDUCATION IN HYDRAULICS, PNEUMATICS AND
ASSOCIATED ELECTRONIC CONTROL. (TRAINING
COLLEGE FOR THE FLUID POWER INDUSTRY)
BEST EQUIPPED CENTRE IN THE UK. SUPPORTED BY
THE BFPA and MAJOR INTERNATIONAL COMPANIES
ISO 9001 APPROVED
PRACTICAL HANDS ON COURSES inc. short courses/
modules
s!4%X/DSEAR Compliance Strategy
(Mechanical/Electrical Equipment)
sEx Maintenance Strategy
s)NDEPENDENT%X!UDITS(EALTH#HECKS
s2ISK!SSESSMENTS(!:!REA2EVIEWS
01224 595 353
WWWICMUKCOM
%MAILPETER
T: 01132 739400
www.danthermfiltration.co.uk
ME Enquiry No.199
ME Enquiry No.996
ICMUKCOM
231A Union Street, Aberdeen AB11 6BQ
ME Enquiry No.1443
ME Enquiry No.209
Enter the relevant enquiry number at www.maintenanceonline.co.uk/ME for more information from advertisers
HEALTH & SAFETY
LIMESCALE PREVENTION
Call Darrell
or Meryl on
NOISE CONTROL
Servais Silencers
409 Harlestone Road,
Northampton NN5 6PB.
Manufacturers of industrial
and marine silencers and
exhaust systems for diesel
engines, spark arrestors,
flame traps, air silencers,
vent silencers, air filters,
exhaust pipework and
flanges etc.
01252 783111
to advertise in
EXHIBITION
17-19 March 2009
NEC BIRMINGHAM
easyFairs®
MAINTEC
Contact: J.N. Green
Tel: 01604 754888
Fax: 01604 759548
www.servais.co.uk
ME Enquiry No.244
INDUSTRIAL DOORS
INTERNAL VISUAL INSPECTION
ME Enquiry No.1015
ME Enquiry No.218
LUBRICATION
PIPEWORK
FULL RANGE OF SELF-CONTAINED
AUTOMATIC LUBRICATORS
CHOICE of the correct size from 125-250-475cc units.
CHOICE of the lubricator with the following as
standard:
• Adjustable operation from 1 to 12 months
• Intrinsic Safety Certificate (EEx)
• Blipping monitoring light
• Visual lube level indication
CHOICE of dealing with the company who provide:
• Refill service for used units
• Site surveys and application advice
• Bering back pressure tests
• After sales service UK wide
• Free Exchange Schedule planner
A.T.S. Electro-Lube (UK) Ltd
383L Jedburgh Court, Eleventh Avenue
Gateshead, Tyne & Wear
Tel: 0191 491 4212 ~ Fax: 0191 491 4224
ME Enquiry No.210
ME Enquiry No.1019
JOBS
LASER ALIGNMENT
ME Enquiry No.1010
LUBRICATION
ME Enquiry No.220
PUMPS
More than just pumps
Looking for a
new job?
For hundreds of
maintenance and
engineering positions,
go to the
Recruitment page at
www.maintenanceonline.co.uk
for more details visit
www.dualpumps.co.uk
ME Enquiry No.245
ME Enquiry No.1446
ELECTRICAL
INSTRUMENT
TESTING
HIRE
LEAK DETECTION
LUBRICATION
INSPECTAHIRE
Find
hydraulics leaks fast
3 easy steps
1 add the UV fluorescent dye
INSTRUMENT
COMPANY LTD
for all your hire requirements:
•
•
•
•
•
•
•
Boroscopes
Video Endoscopes
CCTV Pipe Cameras
EExd CCTV
NDT Equipment
Thermographic Cameras
Surveys
www.inspectahire.com
enquiries@inspectahire.com
Tel: 01224 789 692
Fax: 01224 789462
ME Enquiry No.849
to the hydraulic oil/oil based
fluid
2 allow the dye and oil
combination to circulate
3 scan the machinery with a
UV/blue inspection lamp
call now
01256 460300
Guardian House
Stroudley Road
Basingstoke, Hampshire
RG24 8NL, Fax : 01256 462266
sales@advancedengineering.co.uk
ME Enquiry No.214
SPECIALIST LUBRICANT & SEAL SUPPLIERS
Oils
Greases
Additives
Automotive
Oil Analysis
Site Surveys
Condition Monitoring
Dispensing Equipment
O-Rings
Flat Gaskets
Rotary Seals
Hydraulic Seals
Sealing Systems
Pneumatic Seals
Mechanical Seals
Engineering Plastic Parts
Special Parts Made To Order
ME Enquiry No.1011
Tell
advertisers
you saw
them in
The UK's most
comprehensive event
for the maintenance
& asset management
industry just got bigger!
