uk manufacturing recovery continues the third quarter eef/bdo ‘manufacturing outlook’ report reveals that recovery, which began at the end of last year, has been sustained with output and orders balances reaching record levels for the second quarter in succession. this performance continues to be driven by the strength of overseas markets, with new analysis published by eef showing a close relationship between exposure to export markets and company performance. greater confidence across the sector is also continuing to translate into some recruitment, albeit this is being driven by temporary or agency working which will give employers flexibility should demand begin to slow. uncertainty about future demand had been dampening investment plans, but a number of sectors are now planning to increase in investment. the positive power & temperature rental t: 0845 838 1901 www.acclimatise.eu • air conditioning • air handling • boiler • chiller • generator • heating & cooling when it really matters. . . emissions report the cbi is urging the government to develop a clear strategy to reduce carbon emissions from heat, including encouraging the use of surplus industrial heat to warm homes. launching a new report at the cbi’s energy conference in london recently - the heat is on: delivering an integrated heat policy, the uk business group says cutting emissions from heat is crucial to meeting legally-binding carbon reduction targets by 2050 and mitigating rising energy costs. but the cbi warns that existing heat policy is fragmented and complex, and calls on the government to review the renewable heat incentive (rhi), which will subsidise homeowners and businesses that want to install low-carbon heat technologies. new equality act engineering firms are being urged to step up their efforts on gender equality in the workplace ahead of the new equality act coming into force in october 2010. the ukrc, the government’s lead organisation on gender equality in science, engineering and technology (set) and the built environment is calling for employers to pre-empt any further legislative changes and act now. upon its inception, the act will demand an even more proactive approach to be taken by public sector bodies in their own organisations and good practice on gender equality will become integral to their choice of engineering supplier. private sector suppliers can still be held accountable by their public sector funding bodies if they fail to adhere to the act’s new demands. issue number 345 september 2010 the industry’s voice since 1981 www.pwemag.co.uk investment intentions posted this quarter breaks the pattern of previous recessions by recovering at an earlier stage in the cycle. however, the short-term optimism highlighted by eef’s survey is shaded with a degree of caution about the risks to growth in 2011, as fiscal consolidation gets underway in the uk and others follow suit. commenting, eef chief economist, ms lee hopley, said: “manufacturers have continued to reap the rewards of growth in overseas markets with the upswing being felt across all sectors and regions. not only has this continued to translate into better employment prospects but the recovery in investment has begun much earlier in the cycle than after previous recessions. “however, we have to maintain perspective that the recovery is coming from a very low base and the risks to the economy in the medium term haven’t gone away. britain ‘s manufacturers are continuing to report buoyant trading conditions on the back of rising demand in overseas markets, pointing to good prospects for growth in 2010 according to a major survey published by eef, the manufacturers’ organisation and bdo llp. 6 official media partner of the institution of diagnostic engineers the institution of diagnostic engineers maintenance matters: andrew capella explains why regular maintenance and the safe handling of switchgear is essential. plus much more inside manufacturers have continued to reap the rewards of growth in overseas markets 10 maintain 2010 preview: from 12 – 14 october 2010, industry wide maintenance professionals will gather at the m,o,c, in munich for this year’s maintain 2010 exhibition. pwe reports. 9 01_pwe_0910_01_pwe_0910 20/09/2010 14:30 page 1the world‘s best selling reach truck with the lowest “total cost of ownership“ - always within your reach. for further information please call 0800 357 457 or visit www.jungheinrich.co.uk always within reach. 02_pwe_0910_02_pwe_0910 20/09/2010 13:58 page 1copyright 2009, dfa media ltd issn 0262-0227 plant and works engineering is published 11 times a year. the publisher reserves the right to service only those individuals who meet the publication terms of control. plant and works engineering is only offered to qualified readers whom reside within the boundaries of the united kingdom. paid subscriptions are available at 65.00 (uk) or 90.00 (overseas) pp included. reduced subscription rates available for bulk orders. all subscription correspondence should be directed to: the circulation department, dfa media limited, plant and works engineering, cape house, 60a priory road, tonbridge, kent tn9 2bl. please include the address label from a recent issue with all correspondence and allow up to three months for changes to be effective. the content of this magazine, website and newsletters do not necessarily express the views of the editor or publishers. the publishers accept no legal responsibility for loss arising from information in this publication. all rights reserved. no part of this publication may be produced or stored in a retrieval system without the written consent of the publishers. bcas official media partner editor: aaron blutstein tel: (01732) 370343 e-mail: editorial@dfamedia.co.uk advertisement manager: roberto tondina tel: (01732) 370348 e-mail: roberto@dfamedia.co.uk display sales executive: sarah galbraith tel: (01732) 370342 e-mail: sarahg@dfamedia.co.uk internal sales executive: alistair mckay tel: (01732) 370347 e-mail: alistair@dfamedia.co.uk product spotlight sales executive: leslah garland tel: (01732) 370340 e-mail: leslah@dfamedia.co.uk dfa direct sales manager: ewa fibakiewicz tel: (01732) 370340 e-mail: ewa@dfamedia.co.uk german sales office: victoria hufmann tel: 911 939 76442 e-mail: victoria@hufmann.info eastern us: karen c smith-kernc email: karenkcs@aol.com western us and canada: alan a kernc email: alankcs@aol.com tel: 1 717 397 7100 fax: 1 717 397 7800 production manager and designer: chris davis tel: (01732) 370340 e-mail: chris@dfamedia.co.uk reader/circulation enquiries: capsule publishing services ltd tel: 0845 602 7390 fax: 0845 604 2327 e-mail: circulation@capsule-group.com customer liaison: katherine cairns tel: (01732) 370340 e-mail:katherine@dfamedia.co.uk finance and credit control: clare jackson tel: (01732) 370340 e-mail: clare@dfamedia.co.uk sales director: ryan fuller tel: (01732) 370340 e-mail: ryan@dfamedia.co.uk publishing director: ian atkinson tel: (01732) 370340 e-mail: ian@dfamedia.co.uk published by dfa media limited, cape house 60a priory road tonbridge kent tn9 2bl tel: (01732) 370340 fax: (01732) 360034 info@dfamedia.co.uk www.pwemag.co.uk official supporters: printer: garnett dickinson, uk editor’s comment 3 the compressed air & generator exhibition 17-19 april 2012 nec birmingham www.airtech-expo.com to join the government in precisely that role. and on infrastructure investment, a key business priority ahead of next month’s comprehensive spending review, there are similarly wide disagreements between the coalition parties. 70% of liberal democrat mps surveyed want spending on infrastructure to rise or remain constant in real terms - a view strongly shared by business leaders - while only 27% of conservatives agree. commenting, david frost, director general of the british chambers of commerce, said: “while the coalition government has made important strides to improve the environment for business during its first few months in office, we are concerned about some of the gaps opening up between ministers and their parliamentary parties. “as vince cable’s business department conducts a major review of employment law, with the goal of making it easier for businesses to take on staff, it’s worrying to see that 71% of lib dem back-benchers seem to think that the current amount of red tape facing employers is acceptable.” at the time of going to press the liberal democrat party conference was convening in liverpool, but the lib dem’s conference will be a critical week for nick clegg and vince cable to re-state the importance of business growth to their party colleagues. the uk’s economic recovery depends on a stable government with the backing for policies that put enterprise growth first. t he uk economy is at a critical crossroad what with the forthcoming spending review only weeks to being published. so it makes it even more important that the government shows a unified stance to the public and business. however a recent survey of members of parliament suggest some divisions within the coalition on top business concerns. when it comes to helping companies create jobs and aiding the uk’s fragile economic recovery, the comres-conducted survey found clear discrepancies among mps from the two coalition parties. 87% of conservative mps surveyed felt that the balance of employment law had shifted too far towards the employee, to the detriment of the employer, while 71% of liberal democrats polled disagreed - a profound difference of view on an issue that businesses say is stopping them from taking on more staff. whereas 62% of conservatives were in favour of appointing a full-time trade minister to ‘bang the drum’ for british companies overseas, 50% of liberal democrats surveyed felt such a minister was not necessary - a result that makes interesting reading for hsbc chairman, stephen green, due divisions showing? aaron blutstein editor the industry’s voice since 1981 www.pwemag.co.uk the institution of diagnostic engineers september 2010 plant&worksengineering 03_pwe_0910_03_pwe_0910 20/09/2010 14:37 page 3series bd screw jack complete confidence inside. for further information call 44 (0)1484 465610, email radicon@davidbrown.com or visit www.davidbrown.com/seriesbd at david brown we have been devising efficient engineering solutions for over 150 years and the knowledge and expertise we’ve gained has given us a unique understanding of our customers’ needs. we know that it’s vital you have products you can rely on 100%, which is why we’re so proud of the benzlers series bd screw jack. its simple, compact yet remarkably robust design not only makes it easier to install and maintain, but incredibly effective even in the harshest environments. we can also draw on the experience we’ve gained from providing benzlers screw jacks for thousands of applications worldwide, to customise solutions to suit your specific business needs. to find out more about the only screw jacks backed by the unrivalled full maintenance and product support of david brown, visit our website below. www.davidbrown.com benzlers bd screw jacks 04_pwe_0910_04_pwe_0910 15/09/2010 16:02 page 15 september 2010 plant&worksengineering regular sections contents 1 news 3 comment 8 plant extra a round-up of what’s happening in british industry, including bcas’ monthly column. 9 maintain 2010 preview from 12 - 14 october 2010, industry wide maintenance professionals will gather at the m,o,c, in munich for maintain 2010. pwe reports. 10 maintenance matters - incorporating problem solver andrew capella explains why regular maintenance and the safe handling of switchgear is essential. 19 process, controls, & plant focus on: boilers & burners/ industrial cooling mike baker looks at the latest technologies and developments that have lead to the next generation of burners alongside the different burner types being used in industrial applications. 28 energy, the environment & water focus on: pollution control 29 production engineering 31 premises & facilities management focus on: flooring & roofing when designing a very narrow aisle (vna) system, it is not unusual for insufficient attention to be paid to the specification of the warehouse floor and this can have a dramatic impact on the overall performance of the equipment, says steve richmond, general manager of jungheinrich uk ltd’s systems & projects division. pwe reports. 35 handling & storage focus on: labelling & barcoding/ forklifts & ancillary equipment coding, marking and labelling have become an essential component of modern production technology. don braggins reports. 40 health, safety, & training the health and safety industry’s salvation is in helping small firms understand that health and safety is not just about compliance, but business success and a moral imperative, argues karen baxter. 41 appointments 46 product spotlights 52 classified 55 products & services directory 9 40 19 29 05_pwe_0910_05_pwe_0910 20/09/2010 14:36 page 3news 6 september 2010 plant&worksengineering 13-14 october health & safety 10 - north reebok stadium, bolton www.healthandsafetyevents. co.uk events planner uk manufacturing recovery continues 1 the rebound in exports and modest improvement in investment will need to become much more firmly entrenched if we are to see a much-needed rebalancing of the economy.” tom lawton, head of manufacturing, bdo llp, commented: “the sector has shown seen a significant upturn since the dark days of the recession and this quarter’s results show continued growth in output and orders and more expected for the next quarter, mostly driven by the restocking across most sectors of industry and exports. “this quarter results show more optimism around two key indicators which have been lagging behind the general good news of the sector in recent surveys, being employment and investment. this is excellent news but much more will be needed to enable manufacturing to compete in the space where we have a competitive advantage - innovation, research and development, excellent customer service and fast response to emerging trends.” over the last three months, output and new order balances were 33% and 35% respectively, both record levels since the survey began in 1995 which suggests growth in manufacturing output should at least continue into the next quarter. this growth has been driven largely by export markets (30%), where europe in particular turned out to be stronger than expected. while the domestic order balance weakened slightly, the balance of 20% is still above its long term average. furthermore, growth continued to be broad based across all regions and sectors. the survey was also notable for two other factors. firstly, the balance of companies recruiting almost doubled in the last three months to 17%, the strongest in the survey’s history. secondly, the investment balance turned positive to 7% for the first time since 2008 q2. compared with previous recessions, where investment balances have tended to lag behind increases in output by over a year, this is a somewhat faster recovery in capital expenditure intentions and signals that companies are becoming more confident to begin investing in plant and machinery. looking forward, expectations about future prospects remain positive, with a balance of 27% of companies expecting output to increase in the next three months, and 22% expecting orders to expand. both of these balances are higher than the previous quarter’s figures suggesting there is confidence that the recovery will continue into the next quarter at least. the technician council is chaired by national grid chief executive steve holliday freng and had its first meeting in july. the council was formed in response to the findings of a group, led by lord sainsbury, that included the gatsby charitable foundation, the engineering council, the science council, engineeringuk, the department of health, the royal academy of engineering, the national apprenticeship service, the uk commission for employment and skills and others to develop and secure the uk’s stem based sectors by encouraging the training, support, development and recognition of technicians. the further education team at bis is encouraging the technician council to provide a catalyst for the engineering science, ict and health communities in their work to provide opportunities for progression for people in vocational occupations, and upskilling the workforce. technician council chair steve holliday freng said: “as the chief executive of national grid i am only too aware of how important technicians are to the success of our business. i am delighted to have been asked to chair the technician council. i look forward to working with other key stakeholders to build a framework for a modern class of technician to ensure that this critical role in the workplace is more widely recognised and respected. “i am particularly keen to ensure that young people have a better understanding of what technicians do and the rewards that training to be one brings them.” the call comes on the back of a recent liberal democrat voice poll* which revealed 68% of lib dem members back nuclear as part of the uk’s energy mix. m&c energy group’s energy analyst, david hunter, commented: “chris huhne’s historic opposition to nuclear is well-documented, however it seems that grass roots lib dem members are falling in line with wider public support for nuclear.” in the poll, more than a quarter of respondents even went so far as giving the green light to public subsidy to kick-start the much-needed nuclear new build. m&c, which has been calling for ‘immediate action’ to secure the uk’s energy future, believes that huhne must now put aside his own personal objection to nuclear and take necessary action. hunter added: “the challenge is gargantuan and the secretary of state for energy and climate change must now take the lead to stimulate nuclear new build. ofgem, the industry regulator, estimates that 200 billion of investment needs to be found in the next decade to secure britain’s energy future. if getting the ‘green light’ by members gives huhne permission to press ahead then he needs to do so and fast or the uk will fall further behind in the race to light and heat britain.” * http://www.libdemvoice.org/ l d v - s u r v e y - 6 8 - o f - l i b - d e m -members-back-nuclear-as-party-of-uks-energy-mix-20894.html one of the uk’s largest purchasers of energy, has called on chris huhne to ‘listen to his party’ and get behind nuclear energy. nuclear gets lib dem supporters backing new technician council the royal academy of engineering is now hosting the new technician council, a joint initiative intended to raise the profile of technicians in the uk. it includes members of the engineering, science, ict and health communities and is funded by the department for business, innovation and skills (bis). the joint initiative is intended to raise the profile of technicians in the uk 06-07_pwe_0910_06-07_pwe_0910 20/09/2010 14:32 page 6news 7 september 2010 plant&worksengineering acquisition completed honeywell has completed its acquisition of sperian protection for approximately 1.4 billion. sperian protection is a leading provider of personal protective equipment (ppe), and will be combined within honeywell’s automation and control solutions’ life safety business. “sperian protection is an excellent fit for honeywell”, said mark s. levy, president and ceo of honeywell life safety. “with highly developed product lines, well-recognized brands and a strong global distribution channel, sperian complements and significantly strengthens honeywell’s position in the personal protective equipment segment. the addition of sperian will enable honeywell to further capitalise on the significant opportunities presented by this high-growth industry.” with nearly 50 years of experience in the research, design, and manufacture of safety technologies, sperian’s expertise is focused on head protection (eye and face, hearing, respiratory), body protection (clothing, gloves, safety footwear), and fall protection. sperian brands include howard leight, miller, and uvex (only in the americas) as well as sperian. headquartered in paris, france, sperian employs over 6000 in facilities throughout 13 countries in the americas, asia-pacific, europe, and africa. world news the forum of private business is hosting the questionnaire on behalf of the office of fair trading (oft) in an effort to find out how business owners are being treated by the major lenders. the move comes after new figures from the british bankers’ association, which show bank lending to businesses fell again last month, placed fresh scrutiny on the relationships between banks and smaller companies. the forum hopes as many small firms as possible will take part in the online survey in order to provide the oft with clear evidence of bank-related problems and difficulties facing business owners. the forum’s research manager, thomas parry, said: “clearly, the issue of the way banks treat small firms has received an enormous amount of attention recently and sparked a lot of debate.” the survey can be accessed via the shortened url: www.bit.ly/cpvvcf and should only take a few minutes to complete. a not-for-profit small business support group is urging firms to take part in a new survey to highlight their experiences of dealing with the banks. online banking survey jcb chairman sir anthony bamford (extreme right) pictured with jcb academy principal jim wade and students the uk’s first academy dedicated to engineering has welcomed its first 120 pupils - four years after the vision for the school was conceived. the year 10 students arrived for lessons at the new 22 million jcb academy in rocester, staffordshire where they will study a curriculum designed to produce the engineers and business leaders of the future. the jcb academy is the brainchild of sir anthony bamford who in his 35 years as chairman of jcb has championed the cause of british manufacturing and long voiced his concern over its decline and the dearth of young people with engineering skills emerging from the education system. he said: “i am passionate about engineering and committed to british manufacturing but we need the right calibre of young people to ensure that we continue to be a nation that makes things in an innovative way. “the jcb academy is one small step to helping achieve that aim. the facilities here are second-to-none and offer the students the opportunity to learn about manufacturing and engineering in a way that is exciting and practical and aligned to the needs of employers when they qualify in a few years time.” a total of 120 pupils from all over staffordshire and derbyshire arrived for lessons in a building that has a deep industrial heritage. while the idea for the jcb academy began life in the summer 2006 with a government feasibility study, it has been created in a grade ii listed arkwright mill dating from 1781 and has been equipped with in excess of 1million worth of modern engineering equipment which will help pupils turn their design ideas into reality. the equipment includes the only plasma cutter - a machine tool commonly used in industry - to be based in a uk school. the engineering tasks completed by pupils have been set by the jcb academy’s partners who include jcb, rolls royce, toyota, network rail, bentley, bombardier, rexroth bosch group, national grid, zytek automotive, the institution of mechanical engineers, iet, harper adams university college, the royal academy of engineering and parker vansco. they will complete their engineering tasks alongside maths, english, science and german gcses. so popular has demand for places at the jcb academy been, that it has been fully subscribed for months now. in addition to the year 10 pupils, a total of 50 sixth formers started their studies on september 13th. the jcb academy is the first school of its kind in the uk for the education of 14 to 19-year-olds with a core focus on engineering. like other state schools, the 22 million jcb academy is funded by the department for education, but as main sponsor jcb contributed 10% of the capital and donated the mill in which it is based. as well as delivering a world-class learning environment, the jcb academy is also designed to be highly energy efficient and it has installed an archimedes screw, which will generate around 80 % of the power for the site. rain water is also harvested for recycling. the emphasis on high technology is also evident in everyday life at the jcb academy as it will deploy finger recognition technology using biometric information, enabling pupils to register their daily attendance, pay for their lunch and even sign on to their laptops with the swipe of a finger. the jcb academy also boasts a 3d room where pupils don glasses and see 3d colour animations of the projects they are designing. every pupil will also get a laptop, which they are able to keep once they leave the academy. jcb academy principal jim wade said: “today has been long awaited and it’s very exciting to welcome pupils here after all the years and months of preparation. we have the very best of facilities here geared to educating our young people to a level that gives them the employability skills they - and british manufacturing - need when they leave. “today is only the start of the journey and already we are making plans to recruit the next intake of students and with demand so high for places we urge those wishing to apply to come to one of three