ERIKS Know+How Issue 23, Energy Conservation

THE LEADING MAGAZINE FOR MAINTENANCE ENGINEERS FROM ERIKS

www.eriks.co.uk/knowhow

ISSUE 23

The big picture on energy efficiencyFocus on energy conservation for long term savings p10

Pumping up valueShould you repair or replace your pump? p24

Introducing TIM WOODMemorable, helpful, wasteful p18

When minus is a plusLess energy, more benefits p22

ENERGY CONSER

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Leaking secretsDiscover where the cash is leaking from your business p6

Happy ever afterHow to make your coupling last p14

Contents

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ContentsWELCOME TO KNOW+HOW…Covering the latest news, industry developments and technologies, this edition of Know+How focuses on one of the hottest topics in the maintenance world: energy conservation.

I look forward to hearing from you.

Alan WhetstoneManaging Director, Editor in Chief

UNREGISTERED

Published by ERIKS UK, Amber Way, Halesowen, West Midlands, B62 8WG

With both UK and European legislation clamping down hard on energy consumption across the commercial landscape, the process-heavy nature of the industrial sector is right in the firing line. Whilst the pressure to conserve energy becomes ever greater, the task is not impossible and there are a host of different ways maintenance engineers can streamline consumption without breaking the bank.

Inside, you’ll be able to read up on some of the latest trends and products making the headlines in the energy market, as well as hearing from a number of leading industry players on how to tackle energy conservation. SKF will shed light on the energy-saving impact of bearings in motors and drives; Festo investigates the efficiency properties of electric vs pneumatic components; and SMC delves into the seven deadly wastes of the workplace with ‘Tim Wood’ – but all is not as it seems. We’ll also address one of the age-old arguments affecting maintenance engineers – whether to repair or to replace, with this issue focusing on pumps.

We are also very pleased to welcome Janet Wood of New Power magazine as our guest contributor. Janet will dig deeper into the mechanics behind improving energy conservation, moving away from a focus on fuel cost to emphasising the importance of understanding your processes and pinpointing where the most savings can be made.

As ever, the issue will be rounded off by the TIG, who in this issue ponders the changing face of the UK’s industrial landscape, following the decline of many of the iconic visual reminders of our industrial heritage.

If you have any comments you would like to raise on the topics contained in this issue you can email the editor at: [email protected] or you can visit Know+How’s own website: www.eriks.co.uk/KnowHow where you can register for your own personal copy, enquire about the subjects and products discussed or contact one of the contributors.

LATEST NEWS 04 Solar power cheaper than fossil fuels by 2020?

Energy from footsteps

£1.3bn offshore wind farm given green light

‘Significant’ oil discovery made in Sussex hills

British economy on track for continuous growth

Six hours of energy saving

IN-DEPTH 06 Where does the cash leak from your business?

TECHNOLOGY UPDATE 08 RX launches new range of industrial wiping products

ERIKS partners with INOXPA to enhance valve offering

ERIKS unveils new range of spiral wound gaskets

ERIKS home to most comprehensive couplings offering

RX gives engineers a helping hand

FOCUS ON ENERGY CONSERVATION

10 Is your business energy savvy? p10

Planet Plus – Surveying for savings p12

Searching for closure p13

Couple counselling p14

The right choice p16

The seven deadly wastes p18

Going beyond zero p20

Let us spray and save energy p22

THIS MONTH’S DEBATE 24 Repair or replace

TIME SAVINGS 26 Delivering the milk on time

BEST PRACTICE When saving money on gearboxes costs you money

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For Fenner®, call ERIKS.

Energy Efficient Fan and Centrifugal Pump ControlThe Fenner QD:HVAC sets a new standard for dedicated fan & pump control whilst retaining the ease of use you come to expect from Fenner inverters. Fenner QD:HVAC has an innovative design, combined with robust performance to provide powerful flow control and reliability in a compact drive.

Energy optimisation Energy monitoring Built in cascade control Multiple fan operation Resonance avoidance

QD:HVAC Inverters

Energy Efficient98.8

Energy Efficient95

Energy Efficient96

Energy Efficient98

EXAMPLE SAVINGS BASED ON A 45KW LOAD

Power

Flow %

Input to fixed speed systems

Input to fixed speed systems

Calculation is based on a typical estimated factory working week and energy costs, including estimated components and installtion costs.