Following a successful
event in March, visitor
numbers increased by
10% and exhibitors were
delighted with the quality
of buyers that attended.
“This was our second
year at easyFairs® MAINTEC
and we have done
exceptionally well. Not only
have we received lots of
enquiries, we’ve also made
sales here, so the show has
already paid for itself.”
Stephen Mottershead, MD,
AV Technology
Space for 2009
is selling out fast.
Book your stand
today, call
Joao Costa on
020 8622 4467
T: 01484 718674 - F: 01484 400164
W: www.sovereign-omega.co.uk
E: sales@sovereign-omega.co.uk
ME Enquiry No.1447
ME Enquiry No.205
Enter the relevant enquiry number at www.maintenanceonline.co.uk/ME for more information from advertisers
Service,
repair, testing
and spares for
to advertise in
electric motors,
pumps and turbines
Free Training offer
ti@radir.com
01252 783111
Radir
Call Darrell
or Meryl on
.com
THERMAL IMAGING
Fluke Thermal Imager
Raytek IR guns/sensors
PUMPS
Hayward Tyler Services
Call now: 01582 731144
Visit: www.haywardtyler.com
01908 370000
ME Enquiry No.1444
ME Enquiry No.1311
RISK ASSESSMENT
TEMPERATURE MEASUREMENT
THERMOGRAPHIC TRAINING
THERMOGRAPHIC SURVEYS
TRAINING
THERMALTEC
thermographic surveys
Specialist thermographic
surveys of:
n Electrical systems
n Mechanical systems
n Buildings
ITC Certified
Member of
n Furnaces
Bearing maintenance
and reliability
telephone: +44(0)1732 362385
mobile: 07920 772990
email: info@thermaltec.co.uk
web: www.thermaltec.co.uk
SKF Reliability Systems
01582 490049
marketing.uk@skf.com
www.skf.com/cm/microlog
www.skf.co.uk
UKTA, BINDT, IET
ME Enquiry No.1022
TORQUE CONTROL
Proactive reliability
maintenance
Condition monitoring
ME Enquiry No.246
TRAINING
Technical Training
Solutions
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ME Enquiry No.221
ME Enquiry No.223
RECRUITMENT
TEMPERATURE SENSING
Looking for a
ME Enquiry No.824
www.labfacility.co.uk
new job?