special open evenings at the academy on either 5th, 7th or 13th october.” uk’s first dedicated engineering academy opens 06-07_pwe_0910_06-07_pwe_0910 20/09/2010 14:32 page 7plant extra 8 september 2010 plant&worksengineering ‘new’ machines directive for the compressed air and vacuum world little has changed technically since the introduction of the ‘new’ machines directive on the 29th december 2009 although there have been some administrative changes. one of the most significant has been the introduction of the term ‘partly completed machinery’ which has been introduced to clarify the previous situation on machinery for incorporation. whereas there was a need to produce a declaration of incorporation the contents were limited. the new requirement brings the declaration of incorporation on a par with the full declaration of conformity in respect of the information required. another useful item of note is contained in the various definitions of ‘machinery’. the definition recognises industry practice where machinery including compressor and vacuum pumps are supplied without the electric motor drive or supply disconnect/excess current devices. this is to accommodate the fact that the customer may wish to fit his own. where these are not supplied the manufacturer must supply instructions on the need for fitting them and sufficient information for this to be done safely. along with the introduction of the directive has been the publication of the long awaited eu guidance providing useful and much needed interpretation for the directive. useful as the interpretation is it is disappointing that the much promised electronic version turns out to be a pdf made up of the directive and the related interpretation in a breath taking four hundred and six (yes 406) pages! for further information please visit: www.bcas.org.uk bcas’ monthly column for the compressed air user rotary vane compressor manufacturer mattei has sponsored participants of a gruelling bike ride to raise money for the prostate cancer charity. andy jones, general manager of mattei, sponsored his former boss doug brooks to undertake the challenging bike ride from naples to milan in italy. the 1000km journey was completed in just over two weeks and so far doug has raised 1550. the charity is close to doug’s heart, having been diagnosed with the disease in 2009. he explains: “last year i was diagnosed with prostate cancer and through early detection, i was extremely lucky and able to have the cancer removed. to help other men be as fortunate as me, i decided to cycle the 1000km journey to raise money for the prostate cancer charity. considering i am 61 years old and hadn’t been close to a bicycle for 45 years, it was certainly an interesting two weeks.” general manager at mattei, andy jones, used to work with doug and was keen to sponsor him to raise money for the charity when he heard about the challenge. he explains: “doug is my former boss and we have always kept in touch, so when he told me about his charity bike ride, i was delighted to help. doug’s recovery is a great relief to his family and friends and i hope the money raised will go towards helping other men beat prostate cancer.” to make a donation towards doug’s fundraising for the prostate cancer charity, visit www.justgiving.com/doug-brooks compressor manufacturer sponsors charity bike ride hessian entrepreneur friedhelm loh, owner and chairman of the friedhelm loh group, has been honoured for his social commitment. at a ceremony in bad klosterlausnitz on 30th june, the german welfare organisation arbeiter-samariter-bund presented him with the samaritan cross in gold, its highest award. friedhelm loh is known not only as a successful entrepreneur, but also for his social commitment and generosity. the german welfare organisation arbeiter-samariter-bund (asb) has been a beneficiary of this generosity for many years, and has now thanked friedhelm loh with its highest award, the samaritan cross in gold. for almost 15 years, friedhelm loh has been supporting the asb holzland workshops in bad klosterlausnitz near gera, where 175 people with the most varied disabilities are today offered vocational training and employment. the donations made by friedhelm loh have helped the association to set up a new complex with workshops, two residential homes and a promotional welfare centre for the disabled. in addition, the workshops receive regular orders from member companies of the friedhelm loh group. the award was presented by asb national executive director wilhelm müller, in the presence of guests representing local and regional politics and the economy. in his laudation, he emphasised: “we need more people like friedhelm loh, who supports the work of the asb so selflessly and charitably.” friedhelm loh thanked the asb for the award, but went on to add: “i haven’t really done anything special to deserve it. i am just giving back what life has given me.” as an entrepreneur, too, friedhelm loh is very closely attached to the region. with neef, stahlo, rittal and eplan, four subsidiaries of the friedhelm loh group have facilities in gera and count around 240 employees. rittal also opened a new sales and logistics centre in gera in 2008. together with the group’s more than 10,500 employees worldwide, friedhelm loh makes considerable donations to social and charitable projects each year, for example in connection with a christmas fund-raising campaign. for further information please visit: www.rittal.com social generosity honoured wilhelm müller, national executive director of the arbeiter-samariter-bund (asb), presented the samaritan cross in gold to friedhelm loh (left), owner and chairman of the friedhelm loh group 08_pwe_0910_08_pwe_0910 20/09/2010 14:45 page 89 september 2010 plant&worksengineering maintain 2010 preview 2 010 is an important anniversary for maintain. the international trade fair is celebrating its fifth birthday. norbert bargmann, deputy ceo of messe münchen gmbh commented: “we have given the european maintenance industry a home. that is why we look back over the past five years with pride. after all, to some degree maintain can be credited with the fact that industrial maintenance is now recognized for what it is, i.e. as an independent, strong and future-oriented branch of industry. we are pleased for the chance to continue this journey with our exhibitors.” as a networking platform, this year’s maintain will play a key role in giving the industry new impetus. when it comes to trade fairs, generating business and cultivating new and existing contacts are just as important as a technically founded programme of related events. this year’s slogan, i.e. “invest in tomorrow today,” is a central theme that will run throughout the event. during the three-day exhibition, maintain will give participants a chance to participate in training courses, to make presentations and to exchange ideas and information with fellow industry professionals. a total of 160 companies from austria, belgium, china, croatia, france, germany, uk, korea, the netherlands and switzerland have already registered for the fair. once again, exhibitors will occupy all three exhibition halls and some 10,000m2 of exhibition space. maintain gives maintenance professionals a comprehensive look at the industry and its trends. however, exhibitors and visitors also appreciate maintain’s strong network character. gerhard gerritzen, deputy managing director at messe messe munchen gmbh, explains: “ maintain has a strong network character, which is why we also place special emphasis on the exchange of ideas and information within the industry. we have instituted a number of changes for this year’s fair. for example, for the first time ever this year’s fair will feature specially developed seminars and contact points in the halls for groups of international guests. the “makers & markets” programme of related events features technically founded presentations that will educate participants and spark lively discussions. a long standing tradition is the free bavarian mid-day snack, which has been inviting visitors to get to know one another and exchange ideas in an informal setting since the first maintain in 2005.” the fact that all presentations are being held at a central location in hall 3 is not the only thing about the makers & markets that is new. dividing the lectures up into various theme blocks such as methods and tools for maintenance management; maintenance, retrofitting and modernising or personnel leadership, personnel management and talent management give visitors access to a range of presentations that meet their needs and are easy to integrate into their visit to the fair. the compact range of events allows trade visitors to choose between direct examples of specific applications in the products sector and process oriented topics that apply to all companies. guided tours complete the programme of events at maintain 2010. specialists from fir (research institute for operations management at rwth aachen) will take users and other interested parties on a tour to the stands of exhibitors that sell cmms solutions. during the tours, software manufacturers will examine concrete problems and answer questions. the tours will be held on all three days of the fair, are free of charge for visitors, and will be available in english and german. for further information please visit: www.maintain-europe.com three days all about maintenance! from 12 - 14 october 2010, industry wide maintenance professionals will gather at the m,o,c, in munich to exchange information on the latest developments in the global maintenance sector. pwe reports. 09_pwe 0910_09_pwe_0910 20/09/2010 15:27 page 910 september 2010 plant&worksengineering maintenance matters o ne of the biggest issues in industry today is health and safety compliance. reducing risks and protecting employees and ultimately business is both a legal and moral requirement. research (the hse report 2009, electrical safety, a perspective based on incidents) shows that a significant proportion of low voltage switchgear incidents are caused by incorrect maintenance and poor management. compliance maybe perceived as a complicated process however the truth is that with correct operating procedures coupled with an intelligent approach to switchgear handling and maintenance, compliance can be achieved safely and cost effectively. the importance of compliance electricity-related incidents account for around 10% of all fatalities at work. non-fatal incidents account for less than one per cent of these. with statistics like this, health and safety compliance cannot be underestimated. however the health and safety executive believes that electricity related incidents are woefully under reported. procedural incidents account for around half of all cases reported, this may be down to a basic lack of knowledge on the part of the employee or an employer’s failure to provide suitable training in the use of the equipment. the occupational health and safety management system ohsas: 18001 requires evidence that operators of equipment have received correct training and are with the employee’s competency to perform tasks and assess risks. risk assessments are perhaps the key factors when dealing with compliance. taking a systematic and thorough approach will identify where electrical hazards are likely to occur and where danger is most prevalent. there should be a similar approach taken when it comes to using switchgear handling equipment. a full assessment should be made noting the correct procedures that the operator should employ when using the equipment. in accordance with the management of health and safety at work regulations 1999, risk assessments can only be carried out by a competent person with suitable skills, knowledge and experience. correct handling a thorough risk assessment involves choosing the right specialist lifting equipment to undertake the maintenance, repair and servicing of switchgear and acb’s. making sure that the right handling truck chosen is fit for purpose is not always easy, especially when it comes to replacing older manual lifting equipment. the issue of finding replacement parts is an increasing problem. most switchgear truck manufacturers have ceased trading, so it is important to find a truck and spare parts that are readily available. a few precautionary checks will help prolong the life of the truck and also ensure the safety of the user. lift chains should be checked for signs of broken or worn links and wheels should be checked for wear and tear. inspecting the truck for oil leaks and checking mast channels for signs of damage including worn or broken rollers is as important as is checking for fraying or damage to hydraulic hoses. legislation regarding the application of switchgear handling trucks is subject to the lifting operations and lifting equipment regulations 1998 (loler) which build on the provision and use of work equipment regulations 1998 switch on to switchgear maintenance the maintenance and handling of switchgear and air circuit breakers (acb) is not often considered a priority by electrical engineers. but, as with all electrical applications danger is never very far away. the statistics tell a similar story despite that few accidents are reported. wilmat limited’s andrew capella explains why regular maintenance and the safe handling of switchgear is essential. competent to use the machinery in the correct manner ensuring the safety of other colleagues and themselves. the regulations maintenance of switchgear is an integral part of compliance. the health and safety at work etc. act 1974 (hsw act) focuses on the employer’s responsibility for safety in the workplace and of course this includes maintenance. responsibility doesn’t just rest with the employer; the employee also has a duty of care to ensure that they work in a safe manner, which doesn’t put themselves or their colleagues in danger. there are regulations, which specifically cover the use of electrical equipment at work, how it is constructed, maintained and operated. further legislation deals legislation regarding the application of switchgear handling trucks is subject to the lifting operations and lifting equipment regulations 1998 (loler) a few precautionary checks will help prolong the life of the truck and also ensure the safety of the user 10-11_pwe_0910_10-11–pwe_0910 20/09/2010 16:02 page 1011 september 2010 plant&worksengineering maintenance matters (puwer). choosing the right switchgear truck to carry out maintenance safely and legally is important. maintenance is key low voltage switchgear is regarded as generally reliable equipment, however failures do occur and statistics show that poor maintenance accounts for around a third of incidents. performance of switchgear and acb applications can be affected by inadequate maintenance resources. by following a set of simple guidelines, effective maintenance and compliance can easily be achieved. some switchgear currently in use predates to the 1960’s and tends to function with a direct manually operated closing mechanism (dmo’s). the closure speed of dmo’s is entirely dependent on the speed of the operator. closing onto a full short circuit fault current could have serious, potentially fatal results. in this instance the fault affects not only the safety of the operator, but could also have consequences on the surrounding plant and buildings. it is recommended that by following a planned schedule and carrying out maintenance regularly, downtime, unexpected bills and accidents can be avoided. adopting such a policy, will ensure all switchgear and the handling equipment is not only operational but more importantly it is safe. the facts speak for themselves: low voltage switchgear accounts for nearly a quarter of all electrical incidents in the uk. it is fair to say that the majority of accidents and incidents involving switchgear are caused by poor maintenance, management and non-compliance. by adopting a sound approach to managing switchgear applications the risk to the workforce, equipment and business can be minimised. for further information please visit: www.switchgeartrucks.com simple switchgear maintenance tips visually inspect the external condition of the switchboard on a regular basis for foreign matter, dust and hot spots annually check, using infrared detection, for internal electric hot spots examine the main/arcing contracts for excessive burning/damage and recondition or renew as required inspect, adjust and lubricate mechanisms on withdrawable equipment examine the primary isolating contacts for damage, burning, corrosion and clean and refurbish where necessary check the lubrication of the circuit-breaker isolating mechanism check that the position indicators and interlocks work properly examine and check the voltage transformer if applicable plan for frequent trip-testing of the circuit-breakers via the protection relay system never work on live equipment. or when absolutely necessary, use properly insulated tools to prevent risk of flashover check operation and safety shutters carry out doctor, megger and secondary injection tests and record. wilmat limited’s andrew capella li i lli spminstrument.co.uk i intel l inova.se spm intellinova is a multifunctional system for online monitoring of machinery. with a focus on operatio-nal and cost efficiency, reliable condition information is delivered directly to the control room. condi t ion moni tor ing the intel l igent way v spm is celebrating 40 years and presents a new, sophisticated method for bearing control suitable for low-speed applica-tions. welcome to plant & works, 8-10 june, birmingham. 10-11_pwe_0910_10-11–pwe_0910 20/09/2010 16:13 page 1112 september 2010 plant&worksengineering it’s maintenance. managed. affordable and easy to use maintenance software to discover more agile maintenance management visit www.getagility.com or call 01924 200344 make complex stuff simple. • browser-based • fresh innovative design • completely configurable • simply great value reduce maintenance costs automate preventive maintenance improve asset reliability reduce breakdowns manage spare parts ensure regulatory compliance paper-free pda work orders maintenance matters when volvo was acquired by ford in 1999, it represented an opportunity to bring together the maintenance philosophies of the different organisations and also rationalise the operations of volvo’s five manufacturing sites across europe (four in sweden and one in belgium). the first step the volvo team took, working alongside mainnovation as a neutral partner, was to visit each manufacturing site in turn and to run workshops in order to identify what were the important issues that needed to be addressed. the workshops were structured around the value driven maintenance model, which enables those involved in the maintenance operation to identify which of the maintenance value drivers is most important to their operation. today’s maintenance managers are constantly balancing between higher machine availability (asset utilisation) and lower maintenance costs (cost control). in doing so, they must take into account safety, health and environment regulations. to make everything work, they need to use the right technicians, spare parts, knowledge and contractors (resource allocation). for volvo, at the time, global over-capacity in the automotive market was a major factor to consider and so, closer to home, was the introduction of new models at the different volvo plants. the economic climate, external factors and market conditions all have an impact on determining which is the dominant value driver at any point in time - and the vdm methodology helps guide the way. the market situation at that time meant that the most value for volvo could be achieved by controlling costs. so the right-hand value circle must be configured from maintenance budgeting to cost analysis. interestingly, both value circles include the competences of reliability engineering, planning and preparation and maintenance execution. these competences are the link between the four value drivers and thus form the heart of vdm. now that the important competences had been identified, the next step for volvo was to organize and control them in the right way. for this purpose vdm puts forward best practices from leading maintenance philosophies. for volvo the biggest change (across the five plants) was to get rid of diversity and to establish a common way of working where, for example, there was one way of ordering a spare part. part of this process involved installing some new ‘rules’ and making maintenance less complex. to ensure this common way of working a gatekeeper rule was put in place whereby all modifications coming from the production side and the maintenance side were overseen. the gatekeeper communicated all proposed changes to all parties (i.e. different shifts, different departments) for common agreement that could then be enacted. the result was a ‘blue box’ system where spare parts, work orders, permits, risk assessments were collected prior to a task being actioned, which has increased the efficiency of the technicians. bengt svensson, maintenance manager at volvo says of the factory in torslanda, sweden that: “the results speak for themselves. in 2003, the maintenance cost per car was sek 684 (62). in 2009, it was down to sek 344 (31) per car, a 50% reduction in cost representing a saving of sek 70 million (6.35 million) per year.” for more information please visit: www.mainnovation.com dawnfresh seafoods has selected mainsaver cmms (from spidex software) to manage engineering maintenance activities at its main production site in uddingston, lanarkshire. dawnfresh is the largest trout producer and the second largest supplier of frozen scampi in the uk, with a customer roster that includes most of the uk’s household name retail multiples. the company has a total of three manufacturing sites with a supply chain that includes 22 fish farms. the company’s 16-man maintenance department already had a legacy cmms in place, but were getting little in the way of useful information from it. the choice was to upgrade the existing system or replace it with a new one. brian stewart, maintenance manager at dawnfresh explains: “we knew the pitfalls we wished to avoid. the old system had never been properly implemented and was several versions out of date. it was difficult for our users to operate and as a result the system had largely fallen into disuse. to reinstate it would have meant starting again from scratch, so we looked elsewhere in the market. “mainsaver certainly looked the part when spidex software introduced us to it. it’s straightforward to use, with all the reporting functions we were looking for. it can be expanded as required and operated across multiple sites, which is ideal for us.” for further information please visit: www.spidex.co.uk cmms monitors fishy activities volvo finds value in maintenance bengt svensson, maintenance manager at volvo 12-14_pwe_0910_12-14–pwe_0910 20/09/2010 14:47 page 12we make it igus.co.uk/readychain igus readychain . complete system, rapid delivery. with guarantee. we’ll do all the work and deliver our ready-made energy chains to you within 3 to 10 days. ready to fit to your machine, direct from the igus factory! the benefits for you: increase cash flow. keep capacities flexible reduce processing time. reduce 30-100 orders to only one. eliminate on-site stock. worldwide service and guarantee! readychain – your chain is ready. e-chain systems within 3-10 days ... 