Investment paybackin 8 months

Savings of over€31,000 in 5 years

35,000

30,000

25,000

20,000

15,000

10,000

5,000

00 1 2 3 4 5

€

Hours

Using a Fenner QD:HVAC drive to reduce the fan speed during periods when maximum flow is not required provides the maximum possible energy savings.

www.fptgroup.com

ERIKS UK Amber Way, Halesowen, West Midlands, B62 8WG Tel: 0121 508 6000 Fax: 0121 508 6255

T : 0845 006 6000

Fenner is a registered trade mark of J. H. Fenner & Co.

A 20% REDUCTION IN SPEED CAN REDUCE ENERGY CONSUMPTION BY UP TO 50%.

INSTANT POWER SAVINGS: With variable speed control, HVAC immediately reduces power usage compared to fixed speed systems.

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ERIKS UK

Latest news Latest news

ISSUE 23 www.eriks.co.uk/knowhow4 5

‘Significant’ Oil discovery made in Sussex hills

UK set for back-to-back economic growth, fuelled by manufacturing exports

THE BRITISH ECONOMY IS WELL ON TRACK FOR

CONTINUOUS GROWTH OVER THE NEXT TWO YEARS,

HAVING INCREASED FASTER THAN INITIALLY PREDICTED.

According to the leading business group, the CBI, the UK economy is forecasted to have grown by 2.4% by the end of 2015, and it predicts a further increase of 2.5% for 2016. Whilst external factors such as a sluggish Eurozone have resulted in a slightly revised forecast for growth, the home-grown prospects remain buoyant.

In the same vein, the British Chamber of Commerce has reported an overall growth of manufacturing export orders and sales over the first quarter of the year. Over 46% of the companies surveyed reported a growth in export orders, and 43% recorded an increase in export sales compared to Q4 2014.

John Longworth, director general of the BCC, said: “Manufacturers are turning to export markets abroad to fuel their growth ambitions as the slowdown in domestic growth persists. Encouragingly, the increase in export sales and orders has come about in spite of the rise in the pound against the euro over recent months - a credit to the strength and expertise of the UK’s manufacturing sector.”

Six hours of energy savingThe ERIKS’ Energy Conservation Operation Day – held in Northampton on 17th June in conjunction with Festo – proved interesting, informative and enjoyable for its 90 attendees.

With less than six months to go before the results of ESOS assessments have to be submitted to the Environment Agency, visitors to the ECO Day heard timely advice from experts on the causes of energy loss, along with solutions for energy conservation.

Presentations on thermographic surveys using infra-red equipment, maximising energy savings through creative lighting controls, energy-saving opportunities with pumps, and cost-saving ideas for compressed air all helped to ensure the day provided invaluable guidance and know-how, combined with practical solutions.

Stimulating and simulatingMany visitors made the most of the opportunity to network with ERIKS experts and industry peers. Most also spent time browsing around the event’s exhibition, which included displays from Festo, Grundfos, SKF, CAMfil, WEG and Inoxpa, as well as ERIKS Pumps, Condition Monitoring and Lighting Solutions.

The day included a tour of Festo HQ, and concluded with a Prize Draw, in which Aston Fuller of Ardagh Glass won a presentation boxed pen and pencil set.

Solar power could be cheaper than fossil fuels in five yearsSolar power could become cheaper than fossil fuels by as soon as 2020, according to an industry body.

The Solar Trade Association (STA) believes the new government could double the solar ambitions of the previous administration with just a ‘little more expenditure.’

As part of its new report, Solar Independence Plan for Britain, the STA outlined that with buy-in from 2.1m homes; 24,000 commercial and community schemes; and 2,300 quality solar farms, the new government can guide rooftop-generated electricity to parity with gas power station prices by 2020.

The next (foot)step in energy generationEnergy from footsteps could be the next big thing in the world of alternative energy, after British firm Pavegen has started a crowd funding campaign to develop an energy-generating floor.

The technology works by converting the movement and weight of the person walking across the floor into power, via an electromagnetic generation system. When footstep pressure is applied, a flywheel rotates and the energy from the step is stored in the inertia of the flywheel.

It has unveiled its first urban installation in London, having already trialled the technology at Heathrow Airport, the White House, and a Brazilian football pitch.

£1.3bn offshore wind farm given green lightE.ON has been given the go ahead to construct a 400mW wind farm 13km off the Suffolk coast, following significant financial commitment.