For hundreds of
maintenance and
engineering positions,
go to the
Recruitment page at
thermocouple
cables
thermocouple
connectors
temperature
instrumentation
test
instruments
Labfacility Limited
Bognor Regis
tel: +44 (0)1243 871280
Sheffield
tel: +44 (0)1909 569446
info@labfacility.co.uk
Supplying practical solution
training for your industry
Medical Training Services
Health & Safety Services
Technical Training Services
Operational Training and
Consultancy Services
t: 01256 698050
www.oakley-services.co.uk
Certificate No. 4746
THERMOGRAPHIC EQUIPMENT
Standard
or
custom design
Contact us for your
copy of the 2009
brochure
T: 01634 731470
E: tech.training@zen.co.uk
modern techniques … traditional values
technicaltrainingsolutions.co.uk
ME Enquiry No.1111
ME Enquiry No.825
Tell
advertisers
you saw
them in
SCISSOR
LIFTS
WATER TREATMENT
LEGIONNAIRES DISEASE
Helpline 0870 SAFE H20
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www.tecmach.co.uk
01727 860355
ME Enquiry No.1021
Providing Practical
Engineering
Skills Training For
Industry
oakley services uk ltd
ME Enquiry No.1017
SCISSOR LIFTS
TRAINING
os
Leaders in temperature measurement
Europe’s leading
manufacturer of industrial
temperature sensors &
thermocouple connectors
www.maintenanceonline.co.uk
TRAINING
ME Enquiry No.227
Electrical
Electronics Maintenance
Mechanical
Fluid power
Pneumatics
Motor drives
Instrumentation
Operator training
PLCs
17th edition
wiring regulations
ME Enquiry No.225
ME Enquiry No.1016
ME Enquiry No.820
Enter the relevant enquiry number at www.maintenanceonline.co.uk/ME for more information from advertisers
INDEX OF ADVERTISERS &
PRODUCT INFORMATION SERVICE
Tick the appropriate box(es) below if you (a) wish to receive product information from the advertisers in this issue
of Maintenance & Engineering or (b) wish to continue to receive your FREE copy, fill in your details below, sign,
date, photocopy and fax this page back to +44 (0)1252 783143
Advertiser/Product Review
씲 ABB
씲 Aerzen Machines
씲 Air Curtain Engineering
씲 Atlas Copco
씲 Atlet
씲 Anglia Composites
씲 Balcan Engineering
씲 Baldor
씲 Beaumont Hire
씲 Beko Technologies
씲 Bibby Scientific/Techne
씲 Byworth Boilers
씲 Casella
씲 Castle Group
씲 Cayman Venture
씲 Cirrus Research
씲 Controlled Flame Boilers
씲 Dixon Group Europe
씲 Dunphy Combustion Services
씲 Dura Composites
씲 Easi-dec
씲 easyFairs MAINTEC 2009
씲 Elga Process Water
씲 Emerson Process Management
씲 Empteezy
씲 Enersys Motive Power
씲 Eurovib Acoustic Products
씲 Exide Technologies
씲 Fluke
씲 Gardner Energy Management
씲 Gotec
씲 Grundfos
씲 Hansford Sensors
씲 Hanson Transmissions
씲 Igus
씲 Impac Infrared
씲 J&P Group
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Mr Mrs Miss Ms (delete as necessary) First Name:
Company:
Address:
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James Walker
Jena Rotary Technology
Klimate Doors
Konecranes
Land Instruments
LEM
Lista
Luhrfilter
M&A Engineering
Mitutoyo
Monitran
MTAS
Multi Contact
Mykal Industries
Nederman
Netherlocks bv
Nord-Lock
PCB Piezotronics
PCMS Engineering
Pola Flooring Services
Pruftechnik
PVL
Radir
Reepol Chemical Building Products
Reliability Maintenance Solutions
Schaeffler Group
Sensonics
Shire Systems
Siemens Automation & Drives
Smith Flow Control
Speedy Power
Techne/Bibby Scientific
Testo
Wellman Robey
Winn & Coales
Wymark
Zotefoams
Surname:
Post Code:
Tel
Email:
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THE UK’S LEADING EVENT FOR MAINTENANCE
AND ASSET MANAGEMENT
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In today’s tough economic climate maintaining
existing assets is vital in order to avoid major capital
investments!
That’s why easyFairs® MAINTEC is a must attend
event in 2009 for professionals involved in maintenance
& asset management, facilities management and of
course engineers, operations managers and plant
owners from across UK industry.
It’s YOUR opportunity to uncover the latest innovations
and maintenance technologies designed to improve
efficiency and asset performance.
rFYIJCJUPST Meet cutting-edge suppliers
of preventive / predictive maintenance solutions,
condition monitoring, thermography, plant
& environment safety and enterprise & asset
management.
rMFBSO4IPQT Attend free seminars and case
study presentations on topics including energy
& resource efficiency and value driven maintenance.
1-64/&8'03
r#SPBEFSFYIJCJUPSQSPàMF easyFairs® MAINTEC
will be a showcase for energy management solutions,
building services management, lubrication technology
and mechanical equipment.
Register NOW for FREE entry at www.easyFairs.com/maintecuk
Enquire using 1721 at www.maintenanceonline.co.uk/ME