3d-cad online ... for you! igus (uk) limited 51a caswell road brackmills ind. estate northampton nn4 7pw phone 01604-677240 fax 01604-677242 sales@igus.co.uk plastics for longer life youcanput a price on workplace safety and efficiency. it’s the cost of ahannay reel. you demand a productive workplace. one that’s as compliant with safety regulations as it is efficient. and hannay reels deliver. • protect hose and cables from unnecessary damage • rugged durability for lifetime value • get work done faster and more efficiently our dedicated dealers know your business and will get it right the first time. to find the best reels money can buy, contact your local hannay dealer: bridge engineering at (44) 845 4300401 or www.bridge-engineering.co.uk. www.hannay.com • 518-797-3791 made in u.s.a. plant & works engineering 86mm x 268mm june 2010 13_pwe_0910_13_pwe_0910 20/09/2010 16:47 page 114 september 2010 plant&worksengineering maintenance matters the greater the thermal sensitivity of a thermal imaging camera the more detail the thermographer can see. and the more he or she can see, the more accurate and comprehensive the inspection. for this reason flir has now upgraded its top-of-the-range plant maintenance cameras in line with its policy of continuous development. both the flir p660 and p640 are now able to detect temperature differences as small as 0.03c. and this equates to a thermal sensitivity of 30mk, a rating that is more common among infrared cameras used for research and development. with their 640 x 480 uncooled detectors these cameras are already high performers but this increase in specification takes them into a class of their own. these infrared cameras can now see the smallest anomaly in an electro-mechanical system, subsequently their value in preventing failure is now even greater. even relatively minor problems can now be seen easily on thermal images that are exceptionally sharp. furthermore, higher sensitivity means they can be used effectively at a greater distance away from the target, an important safety factor for those inspecting high voltage installations. flir has also recently announced that its iseries are the first to feature in a new publication entitled thermal imaging cameras for predictive maintenance. this catalogue highlights all the merits of these spot-check cameras and then introduces the reader to more sophisticated features of the flir t-series before summarising the advanced capabilities of the flir p-series. it is an effective guide to the upgrade path that users can take as they become more experienced in infrared inspection and it is available as a download from www.flir.com thermal sensitivity increased the flir p660 and p640 are now able to detect temperature differences as small as 0.03c a software package has been developed to help facilities managers reduce the cost of maintenance and increase the efficiency of assets. a major redbrick university has been running profasi to manage the facilities in 23 of its buildings for the last 12 months and has found a great increase in efficiency in controlling its asset maintenance. profasi is an online facilities management database, which gives all the information needed to ensure plant and electrical systems operate at maximum efficiency. “it covers maintenance schedules on both a planned and conditional basis - and, importantly, keeps a record of the work done”, explains barry neil, chairman, profasi-fm. the comprehensive asset database provides an independent and reasoned assessment of the remaining useful lifetime of plant, improving both replacement budgeting and financial reporting. this constant monitoring reduces the total hours needed for maintenance - and the probability of breakdown. also, by providing clear evidence as to whether each item of plant is operating to its design specification, profasi enhances the client’s position in warranty negotiations for replacements and extensions. profasi is suitable for any building or property over 1000m2, including hospitals, universities, and factories. it covers the complete range of plant, including ventilation and heating systems, data and communication wiring, security ad cctv systems and plumbing and drainage. “we do a survey of the property and record, photograph and barcode each piece of plant and then agree a maintenance plan with the facilities manager”, says mr neil. “everything is tailored to the exact requirements of the people using it - and all loaded into the database.” the data is loaded on handheld devices for engineers, who can access - and update - exactly the information they need for the specific unit/area they are working with. this ensures the database is always up to date and potential problems identified early. customers are billed either on the square metres of the building or per asset on a monthly fee. for further information please visit: www.profasi-fm.com increased asset efficiency quick, simple and accurate fluid power diagnostics parker hannifin, the global leader in motion and control technologies, has launched the latest addition to its proven range of diagnostic instruments for fluid power applications. designed to offer fast and accurate measuring and analysis, with an efficient and user-friendly interface, the new service master plus provides excellent operational convenience and simple handling with high capacity data storage to boost productivity and profitability. developed for use in preventative maintenance, commissioning, troubleshooting and machine optimisation programmes, the portable multifunction instrument monitors, analyses, displays and stores data relating to pressure, flow, temperature and rotational speed and can switch between them all with ease, in both hydraulic and pneumatic systems. the system is supplied complete with internal power pack and parker’s sensowin dpc software. this enables readings to be displayed in various formats including numerical, bar graph, pointer and curve graph, while project templates can be saved and loaded for easy interpretation. all data is displayed on a high definition, large format illuminated 5.7 inch colour display, with simple to use sealed membrane switch function and control keys, ergonomic design and a battery life of up to eight hours allowing the instrument to be used comfortably over extended periods of time. the service master plus also incorporates specially developed parker can bus sensors, with automatic sensor recognition, making it an easy to use plug and play system. additionally, can, lan and usb interfaces are provided, while data transfer can be performed using flash card, sd card or usb memory stick. the instrument is built to meet the requirements of ip64, and is housed within a rubber jacket with all terminals being protected by rubber covers to prevent the ingress of dust or moisture. for further information please visit: www.parker.com the new service master plus 12-14_pwe_0910_12-14–pwe_0910 20/09/2010 14:47 page 14register today! north ireland 14-15 june 2011 • national show centre, dublin scotland 15-16 september 2010 • royal highland centre, ingliston south 22-23 february 2011 • sandown park racecourse, esher, surrey regional health and safety events register today online at: healthandsafetyevents.co.uk free exhibition free seminars 13-14 october 2010 reebok stadium, bolton event partners official educational partner endorsed by 15_pwe_0910_15_pwe_0910 20/09/2010 15:29 page 116 september 2010 plant&worksengineering maintenance matters problem solver trouble shooter the answer to this month’s trouble shooter is provided by fulton ltd. q why is regular maintenance so important for my steam boiler? a in short, regular servicing and maintenance is essential to maintain the optimum operating efficiency and safety; and ensure long-term reliability. however, a key issue that is often overlooked is the consequences of a boiler not being available due to maintenance or breakdown. like any piece of equipment, steam boilers will be more reliable when serviced on a regular basis and fortunately a minimum level of annual maintenance is required due to the legal need to inspect a boiler every year. hopefully this opportunity will be used to undertake all service tasks, but it should be borne in mind that, depending on the level of use, a boiler may require more regular maintenance tasks. an easily overlooked yet important aspect of operating a steam boiler is the need to ensure good water quality. this, at minimum, requires a water softener and regular checks on its performance. just 1mm of scale inside a boiler will increase your fuel bill by 7-10% due to the poor thermal conductivity of scale deposits. unfortunately, scale will accumulate on the hottest parts of a boiler, so these parts will gain the thickest layer of scale, leading to localised overheating and permanent damage to the boiler. don’t fall into the trap of thinking that regular blowdown will remove scale either because it won’t. blowdown will discharge loose particles and sludge, but cannot detach scale from inside the boiler. of course, only servicing the boiler once a year may mean that scale accumulation will not be realised until it is too late. s kf has opened a new solution factory at its uk headquarters in luton. designed to unite the company’s key service and product offerings under a single banner, the new solution factory is part of a programme being rolled out globally with the aim of providing customers with an integrated suite of facilities to help them improve key business processes, while enhancing productivity and profitability. vartan vartanian, president of skf service division unveiled the new facility at an official ceremony, in front of 60 invited guests including customers, distributors and the press. the skf solution factory is based around existing engineering, project management and analytical services at its luton plant, supported as appropriate, by specialist production resources at the company’s manufacturing and technical centres around the world. in particular, the new facility brings together essential services, including asset efficiency optimisation, root cause failure and lubrication analysis, application engineering and spindle and large size bearing refurbishment, plus project, energy and sustainability management. attending the official opening, michael crean, director of skf service division uk, explained: “in the past, skf has been seen as a specialised manufacturer of high quality products, such as bearings, seals, lubrication systems, condition monitoring and linear motion devices. more recently, we have introduced a range of value added services that help engineers extend the performance and functionality of these products. in addition, we have steadily been developing the business tools, skills and infrastructure to enable us to work with customer organisations from the top down; for example, looking at how engineering or process assets can effectively be optimised to meet business goals. “the global skf solution factory programme is therefore a vital element in our long term strategy, as it repositions our business as a key provider of knowledge engineering to customers at all levels, from senior management though planning and purchasing to production and engineering. just as importantly, it enables us to partner with customers to develop unique solutions that deliver tangible commercial benefits from both existing and newly emerging technologies.” the first skf solution factory was opened in shanghai in 2008. since then a second solution factory has been set up in china and a further 10 in taiwan, india, south africa, sweden, germany, italy, brazil, usa and france. as part of the ongoing uk programme, the facility has been restructured, with continuous process and personnel development to strengthen still further the depth and range of services available for key distributors, oems and end users alike. michael crean concludes: “this is an exciting time for skf, and we hope for our customers, as the global economy gradually recovers. it has been a long and continuing journey for us to reach this point, where we now have in place the infrastructure to enable us to deliver the essential core services and facilities of the solution factory. in effect, the solution factory is a key phase in the repositioning of our business and in strengthening our knowledge engineering capabilities, so that we can partner with customers at all levels and help them realise genuine improvements in business productivity and profitability.” for further information please visit: www.skf.com solution factory launched the skf solution factory is based around existing engineering, project management and analytical services at its luton plant 16_pwe_0910_16_pwe_0910 20/09/2010 14:49 page 16thermal imaging surveys machine vibration condition monitoring new plant vibration condition report vibration analysis, consulting and defect analysis, diagnostics and troubleshooting building and demolition environmental vibration impact monitoring specialists in condition based monitoring providing cost effective and professional vibration monitoring and thermal imaging surveys vibration monitoring services limited tel : 01795 479805 or 07840 791587 e-mail : vmservicesltd@btinternet.com www.vibrationmonitoringservices.co.uk vibration and thermal imaging surveys dust and fume extraction hoses from masterflex temperature range -260c to 1100c size range 38 mm to 900 mm very flexible, small bend radius long service life, low operating costs suitable installation and connecting systems masterflex technical hoses ltd gb-oldham ol1 4er tel: 0161 626 8066 www.masterflex-uk.com tube protection pu / fabric hoses connections lvfkl og·vsod\ 44 (0)23 8022 4111 info@shiresystems.co.uk shiresystems.co.uk  free cmms seminar  free personalised demo  free full trial book now! shire cmms 17_pwe_0910_17_pwe_0910 20/09/2010 12:09 page 1byworth’s yorkshireman 2 is the most fuel efficient boiler of its type, achieved by unique x-id tubes, only from byworth boilers. the purchase price of steam boilers is on average only 1% of the lifetime running costs. call the byworth sales team to estimate how soon a yorkshireman2 could give your organisation payback. efficient if all boilers were this my future wouldn’t be adrift call the sales department to discuss your project: tel: 01535 665225 email: sales@byworth.co.uk all boilers 100% manufactured in the uk all boilers 100% manufactured in the uk 18_pwe_0910_18_pwe_0910 20/09/2010 16:33 page 119 september 2010 plant&worksengineering process, controls, & plant focus on: boilers & burners w ith the drive to specify and install renewable technology being at the forefront in recent years, it is sometimes easy to forget that we have to use fossil fuels for manufacturing process as well as space heating. therefore we still need the right combustion equipment to provide the required level of heat. recent developments in combustion technology mean that modern burners have a significant role to play in increasing efficiency and the reduction of carbon emissions. on the outside, the appearance of today’s burners don’t look very different to the earlier versions, but the technology used in modern burners has significantly changed and improved, resulting in a number of advantages for users. high performance with increased efficiency and low emissions are important considerations for those responsible for the specification of burner equipment for industrial and commercial use. as part of its commitment to reducing carbon emissions, the uk government has been highlighting the benefits of installing energy efficient equipment and encouraging the selection of such products across many differing sectors of industry with initiatives such as interest free loans from the carbon trust. for this reason, plant engineers, production and operations personnel will undoubtedly be aware that investing in the latest technology will not only give them reduced carbon emissions, but will also keep their operating costs to a minimum. to this end manufacturers have invested heavily in research and development to ensure they are always offering the best products and solutions for their customers. one of the key ways of reducing overall emissions is to install a low nox burner wherever possible. many leading burner manufacturers offer low nox as a standard feature alongside improved turn down and the minimisation of fuel to air imbalances within the burner. in addition, modulating controls are another important feature to lower carbon emissions by reducing the amount of times the burner has to recycle and fire up. these controls will also maximise demand matching, which will ensure the heat produced equals that required for space heating or the desired process. for increased precision in modulating control of the air and fuel usage, electronic burner programmers can also be fitted resulting in increased repeatability of the air to fuel ratio and giving a reduction in air levels and flue losses. where large applications are concerned, use of electronic burner programmers can offer the addition of oxygen trim controls. these allow for excess air levels to be continuously monitored and the feedback can also be used to adjust the air fuel ratio, enabling optimum combustion to be achieved at all times. in installations where an oil burner is being used, accurate modulation is still available through the use of modulating spill back valves. for maintenance and fault-the critical role of burners mike baker, business unit director for nu-way, looks at the latest technologies and developments that have lead to the next generation of burners alongside the different burner types being used in industrial applications. mike baker, business unit director for nu-way finding, electronic burner programmers offer additional advantages. the programmer will provide the engineer with a history of any previous faults and will also help to improve diagnostics, which is a key benefit when carrying out service. this enables any required repairs to be carried out more easily and quickly, which will prolong the life of the equipment while keeping any periods of downtime to a minimum. this is particularly important in a production situation where any periods of maintenance can be planned well in advance. when working with smaller burners, use of combustion fans, are increasingly incorporating speed control. alongside enhanced air damper design, the turn down will be improved and electrical energy consumption will be reduced. the increased turn down ratio will inevitably reduce the number of burner stops and starts, which in turn offers better operating efficiency. in addition to recent technology developments, the design of burners has been changed significantly over the years to offer further improvements. an example of this is altering the position of the burner head to assist fuel and air mixing at low fire, while also improving combustion efficiency. certain models allow the combustion head to be set during the commissioning process, while others provide automatic adjustment capabilities to position the head at different settings at low and high fire, resulting in optimisation of the combustion quality. there are a several types of burners, which have been designed specifically for industrial process use. these include nozzle-mix gas burners, such as nu-way’s energy stream, that provide an infinitely variable shape concept for in-duct heating with different models that can operate in a straight line or cross pattern. a 19-22_pwe_0910_19-22_pwe_0910 20/09/2010 14:51 page 1920 september 2010 plant&worksengineering process, controls, & plant wide variety of patterns to suit duct dimensions or application constraints can be designed to suit the individual requirements of the installation. industrialised packaged burner units, based on the mp and fmp burner ranges, work with varied fuels including light oil, dual fuel and commercial/process gases. they are usually very robust in construction and are particularly suitable for industrial applications such as ovens, incinerators and furnaces. recuperative gas burner systems offer the option of a self-recuperative burner or a separate recuperator and burner. such a system is designed to extract waste heat from the flue products from a medium to high temperature industrial process and use this to pre-heat the cold combustion air, thereby returning heat to the entire process resulting in lower fuel usage. recuperative systems are an excellent choice for old, existing furnaces, which require upgrading with new, more energy efficient equipment. looking towards the future of burner technology, it is likely that demand for even lower emissions will continue, specifically low nox. to achieve this, the requirement for further development of burner heads and air fuel mixing techniques and maybe variable adjustment heads will be necessary to facilitate even better air fuel mixing at all throughput levels. increased use of solid state micro processor control components will allow even more operational data to be collected and interrogated, thus resulting in lower costs and allowing for best practice such as oxygen trim to be utilised even on the smallest burners. this, together with the linking to modbus or ethernet communications, will simplify installation wiring and provide enhanced monitoring and preventative maintenance, again avoiding expensive downtime in production applications. it is anticipated that the market for small burners will diminish as the use of heat pumps increases, so research and development will be focused on larger burners for bigger commercial and industrial boilers. also the industrial process market will continue to need the higher temperatures available from fossil fuel burners, and these will also use this improved and enhanced technology. for those involved in manufacturing process as well as the industrial and commercial heating sector, the importance of utilising a burner with a higher efficiency should not be under estimated. the latest generation of burners clearly offer significant benefits when it comes to reducing costs. in addition, the need to be energy efficient and more ‘green’ cannot be avoided, and burners certainly have a role to play in addressing carbon emissions and making reductions wherever possible. for further information please visit: www.nu-way.co.uk “recuperative gas burner systems offer the option of a self-recuperative burner or a separate recuperator and burner.” 19-22_pwe_0910_19-22_pwe_0910 20/09/2010 14:51 page 2021 september 2010 plant&worksengineering boiler accessories flash vessels control valves tds probes and controllers safety valves bottom blowdown valves 01608 645755 vdohv#lvlvàxlgfrp zzzlvlvàxlgfrxn 7'6eorzgrzqdqg khdwuhfryhu\v\vwhpv process, controls, & plant within months of launching a series of energy saving products including the modsync boiler sequencing system and tds energy recovery system, fulton limited has demonstrated its ongoing commitment to research and development and the environment with the introduction of a new modulating burner. based on fulton’s existing on/off burner, the new modulating burner uses a linkageless burner management system to operate two modulating actuators. one actuator regulates the flow of gas and the other adjusts airflow to ensure that optimum combustion is possible across the full firing range of the boiler. to optimise combustion, each of the valves is capable of being adjusted by as little as 0.1º allowing small adjustments to be made to the burner output. gas flow into the burner is also controlled by two fuel valves, the first acting as a safety shut-off and the second being a constant pressure governor. burner output is also regulated via a pressure transducer and controller, which use a 4-20ma signal to modulate the burner output. the new modulating burner is available as an option on all gas fired vertical boilers in fulton’s range, including the j series and new vmp multi-por t tubeless steam boiler. it can also be retro-fitted to pre-installed boilers. initial results from a three month trial at cardiff university where two fulton 60j boilers are installed - one using a standard on/off burner the other a new modulating burner - indicate a significant reduction in gas consumption, with fur ther savings being made on electricity. thanks to the burners’ modulation, the boiler is also more efficient as the steam pressure is kept at a more consistent rate. for further information please visit: www.fulton.com new modulating burner fulton has demonstrated its ongoing commitment to research and development and the environment with the introduction of a new modulating burner 19-22_pwe_0910_19-22_pwe_0910 21/09/2010 09:35 page 21oven retrofit 22 september 2010 plant&worksengineering process, controls, & plant process gas burner specialists, lanemark international ltd. has now completed the installation of a second oven retrofit heating system at b g penny & co. ltd. - helping to contribute to the company’s growing success as powder coating subcontractors to a range of industries. the facility builds on a previous lanemark installation at the coventry site and is set to repeat the enhanced performance via high levels of control and reliability. as with the first project, this latest installation is centred on burner replacement on an existing ‘box oven’. however, this time it is on a significantly greater scale, as malcolm penny, works manager at b g penny explains: “the larger capacity second oven sits alongside the previous installation and, similarly, handles an overhead conveyor rail from which parts are suspended. it is the rapid heat up and highly accurate control that we now have with both lanemark systems that make such a significant contribution to maintaining our commitment to quality which is of particular relevance given the type of work which we undertake.” malcolm penny explains that the latest oven is closely linked to a powder coating process line and handles a variety of materials ranging in thickness from 1 mm to 15 cm. this extremely wide variation calls for precise temperature parameters to be specified and maintained depending upon the job in question. “the heating requirement can range from 50ºc to 220ºc and in some cases calls for a temperature variation of only /- 3ºc,” explains penny. “this target has been met every time to date, even with very temperature-sensitive products and, indeed, we have found on a number of occasions that the temperature has actually held within just 1ºc. moreover.” he adds: “heat up times of just 25 minutes to 190ºc help with process scheduling and throughput rates.” at the heart of the lanemark installation is the company’s fd15-c (ga), which synchronises gas and air mixture to ensure that no excess air is produced. in turn this minimises emissions and, at the same time, delivers heated air sufficiently clean to enable direct firing of the burner into the combustion chamber. the installation now means that all box ovens at the site are fitted with lanemark burners, which importantly, have been installed on a retrofit basis. this has allowed b g penny to enhance the effectiveness of existing facilities without the need to replace entire oven units. for further information please visit: www.lanemark.com etc has added a range of servo motors and peripheral devices to the etc6000 burner management family for use in atex zone 1 & zone 2 hazardous area. energy technology & control managing director, martin thirsk commented: “we are continually developing our product range in response to our customers’ needs. the development of peripheral equipment for use in atex controlled areas will allow our customers to meet the requirements of specifications where more expensive failsafe plc systems would previously have been required.” the etc6000 series of electronic burner controls is already the first choice burner management system for many leading burner makers. etc works closely with its customers to develop solutions for the ever evolving industrial and commercial burner markets. new fuels such as waste and biogases, the need to increase combustion efficiently to reduce harmful emissions and legislations such as the carbon reduction commitment, all create challenges that require innovative technological solutions. the etc6000 provides a flexible solution that can address most industrial burner applications and has regulatory approvals that includes ce, trd, ul, fm and aga. the etc6000 has also been assessed to en61580 (2001) and is suitable for inclusion in s.i.l.3 loops. for further information visit: www.energytechnologycontrol.com atex solutions the etc6000 provides a flexible solution the lanemark fd15-c (ga) burner 19-22_pwe_0910_19-22_pwe_0910 20/09/2010 14:53 page 22lanemark international limited lanemark house, whitacre road, nuneaton, warwickshire cv11 6bw united kingdom tel: 44 (0) 24 7635 7405 fax: 44 (0) 24 7634 1166 e-mail: info@lanemark.com www.lanemark.com how do you ensure that your process burner operation is efficient and reliable? your process gas burner system is crucial, so we think it needs looking after. that’s why we created burnercare. we just think it adds up – burner commissioning – on site start up service to ensure maximum efficiency. plus annual service agreements – planned maintenance, discounted service visits and cost effective spare parts pricing. plus 24/7 breakdown response – single visit solution for most emergency call outs. plus spare parts – comprehensive stockholding for virtually any process gas burner system. plus gas flow measurement – supply and installation of kromschroder gas flow meters. so whatever your question about process burner efficiency and reliability, we think total burner care from lanemark is the answer. 