The 116 turbine strong project, known as the Rampion Offshore Wind Farm, will occupy 72km² and represents an investment of £1.3bn from E.ON and Green Investment Bank.

With work starting in June 2015, it is due for to be completed by 2018. The project is expected to reduce CO2 emissions by up to 600,000 tonnes a year and create between 250 and 300 construction jobs, as well as 65 permanent MRO jobs once the wind farm is operational.

The discovery, which equates to more than double the amount of oil produced by the North Sea over the last 40 years, is one of the largest onshore discoveries in the UK to date. However, only a fraction of it could be recovered, according to exploration firm UK Oil & Gas (UKOG).

Having analysed results from a preliminary well drilled at Horse Hill, near Gatwick; the local area could hold 158 million barrels of oil per square mile. The company believes between 5 and 15% of the oil is recoverable, which means that the discovery – when combined with other oil production sites across the South East – could cater for up to 30% of the country’s demand. What’s more, UKOG believes the resources could be accessed without resorting to fracking.

UKOG chief executive, Stephen Sanderson, commented: “We think we’ve found a very significant discovery here, probably the largest (onshore in the UK) in the last 30 years. Based on what we’ve found here, we’re looking at between 50 and 100 billion barrels of oil in place in the ground.”

UP TO 100 BILLION BARRELS OF OIL COULD HAVE BEEN

FOUND IN SOUTHERN ENGLAND.

Energy

ERIKS ECO Event

Date & Time; Wednesday 17th June 2015, 10:00 to 16:00)

Location; FESTO Caswell Road, BrackMills, Northampton, NN4 7PY

EnergyConservationOperation

Festo’s Airmotion Ride attracts attention during the breaks.

All the presentations and overviews from the day are available on knowhow.eriks.co.uk

In-depth

ISSUE 23 www.eriks.co.uk/knowhow6 7

In-depth

FROM YOUR BUSINESS?LEAK

WHERE DOES THE CASH

THE CAUSE CAN’T BE SEEN. IT CAN’T BE TOUCHED. BUT THE LOSSES IT RESULTS IN ARE NO LESS REAL. THERE COULD BE THOUSANDS OF POUNDS LITERALLY LEAKING AWAY FROM YOUR BUSINESS – AND IT’S A PROBLEM ACROSS THE WHOLE OF UK INDUSTRY. YET MOST PEOPLE AFFECTED STILL BELIEVE THE PROBLEM DOESN’T EXIST, EVEN WHEN IT IS, LITERALLY, UNDER THEIR NOSES.

If you haven’t guessed yet what the problem is, then the chances are that you are one of those people who deny it’s a problem at all. The issue is compressed air leakage, and the common attitude is that “air is free, so how can it be losing me money?”

In fact, compressed air is not a no-cost or low-cost resource. So if it’s being wasted, or used inefficiently, then money is, in every sense, disappearing into thin air.

60% lossesOn some industrial sites, as much as 60% of the total compressed air they generate is lost to leaks. Even an average site leaks 30% of its compressed air.

According to Mark Stone, Product Manager at FLEXION Fluid Power, “Big leaks, such as a drain cap on a filter regulator, can cost up to £5,000 every year. Even small leaks, emanating from a control panel, main air drop or push-fit connection, for example, can cost hundreds of pounds in compressed air annually.”

But the leak is not the end of the problem.

A costly vicious circleCompressed air isn’t “as free as air” because the compression process requires equipment, uses energy to drive the equipment, and the equipment incurs additional labour, parts and lubricant costs to remain in operation.

So an unidentified and unrepaired leak wastes the cost of production of the compressed air. But that’s only the start.

A leak also means the air-driven equipment is not being supplied with compressed air at the correct pressure. This means it will not perform at its optimum, and its efficiency and productivity will fall. At the same time, the leak effectively creates a greater demand for compressed air, which the compressors will work harder to satisfy. This in turn increases their own demand for energy, which reduces the plant’s overall energy efficiency, increases its energy bills, and ultimately increases CO

2 emissions.

Since every additional 1kW of electricity used generates another 0.5kg of CO2, unnecessary and excessive energy use not only has implications for your bottom line, but also for your CSR policy and for the environment.

Plugging the leakThink of a compressed air leak as a leak of cash, and suddenly fixing the problem becomes a priority. And it’s a highly cost-effective step to take.

A leaking loose connection on an isolation valve could be costing hundreds of pounds annually in lost compressed air. Yet it can be fixed in a matter of minutes, probably for as little as £25.