23_pwe_0910_23_pwe_0910 20/09/2010 11:38 page 124 september 2010 plant&worksengineering process, controls, & plant focus on: industrial cooling industrial cooling specialist, coolmation, has supplied jcb, with a new cooling system for its raft of new engine test cells in its jcb power systems plant in derbyshire. coolmation says when eu regulation, tier 4/ stage 4 non-road emissions limits, required reductions in engine emission levels, jcb decided to construct new test cells to ensure its engines met the new requirements. the latest investment sees the opening of one of the world’s most sophisticated engine test facilities. jcb power systems has built a new research & development centre that includes10 test cells. these test cells require very accurately controlled parameters to perform the development work required to meet future emissions legislation. since each test cell requires cooling in two areas at different temperatures, jcb’s brief for coolmation was to design a cooling system which would be installed in two phases and combining within each phase, air blast cooling and water chilling. general engine cooling is required where the fluid temperature needs to be cooled from 47oc to 30oc. combustion air-cooling is also required demanding fluid temperature to be cooled from 5oc to 2 oc with approximately 36kw needed per test cell. with the cooling capacities varying depending on the size of the engine being tested. coolmation had to make allowances for this to ensure precise test cell results. phase one of the cooling system was installed to meet the demands of the five initial test cells in 2009 and phase two for the following five test cells in 2010. coolmation’s initial cooling system incorporated two adiabatic coolers, one 440kw and one 800kw combined for the general engine cooling and a 180kwrhoss tcaey bt air cooled chiller for the combustion air cooling. the second phase of the project will require the same capacity of adiabatic and chilled water cooling as in phase one. coolmation’s decision to provide adiabatic air blast coolers for the engine cooling, rather than standard air blast coolers, was based on their requirement for cooling water temperatures closer to all year round wet bulb temperatures. the rhoss tcaey bt 4230 air cooled chillers were selected because the full load will eventually be spread across eight scroll compressors, four in each chiller, which will enhance load matching and energy consumption. their weight and footprint also suited the available space and reduced the cost of the load bearing steel structure. each of the tcaey chillers is also fitted with rhoss’s predictive control system, adaptive function plus, which can reduce the energy consumption of the chillers by as much as 18%, and deliver the close control of water leaving temperature required of this particular application, plus or minus 1ºc or 2c. pumps and buffer tanks were carefully selected by coolmation to maximise the performance and energy efficiency of the cooling and chilling plant and the pipework system, fully insulated on completion, is designed and installed to provide the required water flow rates at minimum pressure drop. the system control panels incorporate energy efficient staging of the cooling and chilled water capacity to ensure that energy is only being consumed in proportion to the amount of cooling and chilling required. stuart thompson, project manager at jcb power systems explains: “as a project manager the challenge of this project was delivering a world class technical facility by employing multiple specialist suppliers chosen for their expertise and product performance, instead of a turnkey solution from one supplier. however, this process was a success as the project benefited from individual industry experts, such as coolmation, that could offer a reliable precise solution to our brief.” steve warnock, managing director of coolmation commented: “coolmation is delighted to been involved in such a world-class research facility which will allow jcb to stay at the forefront of diesel engine technology. with our considerable knowledge of the requirements for industrial cooling systems and our expertise in the design and installation of them, we were able to offer exactly the right solution for the very precise needs of jcb’s test cells.” an intrinsic part of coolmation’s industrial cooling system, rhoss chillers are designed for high energy efficiency and reliability, manufactured to internationally recognised quality standards and tested to eurovent standards within the rhoss eurovent certified laboratory. they are available in the uk exclusively through coolmation. for further information visit: or visit www.coolmation.co.uk cooling system installed for new engine test cells 24-26_pwe_0910_24-26_pwe_0910 20/09/2010 15:03 page 24have you heard ... ics house, stephenson road calmore industrial estate totton, southampton so40 3ry t 44 (0)23 8052 7300 e info@icstemp.com www.icstemp.com ... about our new green cooling chiller range? our green cooling range brings the latest hydrocarbon technology to life. using propane r290, and propylene r1270 our green cooling range offers duties up to 650kw and temperatures from -30 o c to 20 o c. unsure what you need and how it would apply to your application? no problem. ics have local engineers nationwide who are experienced at engineering a solution to your requirement. we can also project manage any installation for complete peace of mind. call ics free on 0800 169 3861 or log on to www.icstemp.com. /rqgrq%ulvwro6rxwkdpswrq%luplqjkdp%odfnsrro%udgirug*odvjrz 25_pwe_0910_25_pwe_0910 20/09/2010 15:01 page 126 september 2010 plant&worksengineering process, controls, & plant following a series of cpd accredited presentations entitled “energy efficient refrigerants” to over 200 design engineers over a 9 month period ics has confirmed that its research and development on energy and natural refrigerants has been well received. this has culminated, with its manufacturing company tricool thermal developing its use of natural refrigerants and the launch of its first range of green cooling hydrocarbon chillers. the range provides a choice of ozone-friendly hydrocarbon refrigerants - propane, r290 and propylene, r1270. these are conditioning systems and a regulation addressing their use in stationary applications, the regulation will be reviewed in 2011, although there is a view that further applications may be included, thus following the progressive stance of denmark and austria”. the ‘green cooling’ range will be manufactured by tricool thermal at its uk manufacturing facility in southampton to iso 9001 standards. for further information please visit: www.icstemp.com the new spectracool range of industrial air conditioners from schroff has been designed to provide efficient cooling of electronic systems in a wide variety of indoor and outdoor applications. manufactured by mclean cooling technology, one of schroff’s sister companies within the pentair technical products group, the new air conditioner employs a rotary compressor to achieve an energy efficiency up to 50% higher than conventional designs. in addition, spectracool is rohs compliant and uses environmentally friendly r134a refrigerant. there are 12 standard models in the range, offering a choice of indoor or outdoor designs, with 115, 230 or 415 3-phase ac voltage ratings and nominal cooling capacities of either 2300 or 3500w. indoor models include an electric heater strip for active condensate management and a power-off relay for the door switch, while the outdoor models feature corrosion-resistant components, head pressure control and built-in heaters. all models use cleanable, reusable aluminium mesh filters for maximum cooling performance. spectracool’s galvanised sheet metal construction enables it to withstand both rugged factory and outdoor environments, and its ral 7035 light grey powder-coat painted finish matches that of schroff’s own range of 19in. equipment cabinets. for applications where stainless-steel enclosures are required, a type 4x option is also available. every spectracool air-conditioning unit is functionally tested prior to shipping and is supplied with mounting hardware, gaskets and user manual. for further information please visit www.schroff.co.uk high energy-efficiency cooling leaping towards a green future naturally produced and non toxic with a global warming potential (gwp) of less than 3. this ‘green cooling’ range is currently being manufactured in a range of duties 50-650kw, offering a wide temperature choice of -30oc to 20oc water leaving. commenting on the launch mike jones, director of ics said: “our ‘green cooling’ range is a very positive step in assisting designers with a natural alternative to hfcs. “the eu has passed a directive to phase out hfcs in mobile air the range provides a choice of ozone-friendly hydrocarbon refrigerants - propane, r290 and propylene, r1270 indoor models include an electric heater strip for active condensate management and a power-off relay for the door switch focus on: industrial cooling 24-26_pwe_0910_24-26_pwe_0910 20/09/2010 15:03 page 26“associations have a crucial role to play in promoting best practice, helping companies become more competitive and formulating effective policy and delivery. subsequently bcas is delighted to announce the launch of its official yearbook and members’ directory, published by dfa media ltd, to coincide with our 80th anniversary.we are confident that the new bcas yearbook will play a crucial role in promoting the benefits of membership of the british compressed air society to the industry.” chris dee – executive director – british compressed air society ltd for more information contact: chris dee: 0207 935 2464 promotions contact: ryan or roberto 01732 370340 published in association with plant & works engineering and hydraulics & pneumatics magazines 2010/11 official yearbook & members’ directory 80th anniversary edition 1930-2010 new edition www.bcas.org.uk 27_pwe_0910_27_pwe_0910 20/09/2010 16:57 page 1atex approved bund water control unit 28 september 2010 plant&worksengineering maintenance matters energy, the environment & water focus on: pollution control darcy spillcare manufacture has introduced a bund water control unit dewatering system into the marketplace that is completely intrinsically safe and atex approved. this product forms part of the wide range of technical products developed by the company to help prevent environmental liability, prosecution and negative publicity providing businesses with environmental peace of mind. bund water control units assist companies in meeting environmental regulations including iso 14001, ppg8: safe storage and disposal of used oils, ppg2: above ground oil storage tanks and the control of major accident hazards regulations 1999. a large fuel distribution company distributing throughout ireland was faced with the task of operating multiple sites from one central office. a common challenge this company encountered, says darcy, was the removal of the rainwater from the bund areas surrounding the tank farms. due to the high level of rainfall in ireland, these watertight bund areas would collect large volumes of rainwater reducing the bunds ability to contain at least 110% of the tank’s maximum capacity. removal of this rainwater proved to be costly especially as some sites are very remote requiring long distance travel for pump out companies. disposal rates were based on hazardous waste even though the majority of the content was rainwater thus increasing costs significantly. darcy spillcare manufacture was commissioned to supply six bund water control units at six of the most affected sites throughout ireland. the bund water control units had to be intrinsically safe (atex approved) for use in hazardous zones and fully integratable into the company’s existing operating system. six units were installed at various sites throughout ireland and have the capability to constantly monitor the rainwater collected within the bund, automatically pumping it out to the on-site interceptor as the levels rise. the system also has in-built oil detection technology that will shut down the pumping operation and send an alarm signal to an authorised person should there be a tank failure or spill of stored product. as a result of installing these bund water control units the company says it now has peace of mind that these remote depots are safer and meet environmental regulations. they no longer have to be faced with the prospect of pumping out and disposing of thousands of litres of rainwater at hazardous waste rates - this waste management cost saving alone is forecast to provide a company with a return on investment within six months of installation. they will also be alerted immediately should there be an unusually high amount of oil present within the bund area. the bund will also be constantly maintaining 110% of the tank’s capacity preventing the risk of a spill spread, which again should bring peace of mind for the company. for further information please visit: www.darcy.co.uk fernco environmental, which focuses on minimising the environmental impact within sewerage and drainage industries, has now completed phase one of a project for a leading aircraft manufacturer. using its ultracoat system it has rehabilitated three fuel interceptor tanks in the client’s bristol operation. two of the fuel interceptor tanks, which are used as holding tanks for the spillage of diesel oil and water, required a preventative coating, while the third, which was suffering from ongoing infiltration, needed a complete rehabilitation. originally built in 1948, some remedial work had been carried out to the structures over the years; but whether it was due to failure of a grp lining or leakage through smaller concrete repairs, the tanks had fallen into a cycle of disrepair. the ultracoat system is used for the rehabilitation and structural reinforcement of a wide range of substrates, leaving an exceptionally hard wearing, smooth and waterproof coating, with excellent chemical resistance - ideal for the aircraft manufacturer’s fuel interceptor tanks. ed fairfield, marketing manager at fernco environmental, commented: “we are extremely pleased our ultracoat system was chosen for a job of this nature. whether it’s for a small job like a manhole or a larger asset management project, ultracoat has a proven track record of delivering the right result; and this project is another fine example.” for further information visit: www.ferncoenvironmental.com complete rehabilitation complete before and after the job 28_pwe 0910_28_pwe_0910 20/09/2010 15:07 page 2829 september 2010 plant&worksengineering production engineering a unt bessie’s yorkshire puddings are manufactured to the tune of 6 million per day in addition to the production of a wide range of other products including stuffing balls, pancakes, biscuits, sponges, pies, and hot puddings. with her hair tied in an old-fashioned bun, aunt bessie seems to have been with us since we were kids, yet in reality the brand was only launched in 1995. today, with the resurgence of frozen food and ringing endorsements from celebrity chef, delia smith, the aunt bessie’s brand has a retail value in excess of 170 million (2008) and an annual growth rate of over 9%, compared to just the 1.1% average across the frozen food sector. aunt bessie believes the brand will reach 250 million in 2012 as consumer demand for traditional, additive free and high-quality convenient foods continues to grow. manufacturing for growth in 2004, tryton foods (as the company was previously known), embarked on a programme of continuous improvement, and set out to create a single change agenda as a core business process across all management levels. to drive the programme, aunt bessie’s decided to measure and use overall equipment effectiveness (oee) as the vehicle to identify losses and quantify improvements. the business motivation for the operational excellence programme included: survival of the fittest - combatting the rising cost of inputs and margin errosion due to retailer pressure. growth, driving the need for increased flexibility - adopting of new technologies to adapt to the increasing pace of innovation. driving a culture of change - breaking inertia and encouraging development. harnessing technology to support this programme, the idhammar oee system was installed across the hull operational sites for aunt bessie’s in-house manufacturing. stuart drysdale, manufacturing director at aunt bessie’s explains: “we chose the idhammar oee system for a number of reasons; firstly, it had a proven track record in the food industry and had many of the features we were looking for to support drill-down analysis, reporting and continuous improvement monitoring. moreover, despite its extensive functionality, the straight-forward user interface allows the system to be used by anyone in the plant and supports our culture of ownership and responsibility. idhammar’s oee system also has a complementary maintenance management system.” aunt bessie’s approach there is a firm belief at aunt bessie’s that maintenance has to be a part of any production improvement programme. idhammar’s cmms software provides coordinated maintenance schedules, controls spares and stock levels and records critical jobs and materials requirements. the system supports aunt bessie’s predictive maintenance programmes, reducing unplanned stoppages and ensuring labour and materials are used more effectively. integrated tpm and oee initiatives thus underpin the key elements of the operational excellence programme: consistent use of process data using oee to report, review, act tpm single-point lessons (short training documents) for each specific topic establish clear priorities driven by the major losses identified by oee use teams to establish new processes and standards and pilot before roll-out the proof of the pudding... the following chart shows actual oee performance improvements across a range of production lines between august 2006 and august 2007. aunt bessie’s has calculated that 1% of oee improvement across every line is wor th around 150,000 of savings per year: beyond an oee score one of the rules at aunt bessie’s is to convert losses to cash in order to make them visible. in the same way, they are able to measure the profitability improvements gained by each percentage improvement in oee. as drysdale concludes: “using oee as part of our operational excellence programme is far more than a theoretical exercise. the intelligent functionality of the oee system highlights losses, drives our improvement agenda and leads to improved effectiveness, a better working environment and savings to the bottom line. our minimum improvement last year was 14% and our best was 47%, so the system paid for itself in a couple of months.” aunt bessie’s is already considering the use of automated data entry to provide real-time manufacturing per formance updates and suppor t faster decision making; however, for now the combination of lean, tpm, and oee is clearly delivering impressive results. for further information please visit: www.idhammarsystems.com investing in innovation looking at the brand logo you might think that the sturdy figure of aunt bessie suggests a liking for her own yorkshire puddings. yet aunt bessie’s takes the concept of lean much more seriously for her manufacturing processes. pwe reports. line increase in oee over 12 months sasib1 38% sasib2 22% sasib3 24% gyro1 14% gyro2 28% pie line 37% ishida 47% 29_pwe_0910_29_pwe_0910 20/09/2010 15:09 page 29yíllyïãyít close to you! ßßßyyìøìlaæá ïøã 0lïíyïíacíyãlï 0læãæíßïíaíïßæïw -íãlææøãlíælæãí2íïllãaïøãlí ælæãíací9íþoãaïíælæã 2ßæïíïlíælïïíãíïíïlíclæãlcí æßïyïííßlãíllclcí 2ßæïíïlíyíãííoícl 30_pwe_0910_30_pwe_0910 20/09/2010 15:58 page 1plant extra 31 september 2010 plant&worksengineering premises & facilities management focus on: flooring & roofing i f a very narrow aisle (vna) storage system is failing to reach optimum levels of efficiency the user’s first reaction is, generally, to assume that the trucks are underperforming. in most instances, however, this is not the case: more often than not the fault does not lie with the equipment but the surface it is operating on. “the floor is the point at which the warehouse building and the truck interact and quite simply, a poor floor will result in poor vna performance”, says steve richmond, general manager of jungheinrich uk ltd’s systems & projects division. steve richmond believes that the design, specification and final finish of the warehouse floor is absolutely critical to the optimised operation of vna trucks. and, he contends, with truck manufacturers pushing the physical design of the equipment close to maximum efficiency, the performance of the floor will come under ever greater scrutiny. he says: “you can invest in the best forklift trucks and materials handling equipment on the market, but if your warehouse floor resembles a ploughed field, the trucks will never be able to operate at their top speeds or optimum efficiency - think of it as driving a ferrari down a cobbled street,” whether faced with a new building where the floor has been laid to a particular specification or an existing site that is to be modified to accommodate a vna application, a warehouse’s floor will present different challenges - although, generally, most problems occur within older buildings. when installing vna systems, the responsibility for specifying the level of the floor finish required lies with the truck manufacturer and there are accepted industry standards that lay down the specification, which the flooring should meet. the responsibility for achieving this specification lies with the flooring contractor. the relationship between the flooring contractor and the materials handling supplier is therefore critical and so, to ensure that everyone is working towards the same goal, a floor survey is always highly recommended. the survey will highlight any remedial works that might be required - as well as the extent of the works and should be used as a basis for all parties to assess the condition of the surface and its likely impact on the operation of vna equipment. from the outset, it is important to realise that floor flatness and floor level are two different things and their respective effects on the operation of a truck are totally different. according to tr34, the technical report from the concrete society, flatness relates to the “bumpiness” of the floor and general stability in operation of the truck. floor level relates to the building as a whole and has to be right to ensure that both static and mobile equipment can perform satisfactorily together. richmond comments: “effects from the floor, can cause trucks to move from side to side or in a front to back ‘nodding’ motion as they travel along the length of the aisle. in some scenarios the movement of the trucks may be so significant that there is a potential for them to come into contact