But sometimes, a leak may merely be the most easily identified source of compressed air losses. Compressed air can also generate unnecessary indirect losses and costs, which may be harder to spot without the necessary technical know-how.

Supplying compressed air to an idle plant, or using higher pressures than necessary, are both a waste of air, energy and money. So is failing to use the most energy-efficient components.

Taking a systematic approach to compressed air management – from leak detection to system design – may lead to some compressors no longer being required, which will obviously lead to significant energy and maintenance cost savings.

For some applications, the most cost-effective option may even be to switch to an alternative technology entirely.

Mark StoneProduct Manager, FLEXION Fluid Power

Compressed Air Savings ProgrammeIt’s to help industry find and fix compressed air leaks, and make significant energy and cost savings, that FLEXION – the international fluid power brand of ERIKS – has established the Compressed Air Savings Programme.

The Programme comprises three elements:

1. Application Audit – an experienced FLEXION team uses a specially designed ultrasonic detector to complete an audit for a medium-size plant in around three hours.2. Full Report – delivered immediately after completion of the audit. The report lists the leaks detected, their size, and their estimated cost to the business.3. First Fix – basic on-the-spot repairs, where possible. These can include remaking joints, and/or replacing fittings, gauges and other non-active parts. First fix capability depends on safe access to the equipment, which normally requires isolation of the mains air supply. A full bill of the materials required to effect all recommended repairs identified in the survey will be provided.

Through this Programme, FLEXION has already achieved significant signed-off cost savings on compressed air use for businesses across UK industry.

If you would like to find where cash is leaking from your business, visit the FLEXION Compressed Air Savings Programme page of the ERIKS website www.eriks.co.uk/flexion or contact your local ERIKS Service Centre.

Technology update Technology update

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RX launches new range of industrial wiping products

The portfolio, which is exclusive to ERIKS, includes general purpose and speciality wet wipes and cloths, and is available in a variety of durability levels to cater for different market sectors and the taking care of the diverse liquids involved.

The RX range of wet wipes have been designed as a go-to product for general everyday hygiene applications, as well as covering more technical sanitising solutions, such as when precision wiping and ultra-low linting wipes are essential. All of the products are dermatologically tested and comply with the European Standards, meaning they are effective against H1N1, Salmonella, Listeria and E-Coli, amongst others.

In order to offer end users further peace of mind when heavy duty workstation hygiene is a must, or when small-scale accidents occur, the new range of industrial cloths and wipers are highly absorbent and durable enough to a number of different liquids, including solvents.

The new RX industrial wiping portfolio is suitable for use across a wide range of applications, but can offer an ideal solution for food processing, healthcare, transportations sectors, as well as general workshop maintenance.

The new range has attained the maximum score – 4.5.4.4 – across all categories for EN388, which protect against mechanical risk, to offer all-round protection for a number of different industrial applications.

Available in five different sizes, the RX Safe5 glove features a close-fitting yet breathable seamless liner to offer optimum dexterity, with a durable Nitrile palm coating to provide both an excellent grip and resilient all-round protection. It also features an elasticated knitted wrist-cuff to ensure a secure fit and keep the hands free from dust and debris.

The RX Safe5 range is suitable for use across a variety of industrial maintenance and repair applications, including component handling and general assembly, across a number of different industries, such as automotive, construction and engineering.

Available in a number of different designs, the INOXPA range is specifically designed for use within the food and beverage, pharmaceutical, cosmetics, and chemicals industries.

Included within the new INOXPA offering is the widely-used seat valve range, which is available in a number of different configurations: a single-seat pneumatically operated shut-off valve; a manually actuated single-set valve; a divert seat valve; a tank bottom seat valve; a regulating seat valve; and a hygienic mix-proof double seat valve, which simultaneously allows two fluids to

pass through the valve, whilst preventing cross-contamination.

Alongside the seat valves, ERIKS will also be stocking a range of manual and automatic butterfly valves; diaphragm and pinch valves; ball valves, for use with viscous fluids containing solid particles; check, or non-return valves; overflow valves for pressure bypass systems; and vent valves, for the release of trapped air in suction pump applications.

For more information, call 0116 272 7300 or email [email protected]

RX HAS LAUNCHED A NEW PORTFOLIO OF HIGHLY ABSORBENT INDUSTRIAL WIPING PRODUCTS

TO HELP COPE WITH HEAVY DUTY CLEANING TASKS AND SMALL-SCALE SPILLAGES.