with the rack structure.” he adds: “meanwhile even relatively small differences in the floor level within a racking aisle can have a significant impact when the truck is operating at heights often in excess of 15 metres. the higher the mast height, the more pronounced the ‘lean’ from uneven floors and the greater the potential problem.” while it is clear that there a number of important factors to be taken into account in this area, the good news is that anyone considering a vna system should not be put off by the condition of their warehouse floor: in most cases, solutions are available to ensure that the floor can be made fit for purpose, as richmond explains: “options include full aisle grinding, or local grinding where problematic areas are easy to identify. but, it is crucial that you engage a company that is competent in all aspects of the solution - from the initial survey to implementing the works.” of course, just as the floor impacts on the capabilities of the truck, the truck will impact on the condition of the floor. in new buildings cracks often appear in the floor as a result of natural shrinkage of the concrete during very narrow aisle (vna) systems can significantly improve efficiencies and productivity within any warehouse or distribution centre operation. however, when designing a vna system, it is not unusual for insufficient attention to be paid to the specification of the warehouse floor and this can have a dramatic impact on the overall performance of the equipment, says steve richmond, general manager of jungheinrich uk ltd’s systems & projects division. pwe reports. surface treatment steve richmond, general manager of jungheinrich uk ltd’s systems & projects division 31-32_pwe_0910_28_pwe_0810 20/09/2010 15:17 page 3132 september 2010 plant&worksengineering premises & facilities management focus on: flooring & roofing the drying out process. however these cracks will worsen over time as heavy trucks run over them. in addition, the location of floor joints can effect the operation - although in new buildings these can often be designed into the system if the truck manufacturer is consulted at an early enough stage in the process. needless to say, as a floor deteriorates, the performance of the materials handling equipment working on it may also suffer. “because the floor forms the platform for the materials handling operation and is, therefore, critical to the smooth running of the process, it is often difficult to understand why floor maintenance is sometimes overlooked within a warehouse”, says richmond. richmond continues: “some warehouse operators specify a coating for their floors. a wide variety of products are available so choosing the coating that’s right for your facility can be difficult. apart from cosmetically enhancing a store, a floor coating will - to a degree - prevent dust build-up. but coated floors can also bring about a build up of static, which can, in turn, lead to forklift problems - especially with electrical and electronic components. there are a number of ways to combat this effect, such as fitting ‘anti static’ discharge devices to the trucks, but it is always advisable to discuss all aspects of the floor with the truck manufacturer before making a decision on the solution that best suits your company’s needs.” the construction method used when laying a floor will also have an impact on a vna system - particularly where wire guidance systems are installed into the floor to guide narrow aisle trucks within the aisles where high levels of steel are incorporated into the design of the floor it is possible that the signal from the guidance system may be effected and this should be considered at the early stages of the design process. richmond concludes: “vna systems can offer significant improvements in performance and efficiency of a warehouse or distribution operation. however, because the warehouse floor can have such a significant impact on the operation of the trucks and indeed the overall facility, it is important to assess the design of the floor at the early stages so that the operational design of the system can be optimised. but, it should also be remembered, that if a survey shows that a floor is not suited for its proposed use there are a host of options available to upgrade the surface in order to achieve the necessary tolerances.” for further information please visit: www.jungheinrich.co.uk as part of its ongoing campaign to encourage safer working at height, fall protection specialist kee safety has urged contractors and specifiers to make sure that the permanent, walkway system selected for a particular roof top installation on projects complies with all relevant safety legislation. “under the work at height regulations 2005, as amended by the work at height (amendment) regulations 2007, there is a legal requirement for anyone who contracts others to access and maintain rooftop equipment to ensure proper safety precautions are in place”, says tracy dunn, global product manager at kee safety. “in this context, it’s important that specified equipment and systems comply fully with existing regulations, european and british standards. as far as we’re concerned, there should be no grey areas on roof top safety - systems that comply are safer than those which do not”. the company says that kee walk is the only permanent walkway system of its type which complies fully with the harmonised european standard en 516:2006 (prefabricated accessories for roofing - installations for roof access - walkways, treads and steps) which became mandatory in january 2006. it exceeds the deflection criteria and slip resistance requirements of this standard and achieves almost double the friction requirement of bs 4592 in both wet and dry conditions. specifying kee walk will help those companies needing to meet the requirements of work at height regulations. the system is fully compatible with all horizontal safety line systems including kee safety’s own keeline system. designed for use on composite, trapezoidal metal profiles and standing seam roofs, kee walk is an off-the-shelf, modular system which can be easily adapted to a wide range of different roof types, pitches and configurations. the systems is also much easier to install and more cost-effective than other walkway systems currently on the market. providing a level, anti-slip walking surface, kee walk modules can be easily connected together to form a clear demarcation route. this ensures that the roof is protected from unnecessary damage with the pedestrian weight uniformly loaded across the surface of the walkway. it is ideally suited to flat, barrel and sloping surfaces. for further information please visit: www.keesafety.com/uk walkway regulations compliance kee walk is an off-the-shelf, modular system which can be easily adapted to a wide range of different roof types 31-32_pwe_0910_28_pwe_0810 20/09/2010 15:17 page 32make a clean sweep this winter *free km 70/20 sweeper with every kärcher scrubber drier purchased between october 1st and december 31st • ideal for cleaning asphalt, pavements, concrete, hard floors and carpets • 480/700mm working width • 42 litre container capacity • simple control to find out how kärcher can make a difference to you call 01295 752 142, email: sweeper@karcher.co.uk quoting pwesep or visit www.karcher.co.uk offer valid from october 1st – december 31st 2010. *excluding br 30/4 c free km 70/20 sweeper* 75 years of kärcher... 75 years of innovation make a clean sweep this winter • ideal for cleaning asphalt, pavements, concrete, hard floors and carpets , www.karcher.co.uk quoting pwesep or visit *excluding br 30/4 c sweeper@karcher.co.uk offer valid from october 1st – december 31st 2010. speedfold 800 high speed door itis big... itis clever... ...and its dp doors and shutters ltd. are pleased to announce the introduction of their new speedfold 800 high speed door manufactured at our modern factory here in sheffield. the speedfold 800 has a unique fold up style operation combined with integral and horizontal wind bars designed to offer maximum wind resistance for external and large width doorways. doors & shutters ltd 23b orgreave crescent, dore house industrial estate, sheffield, s13 9nq. tel: 0114 288 9464 fax: 0114 293 9193 e-mail: sales@dpdoorsandshutters.co.uk web site: www.dpdoorsandshutters.co.uk speedfold 800 high speed door gb 00605 say no to heat loss, airborne particles and ingress of vermin pests and rodents. 01531 637900 www.galebreaker-industrial.com internal partitioning solutions standard flexipart acoustic & thermal flexipart • reinforced fabric partitioning • fixed to existing structures • easy to access, easy to relocate • meets building regulations • temporary or permanent applications all of the advantages of standard flexipart plus: • sound reduction up to 17.5db • excellent temperature control • high thermal resistance gbr industries ltd galebreaker house, new mills industrial estate, ledbury, herefordshire hr8 2ss. page 1 33_pwe_0910_33_pwe_0910 20/09/2010 12:51 page 1toyota, like every other company in the car industry, started fitting plastic bumpers to their cars years ago. so why not do the same with safety barriers? that’s exactly what a-safe did, with a range of products made from polymer which springs back into shape, thanks to their built-in memory. here’s what stefan adamski, toyota manufacturing uk’s senior specialist in health & safety had to say: health and safety is a key priority at toyota uk and vehicle / pedestrian interaction is one of the biggest concerns in this area and also one of the most difficult to control. whilst we considered traditional steel barriers, a-safe barriers were chosen as a more cost-effective, long-term option. a-safe offer an easy to maintain, flexible solution, with different sizes and types of barrier available to fit our varied requirements. they don’t put steel bumpers on cars anymore before impact polymer barrier in workplace scenario. if you’d like to know more about a-safe products, visit our website at www.asafe.com a-safe (uk) ltd, shay lane, halifax, w.yorkshire, england hx3 6rl t: 44 (0) 1422 344402 f: 44 (0) 1422 323533 e: sales@asafe.com www.asafe.com protecting people, property and profits on impact barrier bends as vehicle hits it. after impact barrier returns to original shape, thanks to built-in memory. “ “ 34_pwe_0910_34_pwe_0910 14/09/2010 15:29 page 135 september 2010 plant&worksengineering focus on: labelling & barcoding handling & storage t racking a component and all the processes it has gone through, from manufacturing, assembly right through to end-user requirements for spare parts replacement (from the cradle to the grave) is becoming an essential requirement in complying with industry guidelines and standards as erp, mrp and quality assurance systems become more widespread throughout the manufacturing supply chain. coding can facilitate inventory management. coding and labelling usually takes the form of alphanumeric codes (e.g lot details and best-before information), barcodes and the more recently introduced 2d codes. products and packaging can be tagged either by a stick-on label or by information printed directly onto them. label-free direct marking methods are intended to survive the most unfavourable of production and operational processes, as well as environmental factors. practical applications the complexity of the code reading solution required for date codes, lot codes, stock keeping units, serial numbers and other text based codes depends on a number of factors. these include: regularity of code or label orientation on the product or package position of the code on the product (irrespective of orientation) regularity of the codes or characters (e.g. are the characters stretched or skewed?) is there damage to the code? the contrast between the code or characters and the background the code/background colour combinations reflections from surrounding surfaces the space available for the code reader any interface required to a reject mechanism and/or the rest of the process speed of measurement the sheer variety in coding types and labelling methods places high demands on industrial code readers. marking marking methods include lasers, dot-peening, electrochemical etching, and ink-jet printing. the appropriate technique is chosen according to the application, material composition, surface texture, the amount of data that the mark needs to contain, the available space for printing, and the mark’s location. in practice, many codes are in poor condition when they are read. this may be due to normal wear and tear during the life of the product, or may even be due to poorly maintained marking equipment. fortunately, vision based code readers are well-equipped to deal with code defects. code reading the basic process in reading codes is to: illuminate the code, locate the code, and then extract the data. checking a stick-on label on a packet or carton in a warehouse presents a significantly different challenge to checking a code dot-peened onto a small automotive component as it progresses along a production line. industrial vision code-readers provide an alternative to the more conventional laser scanners. a 1d bar code has a ‘check sum’ built in so that a laser-scanning type of reader can tell if there is an error in reading it, but can do nothing about it except to say ‘unreadable’. a vision system has a better chance of reading a 1d code because if any part of a bar is intact, it can use that information. vision-based readers tend to be used in circumstances where it is simply not acceptable to receive a ‘cannot read - check sum not correct’ from a laser scanner. vision-based code readers fall into two basic categories: dedicated code readers, both for 1d and 2d code reading, and systems based on industrial cameras. both could vary from a hand-held code reader to a dedicated system fully integrated into a manufacturing control system. vision technology dedicated vision-based code readers generally feature an integral illumination source and lens and an image of the code is produced using a ccd sensor. they feature onboard software to process the image and read the code. 1d codes are less robust than 2d codes but vision-based readers can be effective in reading low contrast or damaged codes or those distorted by severe perspective. since these readers generate an actual image of the code, it is possible to archive images of read failures and download them to a pc in order to diagnose the root cause of a problem. 2d codes allow much more information to be stored than is possible with a 1d code and in a much smaller space. the 2d datamatrix code format includes built-in ecc220 error correction to allow the recognition of codes that coding, marking and labelling have become an essential component of modern production technology. correct packaging labelling is critical for consumer safety, especially in the food, beverage, pharmaceutical and medical industries and, of course, for ensuring that the correct spare parts are available for maintenance. in addition, “mark and read” applications are used for product identification and traceability, especially in safety-critical industries such as aerospace and automotive. don braggins, uk industrial vision association reports. reading codes and labels fixed-mount id reader for printed barcodes and 2d direct-marked codes (courtesy cognex uk). 35-36_pwe_0910_35-36_pwe_0910 20/09/2010 15:22 page 3536 september 2010 plant&worksengineering handling & storage aisle-master articulated trucks save time, space and money 50% savings on storage space work in narrow aisles improved efficiency versatile indoor & outdoor operation lower costs replace counterbalance and reach trucks • lpg and ac electric models • lift capacities up to 2,500kg • phone or e-mail for free dvd aisle-master ltd www.aisle-master.com info@aisle-master.com clontibret, co monaghan, ireland t: 353 4780400 (int) t: 07540 970 064 (uk) aisle-masters are superbly designed, built and customised for unbeatable quality, durability & reliability a 27/1/10 10:09 am page 1 are up to 60% damaged, making it particularly popular for direct part marking. some code readers now support the ability to read multiple codes in the field of view, including different code types (1d/stacked, data matrix, qr) at the same time. the ultimate in code reading flexibility is offered by using a fully functional industrial vision system equipped with code reading and optical character recognition (ocr) and optical character verification (ocv) software. these differ from the dedicated code readers in that they feature a full camera and lens, often with an external illumination source. images of the code are recorded for subsequent processing and measurement. the camera may be connected to a pc where the processing is carried out, or smart cameras can be used which are self-contained, standalone vision systems with built-in image processing capabilities. a third option is the compact vision system, where all the processing power is contained in a rugged, din mountable enclosure, instead of the camera head. with a comprehensive choice of camera types and connectivity standards available, industrial vision systems can be chosen for a huge range of industrial environments. code reading and ocr software is available from a number of different suppliers. ocr uses sophisticated pattern recognition algorithms. as barcodes have become mandatory in some industries, so their quality has needed to be analysed. there are a number of grading standards relating to different industries. 1d grading usually specifies a minimum contrast for a colour of illumination in addition to print quality. 2d codes have far more parameters such as the squareness and uniformity of the grid and it may be important to check that a particular software package supports the required grading standard. producing an image of the code or alphanumeric with the best possible contrast can often be dependent on getting the optimum illumination conditions and the development of high intensity led light sources has helped enormously. an added benefit of using more powerful vision systems is their flexibility, since they can carry out a host of inspection tasks as well as reading the code. for label applications, this can include checking that the proper label is on the package and that the label is correctly positioned, as well as looking for consistency in colours and logo positioning for brand image purposes. the ukiva the ukiva is a special interest group of the ppma (processing & packaging machinery association), and its prime objective is promoting the use of vision by manufacturing industry. many of the association’s members are involved in the supply of vision systems and components for code & label reading applications. for further information please visit: www.ukiva.org code reading software from the common vision blox imaging toolkit, (courtesy stemmer imaging) 35-36_pwe_0910_35-36_pwe_0910 20/09/2010 15:22 page 3637 september 2010 plant&worksengineering focus on: forklifts & ancillary equipment handling & storage high productivity and low cost of ownership will be the two themes of the jungheinrich stand (stand no: 19 l100 & 142) at imhx 2010 (16-19 november). among the trucks on display from the company’s wide warehouse range will be: reach trucks with a lift height of 12 metres; the world’s best selling low level order pickers; powered pallet trucks - including a lithium ion-powered pallet truck concept - and a range of very narrow aisle stackers such as the recently launched eks series of order pickers that use rfid technology to guide forklifts quickly and efficiently around a narrow aisle store. products to be shown for the first time include a new model multi-directional reach truck for long load handling. the new truck has been designed to significantly reduce tyre wear during operation - thereby cutting running costs - with all three wheels powered electrically. jungheinrich’s range of electric-powered tow tractors, which are offered in capacities from one to 25 tonnes, will also be highlighted. like all jungheinrich electric-powered handling equipment, models in the tow tractor range feature the latest generation ac motors for high productivity and low running costs. there will also be a strong focus on counterbalanced trucks. among the three and four wheel machines on show will be jungheinrich’s vfg range of ic engine-powered counterbalance lift trucks which, thanks to their hydrostatic drive, are ideal products for applications where a lot of ‘shuttling’ work is involved - such as lorry loading and unloading within and around a busy warehouse or factory environment. used equipment from jungheinrich’s ready-to-go range will also be on display with a ‘cut-away’ truck graphically illustrating the thorough rebuild process that all jungheinrich used equipment goes through before being starting high productivity & low cost of ownership highlighted at imhx its second life. key personnel from the company will be on hand to discuss jungheinrich’s projects and systems capabilities, aftersales support network, rental and financial services, racking systems and warehouse planning services. craig johnson, marketing manager of jungheinrich uk ltd explains: “there will be a comprehensive display of products and services ideally suited to manufacturing, logistics and retail operations of whatever size. “a team of highly trained materials handling equipment professionals will be on hand to provide industry leading advice and operational solutions centred on creating value by increasing productivity and lowering costs. “our stand will be a comfortable place to spend some time amid the hustle and bustle of the show and visitors are invited to call in and see us to learn how we are helping companies - big and small - to drive operational efficiencies throughout their materials handling processes.” for further information please visit: www.jungheinrich.co.uk jungheinrich’s eks order pickers are among the products that will be highlighted at the show combilift, the manufacturer of customised 4-way handling equipment has two adjacent stands at this year’s imhx, the smaller one being a dedicated hospitality area (stands 19k 135 & 130). the highly skilled drivers will be giving regular performances to demonstrate the manoeuvrability of these compact counterbalance design trucks. combilift has introduced a considerable number of new models since the last imhx show, and the number of exhibits on the stand reflects the extensive range available from the global leader in its field. as well as the combi-cb, which is now available with 3 and 4 t lift capacities, other exhibits include the original and “core” combilift; the 4t capacity c4,000, a 4-way sideloader, plus a selection of larger combilifts for heavier duty applications with lift capacities of 6t, 8t and upwards. managing director martin mcvicar commented: “we are continuously adding to and improving our range, and recently built our largest 4-way forklift to date - a 25t model. whether there will be room for this on the stand remains to be seen, so you will need to pay a visit to find out.” for further information please visit: www.combilift.com wide range of models on display combilift has introduced a considerable number of new models since the last imhx show 37-38_pwe_0910_37-38_pwe_0910 20/09/2010 15:20 page 3738 september 2010 plant&worksengineering handling & storage c&g certificate in machinery safety practical application of machinery safety legislation and standards informative and practical, this modular training course explains the current uk machinery safety legislation and standards. classroom sessions, practical exercises and examinations lead to successful candidates being awarded a city & guilds machinery safety certificate. employers benefit from the improved competency of the individuals and the organisation as a whole. the four-day course is ideal for people who have responsibility for new or existing machinery, including designers, manufacturers, maintenance engineers, engineering/project managers and health and safety representatives and managers. scheduled courses take place throughout the year, and additional courses can be run at companies' premises. for further information please contact us :- e-mail: training@pilz.co.uk tel : 01536 460766 fax 01536 460866 pilz automation technology, medlicott close, corby, northants nn18 9nf. tel: 01536 460766, fax: 01536 460866, sales@pilz.co.uk, www.pilz.com training courses city & guilds course page 1 toyota material handling uk will be showcasing its strengths at imhx 2010 - 16-19 november, (stand 20f70) - by showing visitors the company’s products and developments, along with its range of services and solutions. the theme for its stand will be ‘stronger together’. the toyota material handling stand at imhx will provide the first opportunity for visitors in the uk to see the full range of toyota counterbalance forklifts and towing tractors and bt warehouse equipment together since the integration between toyota industrial equipment and bt rolatruc in 2007. the toyota stand will feature three live demonstration areas, which will enable visitors to see the many product features and benefits. combined with a full range of product displays and a seminar theatre featuring a series of master-class workshops, toyota will show how they can help customers improve efficiency in their business. the stand will incorporate three live demonstration areas that will provide the opportunity to show visitors the benefits of the toyota product range. the three demonstration areas will focus on different product areas including hand pallet trucks, the powered range of counterbalance forklifts and warehouse trucks and a virtual warehouse. imhx 2010 will also be the first chance to see the new traigo ht electric counterbalance forklift. this high tonnage electric truck with load capacities from 6.5 - 8.5 tonne is designed to provide a heavy-duty electric alternative to engine-powered forklifts. visitors to the stand will be able to see the full range of materials handling equipment available from toyota and talk to experienced toyota experts from across the company including product specialists, sales, service, rental and operator training. in addition, for the first time at imhx, toyota will be holding a series of workshops in its seminar theatre located on the stand. these master classes are designed to share toyota’s knowledge and expertise and provide attendees with practical guidance on how they can reduce costs in their business. the first workshop will focus on the toyota production system and will demonstrate how elements of this renowned business model can be applied to any business. the afternoon workshops: ‘managing your assets’ and ‘driving down costs’ will show how effective fleet management and damage management can help companies to actively reduce unnecessary cost in their business. visitors to imhx can register for places on these workshops by visiting the toyota website www.toyota-forklifts.co.uk mike mathias, managing director from toyota material handling uk commented: “we want visitors who attend the imhx to leave with an understanding of what working with toyota material handling can offer and the passion and desire we have to meet their business needs in this environment. “ for further information please visit: www.toyota-forklifts.co.uk handling strengths to be showcased the toyota stand will feature three live demonstration areas, which will enable visitors to see the many product features and benefits focus on: forklifts & ancillary equipment 37-38_pwe_0910_37-38_pwe_0910 20/09/2010 15:20 page 38machine safety conference 9 november 2010 bletchley park,milton keynes is machine safety still an enigma to you? theme the 2010 machine safety conference will focus on the practical implementation of functional safety, with an overview of standards and legislation, including the developments with the machinery directive. (hse). tutorial sessions follow, covering practical risk assessment and safety system design. delegates will also benefit from equipment demonstrations with industry experts. the popular q&a session with provides delegates the opportunity to ask to pertinent questions of the expert panel. the safety exhibition affords conference enables delegates to discuss technical solutions with leading machine safety vendors. audience specifiers and designers of machinery specifiers and designers of safety related electrical control systems (srecs) managers and engineers responsible for machinery safety within their work environment presentations include functional safety standards for machinery control systems – “the changing situation" – philip parry/steve shaw, health and safety executive sistema – software tool for the evaluation of applications to iso 13849-1 – paul davies, rockwell automation an overview of bs en13849 applied to a safety function – seb strutt, sick realising safety related control using configurable safety systems – stewart robinson, pilz automation technology dr richard piggin, conference director and chairman of bara's safety sig (special interest group), comments: "these conferences continue to be extremely popular, as witnessed by past attendance. delegates have clearly articulated the need for a forum where functional safety standards and legislation can be discussed, particularly with the changing standards environment. machine designers and builders, system integrators and users of machinery have expressed their better understanding and improved knowledge these events impart. as the area continues to develop, with the transition to new standards,the bara machine safety conference will continue to educate the market and provide a forum for debate." delegates will also get an opportunity to take a guided tour of the site of britain’s codebreaking activities during wwii, and the birthplace of the modern computer. they will be among the first to see a fully working, rebuilt version of the turing bombe – the machine that was used to crack the enigma codes registration & contact details visit www.drives.co.uk for booking and further information conference director, dr richard piggin engd ceng miet email: rpiggin@iee.org tel: 07720 807707 cost 175 per delegate or 165 for bara members all prices are vat. refreshments, a buffet lunch and a cd-rom of conference material are all included in the cost. bara reserves the right to change the programme without notice. after the conference there will be a guided tour     39_pwe_0910_39_pwe_0910 20/09/2010 12:40 page 140 september 2010 plant&worksengineering health, safety & training i t happens at every networking event, when i answer the dreaded ‘so what do you do?’ question. “oh ho, ‘elf and safety’”, they chortle (as if i haven’t heard that one before), “the people who stop kids playing conkers”. well no, we don’t actually. generally speaking, it’s the insurers who stop people doing things by putting in hundreds of unnecessary clauses which might, at some time in the future, avoid them paying a claim, together with the under-trained, confused and unconfident managers who have to go along with it. no joke more importantly, why are we making a joke at all? if a plane crashed and killed 180 people, we wouldn’t be having a good laugh and calling it ‘sky pixie syndrome’. yet that’s the number of people who die every year in accidents at work, not counting the 246,000 that get injured, or the estimated 1,700 who die while driving on business. the health and safety industry has become the acceptable butt of everyone’s humour, partly because the media just loves a story about old people being refused doormats in case they trip over them. it’s also because we have allowed people to believe that health and safety is about speaking in impenetrable acronyms, filling in reams of paperwork and adopting a ‘belt and braces’ approach to everything, in place of good old common sense. currently there are around 4.7 million small and medium-sized enterprises (smes) employing nearly half the workforce. they are present in all industry sectors, including those associated with the highest risks of injuries and ill-health. i would argue that the health & safety sector is still struggling to get to grips with what this huge number of employers needs from us. when you have to be worrying about whether you are going to be able to pay your employees this month, or take a salary yourself; when it’s 2am and you’re just getting around to doing your accounts, then worrying about your health and safety procedures is not top of your list - and we have to understand that. acronym hell even the small business managers who make the effort soon find themselves mired in acronym hell. i read an article recently that contained 32 different acronyms, and not just the ones we’re mostly familiar with like h&s and dwp, but really clever ones like chaspi (corporate health and safety performance indicator), sbtaf (small business trade association forum), and lacors (local authorities co-ordinators of regulatory services). hse research shows that most small and medium-sized businesses do want to comply with health and safety. it also shows that most believe they are complying although realistically, research asking someone to incriminate themselves, even anonymously, is likely to be flawed. the hse itself faces the problem of being both poacher and gamekeeper; there is a genuine fear among small business owners of asking the hse anything, in case it results in an inspector knocking on the door. we in the industry know that isn’t the case but the hard-pressed entrepreneur doesn’t. that’s not to say that small businesses want to flout the laws. it’s disparaging to say that because a business is small, it wants to get away with as much as it can. the issue is that the laws are the same whether you employ two people or two hundred so there is a disproportionate burden on small companies. within the h&s sector, there has developed a tendency to use these laws as a big stick. consultancies looking to make a fast buck have resorted to scare tactics, supported by an ever-helpful media. for small firms, therefore, health and safety first, let’s shoot the elf! the health and safety industry has become the target of vilification and derision. its salvation is in helping small firms understand that health and safety is not just about compliance, but business success and a moral imperative, argues karen baxter*. 40-44_pwe_0910_40-44_pwe_0910 20/09/2010 15:24 page 4041 september 2010 plant&worksengineering appointments to advertise in this section please contact alistair mckay on tel: 01732 370347  !  /0)(,&1-/"/2(1 ,5./(,"#,&(,/1-%(** 3 " ,1.-0(1(-,(,1' -,#(1(-,-,(1-/(,&#(3(0(-,-%(100 *0-/& ,(0 1(-, -" 1#(, , / !14,1' ,#(/(,&' / 1'02""00%2*" ,#(# 14(**' 3 ./-3,1/ ") /"-/#(,06010 *01-./-"00(,#201/6##(1(-, **66-24(**' 3 0-2,#,&(,/(,&! ")&/-2,# 4'("'4(**(,"*2#5./(,"#4(1'3(!/ 1(-, , *60(0 ,#"-,#(1(-,-,(1-/(,&./-"#2/0 /2%1"',() /* #/0(,1'%(*#-%"-,#(1(-,-,(1-/(,&-%/-1 1(,& "'(,0-24(**!/0.-,0(!*%-/ 1'#3*-.,1-%0 *0-%1'(/.-/1 !* ,#,*(,"-,#(1(-,-,(1-/(,&06010 "/-001'(#* ,#0 / -%1' *)(,&#(/"1*61-,&(,/0 1 ***3*0(,./-"00 ,2% "12/(,& ,# (,1, ," -/& ,(0 1(-,0 ,5"**,1! 0("0 * /6"-,02/ 14(1'5./(,".*20 ,2!/-% ,"(** /6!,%(10 4 (101' 02""00%2*" ,#(# 1%2**65.,0#"-. ,6" /-/1'-.1(-,-% " 0' *1/, 1(3(0-%%/# 0(0 "-./',0(31/ (,(,&(,1'./-#2"10 ,#060104 ,2% "12/* 0 ..*6(,4/(1(,&-/!6 (* ,"*-0(,&6-2/1-  * ,1 ,20(,00 /)2/,14--# 1 %%0 *  (* (,%-./2%1"',()"-2) !444./2%1"',()"- new p&s pages_pwe_0910_pwe_p&s_0608 16/09/2010 12:10 page 4142 september 2010 plant&worksengineering health, safety & training in a healthy and safety-conscious environment can have a hugely positive impact on staff morale, attendance and productivity. common sense tells us this is true but when it comes to dealing with the law, then a certain level of competence and confidence is also needed. a manager who has been given the responsibility without support and advice will inevitably take a ‘belt and braces’ decision and that’s where health and safety falls into disrepute. but there is a different way. take driving as an example. most of us do it and we don’t need to keep looking at the manual. we know that to drive correctly we need to put our minds to it and stay in the moment. it’s about practical, simple actions, not process. but we can only do it well if we were taught in the first place and understand the need to comply with the rules of the road. excuses finally, the health and safety industry has to stop making excuses. it is vital to everyone who goes to work - employer or employee. in what other sector (apart perhaps from medicine) would you have the potential to save 180 lives a year and protect 246,000 people from injury? we have to learn to communicate, especially to small companies, what our business is about and that by making health and safety an enterprise-wide culture, small firms can reap enormous benefits. together, we need to shoot the elf and return ourselves to health. for further information please visit: www.sypol.com has become a ‘must do’ compliance issue rather than a culture that can genuinely deliver business success. three drivers for small business people there are three drivers to adopting better h&s practices: compliance, business cost, and moral cost. far too much is made of the first and not enough of the second and third. every death or serious injury at work leaves a trail of tragedy in its wake. no-one who has been involved in causing harm to someone at work ever wants to go through it again. there is a moral imperative to try to get this right. it also makes sense from a business standpoint. the benefits of an effective h&s culture are well documented: accidents avoided, fewer working days lost, improved recruitment and staff retention, improved customer confidence, reduced insurance premiums, and the ability to tender for large corporate and government contracts. as if that wasn’t enough, working *karen baxter is managing director of sypol, the global provider of workplace and eco risk management services. she has more than 15 years’ experience of occupational hygiene, is a chartered member of the institute of occupational safety and health and has been advising customers with regard to management of occupational health and wellbeing for nearly 20 years. karen baxter is managing director of sypol *eppmrksrhiejievw [[[gewippeqiewyviqirxgsq 8lmro)rzmvsrqirx8lmro'ewippe 'epp'ewippexspievrqsvi sviqempmrjsgewippegipgsqxsevverkiezmwmx ;svovipexihlievmrkmqtemvqirxwevigsqqsrtpegi fyxrsmwipizipweviiew]xsqsrmxsv 40-44_pwe_0910_40-44_pwe_0910 20/09/2010 15:24 page 42is your back covered? are you responsible for health and safety in your organisation? do you manage people who are? if your answer is yes to either question and you’re not a member of iosh, you probably should be. iosh has over 37,500 members and as the only chartered body for health and safety in the world, we define the competency standard. join today and get access to a host of benefits including: - legal and technical help - best practice guides - access to an international network of health and safety professionals - free subscription to the safety and health practitioner – the premier industry magazine. alci/060510/pwe0910 the institution of occupational safety and health, the grange, highfield drive, wigston, leicestershire, le18 1nn, uk t 44 (0)116 257 3100 f 44 (0)116 257 3101 www.iosh.co.uk just call 44 (0)116 257 3198 and quote pwe0910 for an application pack – or apply online at www.iosh.co.uk/joinus. 43_pwe_0910_43_pwe_0910 14/09/2010 15:30 page 1health, safety & training 44 september 2010 plant&worksengineering the british safety industry federation (bsif) is highlighting the major problem of musculoskeletal disorders (msds) as the most common occupational injury. with an estimated 538,000 people in great britain who had worked in the last year, suffering from a musculoskeletal disorder that was caused or made worse by their current or past work, the bsif would like to see the number of msd’s fall. an estimated 11.6 million working days a year are lost to work-related msds and the labour force survey shows that an estimated 9.3 million working days (full-day equivalent) were lost in 2009/09 through msds caused or made worse by work. the figures alone show what a significant problem this is and one that every employer needs to be aware of not only to ensure they are protecting their staff to the best of their ability but as the possible loss of working days will also potentially harm their business. as a valuable information source, whose core purpose is to support and represent suppliers, the bsif can offer advice and provide direction in all health and safety matters. statistics gathered through the labour force survey suggest that the overall incidence rate of self-reported work-related msds has fallen over the period 2001/02 to 2008/09 but the bsif would like to see these fall further. in the case of msd’s, some jobs will have risks which will be unavoidable such as manual handling, however with practical advice, training and deployment of a handling aid e.g. a pallet truck, electric or hand powered hoist, or a conveyor, the risk will be minimised. where a mechanical aid or safety equipment is needed it is important to ensure that it is suitable for the job and also conforms to standards if necessary. most personal protective equipment (ppe) will need to conform to the requirements of the ppe directive. by working with a member of the bsif or a bsif registered safety supplier, purchasers can be assured they are using a reputable supplier who is committed to issuing genuine and suitable products and offering trustworthy advice. for further information please visit: visit www.bsif.co.uk bsif urges companies to tackle msds an estimated 11.6 million working days a year are lost to work-related msds for the second year running, health & safety e-learning provider safety media has been short-listed for the e-learning development company of the year award at the e-learning awards. the e-learning development company of the year award recognises companies that have achieved exceptional results within organisations as a direct result of bespoke e-learning content developed. julian roberts, managing director of safety media said: “i’m delighted that we have been short-listed for this award for a second consecutive year. this is a great achievement for the whole safety media team who put a tremendous amount of hard work into developing engaging and innovative courses for our customers.” the winner will be announced at the e-learning awards at a ceremony on 11th november 2010 at the london marriott grosvenor square hotel in central london. for further information please visit: www.safetylearning.co.uk h&s provider shortlisted for e-learning award “don’t let ‘dodgy’ ladders shatter lives”, that’s the message from ladderstore.com for companies who don’t keep a careful eye on their ladders and risk the health and safety of their staff. the company’s message is in support of the 2010 ladder exchange which started on 1st september with ladderstore an hse campaign partner for the fourth year. last year 1400 ‘dodgy’ ladders were taken out of service, with a total of 7000 since the campaign began in 2007, as ladder owners and users were given the opportunity to get rid of bent, broken or battered ladders in exchange for new ones at discounted prices. ladderstore has seen its fair share of surrendered ladders but puts its emphasis on education for ladder users through training and correct on-going ladder inspection. gail hounslea, managing director of ladderstore.com, commented: “this year we have even more to offer businesses and organisations. as before, we are taking in old and damaged ladders and offering a great discount on a new replacement, but in addition we are also offering a free ladderlog starter pack worth 12.95, a ladder safety checklist which can be downloaded for free and 10% off our ladder training courses held at either our bolton training centre or on-site.” for further information visit: www.hse.gov.uk/falls/ladderexchange.htm casella cel will be exhibiting three of its products at the health & safety expo, 13-14 october 2010, at the reebok stadium bolton. casella cel has redesigned its popular dbadge noise dosimeter to increase its robustness, allowing the dosimeter to be used in the harshest of environments with absolute reliability. visitors will also be able to examine a new product in the range, the dbadge lite, which offers simple functionality for users wanting straightforward noise dose results without additional features, at a very affordable price. also on show will be the tuff range of personal air sampling pumps, which has gained atex (intrinsically safe) approval for use in flammable atmospheres. designed to ip54 standards, the tuff is claimed to be the only personal air sampling pump to receive certification to ‘m1’ classification required for mining applications. casella cel’s new distributorship agreement for rae systems’ world-renowned gas detection monitors means it will be showcasing its full range of portable gas detectors for personal monitoring of toxic and flammable gas hazards. for further information visit: www.casellameasurement.com damage limitation for ‘dodgy’ ladders ladderstore has seen its fair share of surrendered ladders complete solution on show 40-44_pwe_0910_40-44_pwe_0910 20/09/2010 15:24 page 44product spotlight dialight’s 150w durosite tm high bay led luminaire will perform for 10 years in the most demanding applications - that’s 3 times as long as hid and nearly 2 times as long as fluorescent. mercury free, the annual energy saving per fitting equates to 2 tonnes co2. weighing under seven kilos, the solid-state low-profile durosite high bay resists shock and vibration, pairing with a range of mounting options for versatility, reliability and easy installation. in a recent pilot us installation dialight matched the lighting levels achieved by 1000 t5 fluorescents in a distribution warehouse with only 800 led high bays. using variable optics to achieve this efficiency, the project is on track to generate combined annual energy, re-lamp and maintenance savings of over 243,000, expected payback period 14 months. tel: 01638 665161 www.dialight.com the aldec g3 decanter centrifuge from alfa laval (uk) provides power savings of up to 40% coupled with reduced environmental impact thanks to significant savings in overall c02 emissions. developed for sewage sludge dewatering operations, its innovative design combines peak performance at all times with reliable and controllable operation. alfa laval says the slim-line design significantly improves solids handling and helps maximise performance. the bowl incorporates specially developed power plates that harness and exploit the energy in the centrate discharge to contribute to the bowl rotation, thereby reducing overall power requirements in addition, alfa laval’s unique 2touch control system ensures simple, reliable process optimisation. the aldec g3 design includes features like a steep cone angle and a progressive pitch conveyor design which combined with the baffle disk design delivers superior performance. a strain gauge torque measurement provides an accurate, instantaneous torque reading which helps improve the process performance of the decanter. separation takes place along the entire length of the cylindrical part of the bowl. a dam between the baffle disk and the bowl wall enhances the hydraulic effect and the scrolling of solids through the bowl. as a result, only the driest fraction of the sludge cake passes from the bowl into the casing through the 360 solids discharge openings. clarified liquid leaves the bowl by flowing over adjustable plate dams into the casing. a major feature of the aldec g3 decanter centrifuge is that key operations can be tailored to meet specific sludge requirements. tel: 01276 63383 www.alfalaval.com hoval’s corporate product brochure has now been updated to include details on the latest products as well as enhanced drawings and additional technical information. products include the royalist high temperature, high pressure three-pass boilers, the recently extended biomass boiler range, including the biolyt 160kw and full details of the ultra-efficient ultragas condensing boiler range. also featured is the new cf ceramic filter for removing 96% of particulate emissions down to 2.5 microns diameter from biomass boilers. further information can be found at www.hoval.co.uk the installation of two process tank heating systems from specialist manufacturer lanemark international ltd is now playing a central role in the success being enjoyed by one of the uk’s leading refurbishers of plate heat exchangers, pj heat exchangers. the site in barnsley is at the heart of the cleaning process which is a key part of the company’s maintenance service. from industries as diverse as brewing and offshore exploration, heat exchangers are a crucial element in a wide variety of operating systems. the inevitable scaling that results can be addressed by regular maintenance and cleaning procedures and it is in this context that the ability and accuracy of lanemark’s systems is proving so beneficial according to managing director, vince moore. tel: 024 7635 2000 www.lanemark.com doncaster-based mcl energy has been awarded a long term fully inclusive operation and maintenance contract for leading yarn spinner thomas b. ramsden & co based in guiseley. thomas b. ramsden manufacture premium wool brands such as wendy & robin, with hand knitting yarns accounting for the majority of production at the guiseley based spinner. the contract includes all daily operation duties, planned preventative maintenance, 24/7 callout, solid fuel supply and chargeable works ranging from condensate pipe work to steam traps throughout the steam distribution system. jason perry said “we are looking forward to working with a leading british yarn manufacturer and delivering a first class service solution.” for more details on energy and technical service solutions please call business development on 01302 738000 or visit www.mclenergy.co.uk with the vitosol 300-t, viessmann offers a high performance vacuum tube collector that meets the highest demands for efficiency and safety. the high performance vitosol 300-t vacuum tube collector is based on the proven heat pipe principle. the preferred areas of application for the vitosol 300-t include systems in which no heat is transferred over a prolonged period of high solar radiation. this includes school buildings, for example, in which no energy is required during the summer holidays. the system works according to the proven heat pipe principle, which gives high operational reliability and provides protection against overheating. sol-titanium