RX HAS RELEASED THE LATEST IN ITS LINE OF PERSONAL

PROTECTIVE EQUIPMENT (PPE) – THE RX SAFE5 GLOVE, WHICH

MEETS THE MOST STRINGENT EUROPEAN SAFETY STANDARDS

FOR GLOVES FOR MECHANICAL PROTECTION.

ERIKS IS NOW STOCKING A WIDE RANGE OF INOXPA SANITARY VALVES TO

CONTRIBUTE TO ITS BROADEST INDUSTRIAL VALVE OFFERING TO DATE.

ERIKS partners with INOXPA to enhance valve offering RX gives engineers a helping hand

with ultimate protective glove

For more information, please visit eriks.co.uk/RX-Safe5-Gloves/4130

For more information, please visit eriks.co.uk/RX-Wiping-Products/4131

The Leader Gasket Technology (GT) range is available in four different styles: S – spiral winding only, which consists of a wound gasket but with no inner or outer ring; SI – a spiral wound gasket with a solid metal inner ring designed to minimise turbulence in process material flow, and prevent inward buckling of the spiral wound gasket element; SR – a spiral wound gasket with a customisable outer ring; and SRI – a gasket with a spiral winding and both an inner and outer ring.

The Leader GT range is suitable for both OEM and MRO applications across a number of different industries, including oil and gas; chemical; petrochemical; pharmaceutical; power generation; hygiene; and marine.

What’s more, all gaskets can be manufactured in our European facilities to bespoke specifications using ERIKS Gasket Technology’s state of the art engineering and design studio, including ASME B16.20 and in line with ISO 9001.

For more information, please visit eriks.co.uk/Gaskets

ERIKS has been at the forefront of the design, manufacture and supply of gaskets for over 40 years and has launched a new range of spiral wound gaskets which can be used across all relevant industrial applications.

Technical Support across extended range

AS A VITAL ELEMENT IN MOST

POWER TRANSMISSION SYSTEMS,

ERIKS OFFER ENGINEERS THE

MOST COMPREHENSIVE COUPLING

SELECTION AVAILABLE.

Given the drastic consequences associated with incorrectly specified couplings, the ERIKS offering boasts a number of market-leading brands, supported by a dedicated Couplings and Drives Centre of Excellence. As such, any potential customer has access to unparalleled industry knowledge and expertise to ensure they are sold the most appropriate coupling solution for their application.

ERIKS exclusively stocks a wide range of couplings from one of the most renowned brands worldwide, Fenner. From the basic Jaw Couplings to Fenaflex Tyre Couplings which is regarded as the ultimate in machine protection, the Fenner range has it covered.

Alongside Fenner, ERIKS is also the sole supplier of Falk couplings including Steelflex, Wrapflex and Lifelign.

Well known for their durability in critical applications, Falk couplings can be used across a huge range of industrial applications, and offer one of the lowest Total Cost of Ownership (TCO) ratings on the market.

What’s more, ERIKS’ in-house machining centre can produce bored and keyed couplings modified to precise and bespoke requirements.

For more information, please visit eriks.co.uk/Couplings

ERIKS unveils new range of spiral wound gaskets

Focus on Energy Conservation Focus on Energy Conservation


the government has given industry a push towards better efficiency, requiring many companies to measure and report their use or carbon emissions. The ESOS certificate scheme is the latest approach to audit – one that has yet to convince companies, and perhaps that is why by the end of May fewer than 50 of some 14,000 firms who have to demonstrate compliance had done so.

Whether or not you want to report it, understanding your usage is fundamental to reducing it. Metering and submetering (between, say, areas of a building or parts of a factory line) is improving all the time and although domestic and microbusiness customers are still on simple meters read annually, most businesses now should at least have meters that measure consumption half-hourly. That means you can identify and remove stray usage that is unnecessary. It also means that you can be aware of when you use most energy. Again, this doesn’t affect domestic and very small businesses yet, but most others will have a time element in their charges – because there are several components in your bill, like the network charge and the cost of power, that can rise dramatically at peak

times of the day. You are already paying for that, even if your supplier absorbs it into a flat tariff. But if you can understand when those peak hours are and focus your energy efficiency efforts on those periods, payback will be quicker.