coated absorbers are integrated into the vacuum tube to maximise the collection of solar energy. tel: 01952 675000 as part of an initiative to improve process efficiency at its sewage treatment works in newthorpe, nottinghamshire, severn trent water has installed a chroma progressing cavity (pc) pump from framework supplier nov mono to pump digested sludge to the site’s centrifuges for thickening. this major water supplier had been experiencing problems with the reliability of its previous pump gearboxes which were causing significant downtime at the plant and de-ragging the pump was also problematic due to the small access port which provided limited access. requiring a safe and cost effective solution fast, severn trent water turned to mono for the answer. mono supplied its chroma pc pump, which was delivered on a quick lead time, competitively priced and more importantly, was directly interchangeable with the existing pump so required no additional pipework modifications. tel: 0161 339 9000 www.mono-pumps.com. high bay led mcl energy awarded long term contract lanemark gas fired immersion tube process tank heating technology vacuum tube collector hoval’s corporate product brochure leslah@dfamedia.co.uk spotlight new sludge decanter offers 40% power savings nov mono ’s chroma pump improves efficiency for severn trent water 45_pwe_0910_new ps 0109 17/09/2010 10:18 page 1product spotlight accidents in the workplace are increasingly being reduced because of a tough and extra heavy duty matting created by international matting manufacturers plastic extruders ltd. flexigrid is specially designed for the harshest environments to provide safety and comfort underfoot and to minimise the risk of slipping and tripping. the matting has a deeply etched surface which will resist dirt, grease, grime, production waste and spillages from oils or other liquids. importantly, its aggressive slip resistant tread is rated to a high r11 slip resistant rating. due to its 20mm thick open grid construction, it not only allows debris to fall through the matting but also efficiently drains and dissipates spills (meeting the highest possible v10 rating for liquid drainage). tel: 01268 571116 sales@plastex.co.uk www.flexigrid.com eplan unveiled the new eplan electric p8 2.0 electrical controls design software, in beta version at the hanover fair. whether point wiring, active device protection or channel oriented plc design, the software offers practical potential for more project reliability, functionality and speed. the quality of all documentation is guaranteed by active check functions and the system automatically prevents incorrect data from being entered. with the new “protected device” function, all project parts are retained, even in the case of graphic delete commands. active protection of project data is freely defined in the parts definitions in the eplan platform. the new machinery directive requirement for reliable, understandable project documentation is implemented in a practical way. tel: 01709 704100 www.eplan.co.uk crowcon has expanded the capabilities of its tetra:3 (t3) personal multi-gas detector with three more toxic gas sensors: ozone, sulphur dioxide and ammonia. these complement its existing sensor range which includes flammable gases, oxygen, hydrogen sulphide, and carbon monoxide. the new sensors widen the applications for the t3 to include the chemical, pharmaceutical, food and beverage processing industries, and water and wastewater treatment. featuring a top-mount display and the capacity to detect up to four gases at once, the t3 is designed for demanding industrial environments, including confined space work, and has intuitive, single button operation. if a hazard is detected, it warns by means of a 95dba audible alarm, bright red/blue led, and by vibrating. a lithium-ion battery provides over 18h continuous operation from a single charge, and there is a 30 day countdown warning of calibrationdue date. tel: 01235 557700 www.crowcon.com nederman is continuing to develop products and enhanced expertise to extend its capabilities under the atex directive (regulating explosive atmospheres). “demand is rising,” said mark hodgens, md. “customers should check their suppliers really understand the legislation, the operating environment and the equipment. it’s a specialist area.” nederman’s in-house projects division has access to documented guidelines and technical support to stay updated on products and applications. the manufacturer has just extended its atex range with zone 22 compliant vacuum hose reels as well as a complete range of tav pneumatic high vacuum valves. tel: 08452 743434 www.nederman.co.uk recent tests by the hse have shown that vibration exposure for operators using pneumatic torque multipliers to tighten 100 commercial vehicle wheel nuts was 10 times lower than when traditional impact wrenches are used. the norbar pneutorque ptm-72-1350b and one other multiplier were subjected to lab and field tests by the hse and both tools confirmed manufacturer claims of low vibration emissions. the control of vibrations at work regulations impose a daily exposure action value of 2.5 m/s2, above which employers must introduce controls to eliminate or reduce exposure and provide health surveillance to those regularly exposed to vibration that exceeds this level. the pneutorque pneumatic torque multiplier does not exceed 2.5 m/s2., so there is no restriction in its use during the working day. tel: 01295 270333 www.norbar.com global printing group, elanders ltd., is reaping the rewards of a substantial reduction in overall running costs. the company has simply replaced its existing lighting with uni-form pulse start 350w lamps, in combination with energy saving conversion kits, from metal halide lighting specialists venture lighting europe. based in north tyneside, elanders design and produce a variety of literature, from a uk facility covering 7,804 sq metres. following a discussion and initial survey by local electrical wholesaler apex electrical, the results showed that a simple change to venture’s lamps and energy saving conversion kits (which include ignitor and ballast) would achieve better light output/colour uniformity, faster warm up time and, as the lamps have a life of over 20,000 hours, reduction in maintenance costs. enquiries to: vpl, the pool house, 2 spring lane, great horwood, bucks, mk17 0qw jan@vastpublicity.com grid safety underfoot new eplan electric p8 2.0 hse confirms norbar multiplier’s good vibrations new engineering brochure new approach to reducing air consumption elanders venture into sustainability spotlight leslah@dfamedia.co.uk the new denios engineering brochure, now available free of charge, uniquely combines all the facts relating to the denios ethos of matching environmental protection and safety with the technical details of hazardous materials storage and safety. being a specialist manufacturer and offering unrivalled know-how with value-for money, denios ensures the optimum solution whether from standard stock or tailored to your specific needs backed by ongoing support at every stage and the comfort of guaranteed legal conformity. the product range in the new brochure embraces walk-in and system containers for hazmat storage without fire protection: modular hazmat stores; fire protection containers; fire protection containers with shelving; and a guide to the notable personalised customer service system. tel: 01952 811991 www.denios.co.uk personal multi-gas detector nederman - atex expertise axflow now offers a new approach to reducing air consumption for larger size air-operated double diaphragm (aodd) pumps. using the mizair, it is said to be possible to reduce air consumption by up to 50% with minimal loss of fluid flow. designed for close-coupling to the pump, mizair requires just a 24vdc power supply. a self-powered atex version will follow later. the microprocessor controlled mizair consists of a high-flow normally open two-way valve and an electronic control unit. valve and control unit operate to deliver precisely timed pulses of air to the pump at the start of each pump stroke. because less air enters the pump there is less air to exhaust and this helps the pump to start its next cycle as there is less resistance to the return stroke. tel: 0208 5792111 www.axflow.co.uk 46_pwe_0910_new ps 0109 14/09/2010 15:23 page 2product spotlight casella cel has announced a limited special offer on its noise at work kit, representing a saving of up to 1400. the kit helps the busy health and safety professional ensure compliance with the specific requirements of the control of noise at work regulations 2005 and consists of: * cel-620 sound level meter, a comprehensive colour screen sound level meter * casella ‘insight’ software * cel-350 dbadge noise dosimeter, plus * a free second cel-350 dbadge noise dosimeter. the digital, cable-free, cel-350 dbadge noise dosimeter accurately measures all occupational noise parameters, and gives the time history of an individual’s noise exposure throughout the day via a built-in graphic display. the prices of the kits start from just 1,969. a variety of kits are available depending on requirements. tel: 01234 841468 www.casellameasurement.com andrew muirhead & son is based in glasgow and employs over 100 people in the manufacture of technical leathers which are exported all over the world for a wide variety of applications. alec brycelend, muirhead’s engineering manager, first contacted nu-star in may 2003 with a requirement to reduce the manpower required to move the 2,000kg trestles in the tanning process. due to their size, weight and four swivel castor configuration, the trestles required up to four staff to move about and also occasional use of a forklift truck. nu-star recommended their powertug as the most suitable product and since initial trials in 2003, andrew muirhead have now gone on to purchase four such units. tel: 0870 4435646 www.nu-starmhl.com aveva group plc, providers of engineering design and information management solutions to the plant, power and marine industries, announced that thai-based the bangkok dock company (1957) limited, and indian-based ska marine services pvt ltd. have concluded contracts for the use of aveva marine solutions within their respective yards. the bangkok dock company is among the country’s leading shipbuilding and ship repair enterprises. ska marine services offers a complete spectrum of services to ship builders. peter finch, president, aveva asia pacific, said: “aveva has long been used by top yards around the world. with countries such as india, vietnam and thailand beginning their shipbuilding programs, aveva is confident that we can support these yards to become more efficient and hence more able to compete with the major players.” aveva solutions ltd, suite 7, venture house, venture way, dunston technology park, chesterfield, derbyshire, s41 8nr tel: 01246 572916 matt.wren@aviva.com the organisers of wwem, the world’s largest environmental monitoring event, have announced a new gas detection zone at the 2010 conference and exhibition, signalling coverage of the workplace environment for the first time. traditionally focusing on environmental monitoring, the event will now also highlight airborne industrial hazards and risk assessment across all industries, with the participation of the council of gas detection and environmental monitoring (cogdem). hazards include accidental exposure to low oxygen levels in confined spaces and to toxic, flammable or explosive gases.most of the world’s leading manufacturers’ products will be on display at the wwem exhibition, including; alphasense, boc, bw technologies, clairair, crowcon, cryoservice, draeger, gas data, gfg, gmi, gss, honeywell analytics, infratec, ion science, jms, linde, quest technologies, rae systems, sensidyne, shaw city, sperian instrumentation, stg and trolex. tel: 01727 855574 www.labmate-online.com being able to make the ideal pump choice to suit the needs for your specific requirements has just been made easier by the release of the latest tool from grundfos - wincaps 2010 - a very comprehensive uk specific dvd selection tool. the new wincaps dvd contains an extensive catalogue of uk specific grundfos products with a pump catalogue to help you select the most suitable pump for your application. this newly updated disc offers anyone who needs to specify pumps for a huge range of different applications including: hvac, water and sewage, industrial and process applications. the usefulness of the dvd doesn’t end there. wincaps gives you access to a comprehensive pump replacement guide and the ability to produce detailed quotation texts; including curves, drawings, wiring diagrams etc. tel: 01525 850000 www.grundfos.co.uk flexicon (europe) has introduced to its permanent portfolio of bulk bag dischargers a dedicated option for processors or movers of bulk solids who receive raw material in flat bottomed, single trip, bulk bags. the system comprises a receiving hopper with a centrally mounted, pyramid shaped cutter, designed to make the process of raw material discharge, simple and cost effective. using a fork lift truck or cruciform attached to an electric hoist, an operator positions the bag on the discharge frame above the pyramid shaped cutter. as it is lowered to sit on a dust confining, thick rubber membrane on all four sides of the hopper, the four-bladed cutter simultaneously splits the bag, bottom dead centre, enabling material to be gravity fed to the hopper via a 35mm square mesh to filter any loose paper or foreign bodies. tel: 01227 374710 www.flexicon.co.uk loctite 5612 is a new two-part, silicone adhesive for bonding glass, metals, ceramics, most plastics and elastomers where temperatures up to 220c continuous or transient peaks of 300c are involved. like similar loctite two-part silicones, a rapid cure can be achieved and the bond is extremely flexible and gives good adhesion without the need for a primer. although a two-part product, no manual mixing is required, with dispensing being carried out by means of a bi-mixer nozzle attached to a pneumatic gun. typical uses include the bonding and sealing of glass and ceramic stove tops to appliance frames, sealing washing machine drums, and replacing gaskets and various mechanical fixings. henkel limited, wood lane end, hemel hempstead, hp2 4rq. tel: 01442 278100 e-mail: technicalservice.loctite@uk.henkel.com second noise dosimeter free with noise at work kit updated grundfos selection tool now available on dvd new gas detection zone at wwem 2010 range of lids bulk bag discharger aveva marine solutions continue to build momentum leslah@dfamedia.co.uk spotlight andrew muirhead takes fourth nu-star powertug two part silicone for high temperatures inspection doors, manlids, manways and hatches manufacturer for tanks and containers. round, rectangular, oval, external lids, high pressure (25 bar), autoclave lids and manways, ready for welding, diameter 100 to 1600mm, mild steel or stainless steel, drip trays, seals, pressure sight glas, vat and tank accessories, spare parts. high stock levels on exisiting products with same day dispatch. tel: 0033 325 743355 www.portex-sas.com 47_pwe_0910_new ps 0109 20/09/2010 12:03 page 1product spotlight grundfos pumps ltd is delighted to announce the immediate appointment of nick christopher as area sales manager with responsibility for the industry, water & waste distribution network in east anglia, midlands & yorkshire. nick has several years experience working in pump sales and service. he will offer the grundfos customer base a broad range of pump knowledge for clean water, sewage, irrigation, process and general industry pump applications. nick commented “i am delighted to be joining a market leading company, who strive to provide excellent products and service to its customers. i look forward to further developing close working relationships with our distribution network, and offering the support they require to grow their pump sales. to contact nick with your enquiries please call 07969 007552. www.grundfos.co.uk uhp water jetting is the most powerful and environmentally sensitive cleaning technique available to industry. when used in conjunction with specialist tooling and accessories water jetting can be the most effective solution in a diverse range of applications including surface preparation, tank and vessel cleaning and cold cutting. hughes pumps range of ultra high pressure (uhp) positive displacement plunger pumps and water jetting equipment is designed for heavy duty cleaning and cutting at pressures to 2,750bar (40,000psi) and power ratings to 375kw (500hp). options available include diesel engine or electric motor drive, trailer or skid mounted, with variants to suit any specific requirements plus a full range of accessories. tel: 01903 892358 sales@hughes-pumps.co.uk lifting equipment manufacturer, demag cranes & components ltd, has reinforced its commitment to quality, health & safety and the environment with successful certification under three key industry standards. hot on the heels of the renewal of its iso 9001quality management systems’ certificate, demag has received certification to the environmental standard bs en iso 14001 and the health & safety standard ohsas 18001. demag is one of the first companies within the uk materials handling sector to achieve full integration of these three standards. the certification follows a period of vigorous self assessment and step by step recognition under the lrqa’s progressive route into systems’ management (prism). demag has held certification of its quality management systems for nearly 25 years. tel: 01295 676100 help@demagcranes.com www.demagcranes.com brownell has introduced an electronic relative humidity indicator as an alternative to paper and chemical colour based indicators. the new electronic relative humidity indicator uses a polymer humidity sensor combined with a thermocouple to provide a digital display reading of relative humidity, ambient temperature and dewpoint. the operating range of the electronic relative humidity indicator is 5 to 80%rh, -20c to 15c dewpoint and -20c to 60c temperature. traditional humidity indicator papers rely on a distinctive colour change usually from blue to pink to signify a dry to wet humidity change. the electronic rh indicator removes the uncertainty associated with colour change indicators by converting the readings to dewpoint. dewpoint is an absolute measure and is not influenced by temperature. tel: 0208 965 9281 www.brownell.co.uk the tork luxury foam soap system has been upgraded to make life easier for cleaning and facilities services staff. the changes to the system will also reduce cost in use while cutting handling and logistics costs. “we will still be offering the same premium quality luxury foam soap, but each bottle will contain twice the amount,” said sca tissue europe product and market manager charlotte branwhite. “this means cleaners will have half the number of bottles to throw away, while the fact that the bottles are collapsible will reduce the volume of waste produced.” each new 800ml cartridge refill delivers 2,000 shots of soap, which means staff will spend only half the time refilling the system. tel: 01582 677570 customer.services@sca.com abb has extended its 2600t pressure transmitter family with a host of new features, offering even greater levels of simplicity and cost effectiveness whilst reducing the time needed for commissioning and maintenance. a key part of the 2600t’s simplicity lies in its use of abb’s new universal hmi. using a menu-based interface in clear text, the 2600t transmitters can be easily configured in just seconds, compared to the several minutes required for competitor devices using handheld configurators. this menu can also be used to quickly select and display different variables, providing operators with fast access to additional data. these benefits are further extended by the ability to quickly repair or upgrade the transmitter in the field by easily changing the electronics module, rather than the whole transmitter. for more information about the 2600t range, email moreinstrumentation@gb.abb.com or call 0870 600 6122 ref. ‘2600t’. grundfos appoint new area sales manager uhp pumps and water jetting tork luxury foam soap the tbn 200 breaking torque wrench - a robust production tool new ari-encosys - compact, efficient and fully assembled heat exchange system abb evolves 2600t pressure transmitter family spotlight leslah@dfamedia.co.uk torqueleader’s tbn 200 breaking torque wrench utilises a 20 breaking action that reduces the possibility of overtightening by clearly indicating to the operator when the preset torque has been achieved. access to more awkward places is allowed by having the breaking action further down the tbn 200 wrench. the tbn’s precision mechanism ensures that the set torque is applied consistently, delivering excellent repeatability making certain our customers’ quality objectives are met. the robust construction built to withstand the harshest industrial environment, ensuring long service. the tbn 200 models can be supplied either with a 16 mm spigot or 14 x 18 carrier rectangular fitting drive which allows use of current end fittings. we do sell appropriate accessories if required. please contact us for more details on sales hotline: 44 (0) 1483 894476, email: salesandrepairs@torqueleader.co.uk or go to www.torqueleader.com demag - lifting the standards electronic relative humidity (rh) indicator the ari-encosys steam-to-water heat exchange system is designed to provide instant hot water up to 2100kw, whatever the load conditions and without the need for a water storage vessel. complete solution delivered fully assembled and tested ready for connection. controls at /-1c under steady conditions, responds quickly to large or sudden load changes. compact design - smallest unit occupies less than 1.5m3, largest less than 3m3. low maintenance and greater energy efficiency means lower fuel bills and less co2. encosys is suitable for various applications including the generation of domestic hot water, low temperature hot water (lthw) and process heating duties. tel: 01684 275752 ndavies@ari-armaturen.com www.ari-armaturen.com 48_pwe_0910_new ps 0109 15/09/2010 11:07 page 2product spotlight wittenstein announces the newest development in the world of mechatronics - the tpm/tpm high torque sizes 300/500. these sumo-sized actuators offer maximum rigidity and the highest torque combined with wittenstein’s signature compact design. the new sizes 300 and 500 meet the highest requirements concerning torque, compactness and dynamics. features include high rigidity, extreme precision and excellent performance, making the tpm 300/500 actuators a fundamental contribution to increase the productivity of any machine. technical specifications at a glance: * torque up to 10,000 nm * compact design coupling the alpha tp 300/500 gearbox and 220 series motors * optional strengthened output bearing (special gear housing) tel: 0870 844 0120 sales.uk@wittenstein.co.uk www.wittenstein.co.uk twi ltd, the independent joining technologies research centre, has solved a persistent dust problem with the installation of a new airbench fn. the airbench is being used to capture metallic dusts generated by two vibrating sieves. “the build quality and sturdiness of the machine is outstanding and even with 2 vibrating sieves running at the same time there is no rattle. i particularly like the front loading filter design, it works very well and means that the bench top can be made more rugged as it does not have to be lifted.” said phil mcnutt of twi. visit www.airbench.com/twi or www.twi.co.uk for more information. new generation diaphragm valves from gf piping systems offer safety, efficiency and simplicity. instead of the commonly used four metal screws it has a central union nut. this non-corrosive connection is characterised by homogeneous temperature behaviour, an even surface pressure and high pressure rating up to 16 bar. the optimal flow geometry offers double the flow rate with the same pressure loss as the previous version. with almost linear flow characteristics this guarantees stable processes. beyond that, the weir of the branched zero dead leg/zero static valve has been moved directly to the pipe wall of the main line. this means the dead leg has been reduced to a minimum, increasing hygiene. standard equipment includes a lockable handwheel, a two-coloured indicator and a userfriendly interface for a self-adjusting limit switch. tel: 024 7653 5535 www.georgefischer.co.uk photoluminescent floorline is a specially designed type of matting designed to provide an effective escape route guidance system that requires no illumination or maintenance. it is manufactured by plastic extruders with an integral photoluminescent compound. the photoluminescent strip only requires normal ambient lighting to energise so that if the emergency lighting fails or, in a more serious fire, smoke obscures the lights, the guidance strip will immediate illuminate to show people the route to safety. floorline is a flexible open grid slip resistant matting which is impervious to liquids, acids and spillages which are simply dissipated and thereby increase safety underfoot. the soft tubular grid construction is particularly suitable where hard wearing performance combined with cushioned comfort underfoot is required. it also