Finally, it’s worth thinking about water. Scientifically, water is a strange and interesting liquid. Among those interesting features are that it is extremely heavy to move around, and that it takes an inordinate amount of energy to heat it up. That means that for many companies a good proportion of the energy bill is for hot water use, whether that’s for general heating, processes heat, or just making sure it’s in the right place. Using water more efficiently can mean big energy savings.

Once again some of that is very low hanging fruit indeed – turning down the heating when the building is out of use – and water saving devices are increasingly available. And again, if you want ideas you should get your supplier to step up. Businesses are about to gain some more market power here: soon all business customers will be able to switch their water company as easily

as they do their energy supplier. Water companies afraid of seeing customers slip away have already identified help on water efficiency as a key opportunity to hold onto their customers, so contact them and see what they have to offer.

OIL AND GAS PRICES HAVE BEEN TUMBLING GLOBALLY OVER THE LAST YEAR, DRIVEN DOWN BY A BOOM IN SHALE GAS PRODUCTION AND GENERAL OVERSUPPLY ON THE WORLD MARKETS.

But that high level story of lower energy prices shouldn’t mean energy efficiency slips down the agenda for businesses. Oil and gas prices do influence the price you pay for gas and electricity at the meter, but they are a relatively small amount of the total, and even the GB energy regulator has noted that while your bill rises fast when commodity prices increase, it takes a long time to fall when they go down. In the long term, it will always make sense to reduce your energy bill.

What we have learned over the past decade is that there are huge savings to be made. But they may not be immediate.

There is no politician in the energy sector that does not like to end a speech with a flourish on energy efficiency. It’s the one energy measure everyone can agree on, and I’ve heard it described as “completely free”, and even as “negawatts”. That’s too simplistic: it pays back, sometimes quickly and sometimes slowly, but there is generally some cost to implementing it, even if that cost is in learning new habits.

The government has tried to provide more impetus for companies to consider their

energy use and take steps to reduce it. Sometimes that takes the form of taxes, so that energy-saving businesses could make savings on both their energy bills, and on extra taxes like the CRC energy efficiency commitment, which are levied according to the amount of energy used.

There are some relatively simple early steps that any business should take.

Lighting is a good example. It is familiar and often unnoticed, so it seems unlikely that changing it can make much difference to the bill. Nothing could be farther from the truth – in fact, the effect is visible on a national scale. Electricity system operator National Grid has seen a 3% reduction in domestic electricity demand since customers started switching from old-style light bulbs to new compact fluorescents, and shifting to LEDs will cut that by at least another percentage point. Businesses can cut their lighting costs by a third, and it is still for many the quickest and easiest way to start saving energy. Another is checking your energy still does what you expect. Is the heating timed right? Do people switch off lights and power where it’s not needed?

These are obvious and possibly simple changes. There are many more options, and many companies out there that can help you improve energy efficiency in the long term in exchange for an initial outlay. But as we’ve seen, there will be a cost.

How can you fund that? There are some differing schools of thought here. One says that you should grab the low hanging fruit immediately and take the savings. The alternative is to look at the bigger picture: package up the cheapest and easiest changes with some that require more initial outlay, so fast savings fund some of those that take longer to make a return.

You should get your energy supplier and equipment sellers working for you here. Some have stepped into the market gap between companies’ wish to save energy and their inability to pay upfront. That might mean easier payment terms or more innovative schemes that recoup the cost of energy-efficient equipment from energy savings over time.

Fundamental to saving is knowing what you use and when. That’s another point where

Janet WoodEditor, New Power

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About our guest editorJanet Wood is editor of New Power, a monthly report and database on UK power sector development.

She has been a journalist covering the power and energy sector for 20 years, covering technology, policy and politics as editor of magazines including Power Engineering, Asian Electricity, Middle East Electricity and Utility Week.

She is also the author of two books for the Institute of Engineering and Technology (IET), on nuclear energy and on local-scale heat and power projects in the UK.

IS YOUR BUSINESS ENERGY SAVVY?

Focus on Energy Conservation

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Bearing Shield and Seal Bearing Comparison Table

ZZ VV DDU

Dust resistance Normal Good Excellent

Water resistance Unsuitable Unsuitable Excellent

Torque Very low Very low Normal

Speed High High Normal

Grease retention Normal Good Excellent

BEARINGS CAN BE FOUND IN A VAST RANGE OF MACHINERY INCLUDING ELECTRIC MOTORS, PUMPS, FANS AND ELECTRICAL APPLIANCES, AND MANY OF THOSE BEARINGS WILL BE MADE BY NSK – THE WORLD’S LARGEST MANUFACTURER OF DEEP GROOVE BALL BEARINGS. EVERY PRODUCT IMPROVEMENT AND NEW DEVELOPMENT FROM NSK CAN MAKE AN IMPORTANT CONTRIBUTION TO LOWER FRICTION AND MORE ENERGY EFFICIENT OPERATIONS.