insulates against cold and hard floors. tel: 01268 571116 sales@plastex.co.uk www.plastexmatting.com stertil stokvis has removed an outdated door for component manufacturer tyco electronics, replacing it with a rapidroll 3000l. the new, high-speed door has transformed the area previously serviced by the old door, which was in a poor state of repair and could only be operated manually. stertil stokvis installed a rapidroll 3000l, a high-speed hybrid of the popular 3000 security shutter door incorporating alternate transparent laths to allow natural light through. the fast-action door moves at speeds up to 2.5 metres per second, allowing high volume use. in fact, during the first two weeks after installation, the new door had over 2000 operations. tel: 0870 770 0471 www.stertiluk.com advantage control of northern ireland becomes the 12th abb drives alliance member following its appointment in july. based in downpatrick, advantage control offers abb variable speed drives from 0.18 kw to 400 kw. as with all abb drives alliance partners, advantage control offers a lifecycle of drive services, from pre-purchase including energy appraisals and application advice; through to installation and start-up; operation and maintenance; upgrade and retrofit; replacement and recycling. the company can be contacted 24/7, allowing a fast response to breakdowns. advantage control has specific expertise in converting plastic extruders and cable winding machinery from dc drive control to ac drive control. the company also manufactures frequency converters using variable speed drives to convert 240 v single-phase supplies to 415 v 3-phase up to 5.5 kw. tel: 01925 741111 www.abb.co.uk/energy new sumo sizes added to range new powercuts provide high quality cutting on the move advantage control joins abb drives alliance photoluminescent matting shows the way new generation diaphragm valves leslah@dfamedia.co.uk spotlight twi captures dust from vibrating sieves - with airbench castle group has announced the winner of its competition for a 4-in-1 environmental meter, held at the safety and health expo in may at the nec. the winner is craig edgar of g.i. hadfield & son, based at manchester. the meter is a single device that can measure noise, light, temperature and humidity. the prize was awarded to craig at a free half day environmental noise seminar run by castle in carlisle in june. he said: “it was such a surprise to receive the call from castle and i’m delighted to take delivery of the prize in person. i really do have a need for this piece of equipment, so it couldn’t have found a better home!” tel: 01723 584250 www.castlegroup.co.uk castle group announces winner esab has introduced two new models in its powercut tm line of manual cutting packages. the lightweight portable powercut 900 and 1600 packages make cutting easier and more economical thanks to design features that simplify operation, reduce set-up time and enhance consumable life. the powercut models offer the highest speeds and thickness capabilities in their class, as well as high duty cycles, for outstanding productivity and performance. through a combination of long parts life, high speeds and simple torch design, they give the lowest cost per metre of cut of any machine in their price class. the power source is contained within a durable, damage resistant external housing which is also corrosion and weather resistant. the sensitive internal electronics are suspended from the aluminium frame and insulated from shock and vibration. tel: 0800 3893152 info@esab.co.uk stertil stokvis rapidroll door improves speed and efficiency 49_pwe_0910_new ps 0109 14/09/2010 15:26 page 1product spotlight an efficient production system and a good quality end product are important objectives for the mashhad packaging industries company, who are iran’s largest manufacturer of metal cans. the factory is based in a hard water area and the resulting build up of limescale was identified as a major production problem. limescale build up around the solenoid control valves on the welding machine meant inaccurate and inefficient welding leading to damage to the metal. to combat the problem, a decision was made to trial a limescale prevention system; hydropath’s patented water conditioners were installed which made a positive impact and so two hydroflow hs-38 units were fitted permanently. over a year later there has been no problems reported in connection with limescale and therefore no associated maintenance work has been necessary. tel: 0115 9869966 www.hydropath.com . designed to provide developers and testers of safety-related machine controls with comprehensive support in the evaluation of safety in the context of en iso 13849-1, sistema software is available for download on www.wielandsafety.net. sistema stands for “safety integrity software tool for the evaluation of machine applications’ and enables users to model the structure of the safety-related control components based upon the designated architectures. this, in turn, allows automated calculation of the reliability values with various levels of detail, including that of the attained performance level. relevant parameters such as the risk parameters for determining the required performance level, the category, measures against common-cause failures on multi-channel systems, the average component quality and the average fault detection level of components and blocks, are entered step by step in forms. tel: 01483 531213 www.wieland-electric.com designed to detect flammable gases and vapors, the atex approved draeger sensor ir has been specifically developed to allow existing pellistors or catalytic bead sensors to be replaced easily, without creating technical problems. the inclusion of wheatstone bridge emulation, which duplicates a standard pellistor output, this also means that existing cables and control devices, from the majority of manufacturers, can still be used. even in the harshest of conditions, these new poison immune, fail-safe sensors are simple to install, simply unscrew the traditional pellistor and screw in the innovative draeger sensor ir. featuring an expected lifespan of more than 15 years and benefiting from significantly reduced maintenance costs, the sensor is protected by a robust stainless steel enclosure and provides high reliability as well as excellent measurement performance. tel: 01670 561413 marketing@draegersafetyuk.com global explosion consultants gexcon uk are holding the following very popular 2 day comprehensive explosion science atex / dsear training course at their offices in skelmersdale, lancashire. december 7th & 8th these courses offer a unique opportunity for obtaining a full understanding into the phenomenon of explosions, what effects and consequences can be expected, how to become compliant with the regulations in force whilst delivering a sound basis of safety to protect personnel and plant within alarp as low as reasonably practicable. gexcon also offer on site tailor made training packages in accordance with regulation 9 of dsear.gexcon is wholly owned by the university of bergen within christian michelson research of norway, the staff of gexcon have over 400 years explosion safety experience. tel: 01695 726565 info@gexcon.co.uk www.gexcon.co.uk cc-link open comms has played a key role in the refurbishment of a massive overhead crane at the emz foundry in ukraine, boosting productivity and giving energy savings so that payback on control system development will be a matter of months. emz opted for cc-link, an open field device level network that provides high speed deterministic comms, linking a range of automation technologies over a single cable. it is suitable for machine, cell or process control in manufacturing and production industries. the project was a six axis drive system and engineers, csc automation identified mitsubishi drives as having dedicated crane drive software. it was decided to fulfil all processing requirements through a single mitsubishi q-series plc, and to provide operator information through one main and two secondary hmis. tel: 01707 278953 www.clpa-europe.com “the e5 is great, but we also need a 10 ton automatic hook”. we’ve heard this so many times, and now we are happy to announce that the elebia e10 is now here. based on the same innovative design of the e5, but using higher grade steels, the e10 achieves a working load limit of 10 tonnes, safety factor 4:1. the e10 is 715 mm high and 40 kg in weight, only 65 mm and 5 kg more than the e5. the elebia e10 is available now and has been tested according to en1677: permanent deformations under 1% when overloaded at 250% of it’s wll. doesn’t drop the load when overloaded at 400% of it’s wll. doesn’t show deformations after 20.000 cycles at 150% of it’s wll. tel: 34 93 444 1707 info@elebia.com maintaining welding quality at can manufacturing plant systema - comprehensive support for safety related machine control cc-link plays key role archco-rigidon coating murex tradesarc the 10 ton elebia hook spotlight leslah@dfamedia.co.uk contractor blastpride holdings ltd of cardiff is using the winn & coales archco-rigidon 423d lining to protect specially designed large process vessels for the offshore oil industry. the archco-rigidon coating is based on glass flake vinyl ester. there is a total of eight process vessels measuring 4.9m in diameter and ranging from 15 to 18m in length. before lining the vessels with the archco-rigidon coating, blastpride is shot blasting the surfaces to the swedish satandard sa 21/2 - 3. winn & coales (denso) ltd specialise in the manufacture of exclusive corrosion and chemical resistant coatings and linings for the long term protection of steel and concrete. all products are manufactured under a management system that complies with the stringent requirements of bs en iso 9001: 2000. tel: 020 8670 7511 www.denso.net easy infra red upgrade and longer sensor life atex / dsear training & consultancy designed for the heating and ventilation sectors, the murex tradesarc range includes lightweight and durable welding units. although the tradesarc 150 and 200 weigh just 7.9kg and 8.3kg respectively, there is no compromise in their design. large heat sinks ensure a cooler running machine with a longer life expectancy. the design also helps to keep all sensitive parts inside the machine clean and dust free. the tradesarcs are built in accordance with ip23, so they can be used outdoors. the tradesarc 150 and 200 are 230 volt single-phase power sources equipped with a power factor correction (pfc) circuit which protects the machines against fluctuating mains voltage and makes it safer to use with a generator. both tradesarcs can work with extra long mains cables, over 100 metres, giving a very large working radius. tel: 0800 3893152 info@murexwelding.co.uk 50_pwe_0910_new ps 0109 16/09/2010 10:29 page 2product spotlight for the second year running, health & safety e-learning provider safety media has been shortlisted for the e-learning development company of the year award at the prestigious e-learning awards. the award recognises companies that have achieved exceptional results within organisations as a direct result of bespoke e-learning content developed. safety media are pleased to offer a bespoke development solution to clients and work hard to provide a bespoke system tailored to the specific needs of the client. julian roberts, managing director of safety media said: “i’m delighted that we have been shortlisted for this award for a second consecutive year this is a great achievement for the whole safety media team who put a tremendous amount of hard work into developing engaging and innovative courses for our customers.” the winner will be announced at the e-learning awards at a ceremony on 11th november 2010 at the london marriott grosvenor square hotel in london. tel: 0845 345 1703 www.safetylearning.co.uk the safety hasp or ‘multi-hasp’ has long been used as a simple device which enables multiple maintenance personnel to work on a common isolated circuit or device, safe in the knowledge that power/energy cannot be restored until their work is finished and they have removed their personal padlock. this is a basic safe working practice and made reference to in the provision and use of work equipment regulations 1998 and the electricity at work regulations 1989. the device works by fitting it to the isolating switch in the off position, followed by a padlock. the hasp usually has up to six padlock holes, meaning that six engineers can all fit their own padlock in place while they carry out maintenance work on the same isolated device, process or machine. regardless of which of the engineers finishes work first and removes their padlock, energy cannot be restored until the last engineer finishes and removes his/her padlock. with the last padlock removed, the hasp can be taken of the isolating device and the equipment switched back on. the new stainless steel hasp from total lockout (safety) ltd is manufactured entirely from 316 stainless steel, thereby making it highly resistant to corrosion in marine environments or environments where chemicals are used. in addition it has 8 padlock holes providing greater capacity for additional engineers working on the same equipment. tel: 01376 325506 th@totallockout.com www.totallockout.com ktr’s new mmc combined cooler simultaneously proves its worth three times: used as a water cooler, used as an oil cooler-cooling either hydraulic or gear lubricant oil, used as a charge air cooler it assures the right temperature of the combustion air. in addition, it can even be used as a fuel cooler! the mmc also proves that less is more. less size: a compact design offers greater options for installation. less expense: costs are reduced and efficiency increased thanks to the mmc’s great adaptability covering a diverse range of applications. this makes it the ideal cooling power pack for mobile agricultural and construction machines, but also stationary i. c.-engines. tel: 44 (0)114 258 7757 www.ktr.com safety media shortlisted for the e-learning development company of the year award leslah@dfamedia.co.uk spotlight new stainless steel multi-hasp new mmc combined cooler for water, oil and air avery weigh-tronix has launched its new automated weighbridge control station avs-7, which it claims offers more functionality and flexibility as standard than other solutions. the avs-7 is an automated control console with an advanced e1310 indicator and thermal printer inside an ip56 enclosure. it is supplied with a standard qwerty keyboard, id card reader and intercom. the new system has an easy to read display with clear and simple driver prompts. says product manager chris mcallister: “the advantages of fully automated weighbridge access for 24/7 operation, to ensure accurate data capture and to lower costs are well rehearsed. we have introduced this new system to offer customers maximum flexibility from a standard system. other manufacturers offer many of the features found on our standard unit as optional extras.” tel: 0845 3 66 77 88 www.averyweigh-tronix.com new automated weighbridge control station the ct range of regenerative pumps from salamander has received a facelift, improving both the appearance and functionality of this robust and ultra reliable pump. in the updated ct50 models, the most obvious change is the incorporation of a new more robust foot, which is integral to the pump motor, making it much more durable in transit than its predecessor. the protrusion on the end of the shaft drive has also been removed, leaving a sleeker line. aesthetics aside, the updated pumps now all have isolating valves on the inlet couplers fitted as standard to make the servicing of the pump that much easier. there is also an improved switching system giving even better repeatability and reliability. tel: 0845 3779160 www.salamanderpumps.co.uk ct range of regenerative pumps the bath stone group is reaping the benefits of a change in tyre policy which has seen tyre longevity on its underground loader shovels rise by 800 per cent, significantly increasing productivity at its stoke hill mine. the move has seen its two wagner st2d underground loader shovels switch from budget asian tyres to michelin x-mine d2 radial tyres. the low-cost protector tyres being used on the machines were lasting between 50-250 hours, with an average life of 10 working days. conservative projections showed that the michelin x-mine d2 radial tyres were likely to achieve at least 2,000 hours in operation, in comparison to the protectors’ 250. designed for the ultimate in traction, flotation, stability and comfort, the x-mine d2 tyres are renowned for their resistance and durability. tel: 01782 402341 www.michelin.co.uk michelin makes a world of difference in underground mining operation the new hand held primetest 250 is the first electrical tester in its class to provide all the electrical tests required for compliance with the iee code of practice for the in-service inspection and testing of electrical equipment - and also includes a host of other features. these additional test capabilities include an rcd trip time test, a 3-phase leakage test and a 250v dc insulation test suitable for testing sensitive electrical appliances and surge protected leads. the primetest 250 forms part of a comprehensive range of portable appliance testers from seaward that comprise eleven different models and test specifications to meet all workplace electrical safety testing needs. tel: 0191 586 3511 www.seaward.co.uk. prime test 250 pat tester breaks the mould 51_pwe_0910_new ps 0109 20/09/2010 16:28 page 152 september 2010 plant&worksengineering classified to advertise here call alistair on 01732 370347 www.pwemag.co.uk dispensing equipment for all your liquid dispensing needs! l 3 and 4 axis robots l bead and dot application l accurate, repeatable dispensing l easily programmable l eliminates operator error henkel limited, technologies house, wood lane end, hemel hempstead, hertfordshire hp2 4rq phone 01442 278100 - fax 01442 278071 - email technicalservice.loctite@uk.henkel.com - www.loctite.co.uk ‘these buildings do it all’ call: 01709 578333 01709 578333 save all buildings to bs5950 & bs6399 30 years guarantee 100% useable space no maintenance worldwide delivery extremely cost effective simple to assembly saves you money blueline delivers quality, strength, and service at factory direct prices on general steel buildings, metal storage sheds, steel building kits. call today for specials on our building kits blueline buildings q:blueline buildings q 3/6/08 11:37 page 1 newbie works annan dumfries & galloway dg12 5qu tel: 01461 202111 fax: 01461 205511 email: sales@cochranhire.com www.cochranhire.com cochran hire limited trailer mounted boilers containerised boiler hire static boiler hire ancillary equipment water treatment operator training service low running costs cochran hire limited the industry experts a cochran hire boiler can resolve many site problems quickly and efficiently and our fleet is available for both long and short term hire, can be fully commissioned and installed with full training and operational support. classifications for: pumps & valves heating & ventilation buildings & construction flooring computer maintenance management systems adhesives handling & storage applications: trench covers industrial flooring work platforms tank covers service duct covers bridge decking benefits: light weight / high strength easy installation anti-slip surface corrosion/fire resistant impact resistant zero maintenance tel: 44 (0) 1255 423601 fax: 44 (0) 1255 435426 www. trench-cover.co.uk info@duracomposites.com dura composites ltd., unit 14 telford road, clacton-on-sea, essex co15 4lp uk for new or replacement trench covers, work platforms and industrial flooring fibreglass structural flooring dura slab 11 tonne swl covers halfpagelandslab(cons) 11/11/09 11:40 am page 1 pwe_classified_0910_classified 16/09/2010 10:25 page 5253 september 2010 plant&worksengineering over the last half century we have worked hard to establish an enviable reputation for quality products, reliability and innovation. from general purpose standard valves and customer specials, to phone masts, ships, reneries, engines and complete bespoke oem solutions we constantly give our all we have to oer. our commitment to invent, innovate and invest give us the condence to know that our next half century will be just as successful as the last. fit itt and forget tel: 44 (0)1902 305678 fax: 44 (0)1902 305676 pressure proving system commercial gas interlock panels gb series en161 gas valve's hwa series gas board approved acd series general purpose for air, oil and water www.alconsolenoids.com applications: trench covers industrial flooring work platforms tank covers service duct covers bridge decking benefits: light weight / high strength easy installation anti-slip surface corrosion/fire resistant impact resistant zero maintenance tel: 44 (0) 1255 423601 fax: 44 (0) 1255 435426 www. trench-cover.co.uk info@duracomposites.com dura composites ltd., unit 14 telford road, clacton-on-sea, essex co15 4lp uk for new or replacement trench covers, work platforms and industrial flooring fibreglass structural flooring dura slab 11 tonne swl covers pwe_classified_0910_classified 16/09/2010 10:23 page 53to advertise within these sections please contact alistair mckay on tel: 01732 370347 email: alistair@dfamedia.co.uk 54 september 2010 plant&worksengineering with the world concentrating on cutting carbon emissions for sound ecological reasons and industry working hard to save money by reducing energy bills, it is rare to find a simple and proven technology that readily meets both criteria. thermal fluid systems from babcock wanson have regularly shown energy savings over conventional steam process heating of between 30-50% with reduced maintenance needs and fully automatic operation. to learn how this technology could help your business why not request a copy of the practical application of thermal fluid heating. babcock wanson uk ltd, 7 elstree way, borehamwood, hertfordshire wd6 1sa. telephone: 020 8953 7111 fax: 020 8207 5177 email info@babcock-wanson.co.uk web address: www.babcock-wanson.co.uk cut costs and go green with thermal fluid '%('",&-,*"''*"& & "'%('",,     "&'& "'%('",'-# ///& "'%('",'-# &'/'***'!-* &%(  '*."",'-*/", ///& "'%('",'-# "* '%('",,*-,-** '**'"'&*",&,"**",&," !, /" !,,!*%0,&*)-"* 1*' %"&,&& ,"* * !&*",0 ,*''/#/0 (,'*%*%(& *,"& & % ,' 0'-* ("","'& & "&,0'-*'/&#"*,%& pwe_classified_0910_classified 16/09/2010 10:23 page 5455 september 2010 plant&worksengineering products and services directory boiler hire & sales blower repairs (roots) air conditioning hire stockists of all manufacturers of new and reconditioned blowers blower repairs hire blowers conveying systems unit 6, river brent business park trumpers way, hanwell, london w7 2qa tel: 020 8571 3988 fax: 020 8571 3955 email: sales@ibsblowers.com contact: graham matthews web: www.ibsblowers.com uk’s no.1 choice for boiler hire for one-stop service talk to the experts today... king boiler hire sales repairs 500-35,000 lb/hr. up to 250 psi trailerised, containerised, mobile & static. hot water boilers 150-4500 kw comprehensive hire rates - long or short term. expert boiler servicing & repairs boiler spares, valves etc. worldwide export bunded and un-bunded tanks - hire & sales visit our website today www.kingsboilerhire.com tel: 01992 451629 fax: 01992 448783 k 7/3/08 14:09 page 1 blowers & compressors blowers, compressors & vacuum boosters repair and hire aerzen machines limited 44 (0)208 502 8100 sales@aerzen.co.uk www.aerzen.co.uk advertising gifts/ incentives g view and buy online phone fax email for catalogues grip calculator printed 1 colour 100 @ 1.75 ea. speedy fm scan radio printed 1 colour 50 @ 3.45 ea. card holder printed 1 cotton shopping bag printed in full colour 50 @ 2.75 ea. laptop backpack printed1colour 25@13.95 ea. emc advertising gifts 1064 high road, london, n20 0yy • easy to order • free artwork • free design! • easy to order • free artwork • free design! • easy to order • free artwork • free design! • easy to order • free artwork • free design! • easy to order • free artwork • free design! • easy to order • free artwork • free design! balancing access equipment united we stand 0808100 3602 a phone call or e-mail will secure a machine for every application, with the largest range available in the uk. please mention pwe when responding to these adverts for temperature control rental turn to the experts • fluid chillers • boilers • air conditioning • heating • dry coolers/ free cooling 0800 026 4717 rental systems to advertise in the directory contact alistair mckay on: tel: 01732 370347 e-mail: alistair@dfamedia.co.uk www.pwemag.co.uk the october 2010 issue will include the new look editorial features: maintenance matters process, controls & plant (drives & controls) energy, the environment & water (compressed air) production engineering premises & facilities management (access equipment & signage) handling & storage (lifting equipment & conveyors) health, safety & training exhibitions & special reports (bcas yearbook, imhx preview & training & recruitment report) the compressed air & generator exhibition 17-19 april 2012 nec birmingham contact ryan fuller on 01732 370340 e-mail ryan@dfamedia.co.uk www.airtech-expo.com in association with new p&s pages_pwe_0910_pwe_p&s_0608 14/09/2010 14:29 page 55