The deep groove ball bearing is the world’s most widely used type of bearing. In general industrial applications, many deep groove ball bearings are classified as “sealed for life”, meaning they are supplied with a closure on each side of the bearing and cannot be re-lubricated. Because bearings are a critical component in machines, bearing lifetime is directly related to machine uptime, so choice of closure is an important decision for a machine designer or maintenance operator.

Non contact ZZ metal shields are the most basic type of bearing closure. These shields, which are treated with a special anti-corrosion zinc coating, help to retain the grease within the bearing and protect the bearing from

large contaminants. There is no speed restriction with ZZ shields, meaning they are commonly found in high speed applications such as motors.

NSK also offers “VV” seals. The non contact VV rubber seal is moulded so that its sealing lip sits tightly in a unique groove found on the inner ring of all standard NSK deep groove ball bearings (10mm bore diameter

upwards). This creates a very fine clearance labyrinth, resulting in zero seal drag, low starting torque and no reduction in bearing limiting speed. These properties are very

important when energy efficiency and low power loss are critical, e.g. small electric motors. Grease retention and contamination protection are also greatly increased compared to the ZZ shielded design.

The seal groove on the inner ring of all standard bearings has also allowed NSK to develop a high performance contact seal design. The NSK “DDU” seal is designed with 3 sealing lips; one lip forms a contact with the side

face of the inner ring groove, the other sealing lips form tight non-contact constrictions at either side of the contact sealing lip. This triple lip sealing mechanism gives excellent protection against dust and water contamination. The axial sealing lip means that grease leakage is significantly reduced compared to standard seals, particularly in outer ring rotating applications. The innovative seal design has been well proven in the field, with numerous cost savings achieved simply by switching

from a standard rubber seal to an NSK DDU seal. DDU seals are standard on all NSK deep groove ball bearings above 10mm bore diameter.

NSK’s different closure options allow ERIKS customers to choose a bearing for any application condition, be it high speed, low torque, water splash, dust protection, grease retention or a combination of these. Using the NSK high performance sealing options ERIKS have been able to work with a large number of MRO accounts to realise significant cost saving benefits.

SURVEYING FOR SAVINGS

ONE OF THE BEST WAYS TO REDUCE ENERGY USE – AND THEREFORE SAVE ON ENERGY COSTS – IS TO FIND OUT WHERE YOU ARE WASTING ENERGY IN THE FIRST PLACE. THAT’S HOW ERIKS RECENTLY HELPED TWO DIFFERENT MANUFACTURERS MAKE SIGNIFICANT COST SAVINGS.

A large dairy manufacturer was losing heat energy due to damaged and missing insulation, on the steam service lines for their production and Clean in Process equipment. An ERIKS Condition Monitoring team carried out a survey of all the customer’s steam services, and found far more than the customer bargained for.

In fact, the survey identified not just a handful of areas where heat and energy were being lost, but a staggering 93 different locations. These added up to a cost to the customer of almost £50,000 a year.

Having identified the problem areas, ERIKS quoted for repair and replacement of lagging and insulation to eliminate the losses. The customer also acquired other quotes, but ERIKS’ was by far the most competitive.

Not surprisingly, ERIKS won the contract, and carried out the necessary work. As a result, the customer will save £15,573.13 in the first year, and £49,573.13 in subsequent years.

Performing under (less) pressureA food manufacturer also had an issue with energy use, involving pumps which provide their high-pressure water for washing-down.

This time, in addition to the pump audit requested by the customer, ERIKS Pumps specialists carried out a pipework survey to identify potential improvements in the wider system.

The existing pumps were not only old, but also labour intensive, noisy, and consumed 3,510kW per week. At peak periods, they simply couldn’t cope with demand. However, the pump audit identified the possibility of reducing the water pressure required, due to improvements in cleaning chemicals since the original pumps were installed.

Meanwhile, the pipework survey revealed several hundred metres of redundant pipework which, if eliminated, would mean pressure throughout the system could be further reduced.

Boosting efficienciesThe customer accepted ERIKS’ recommendations, and the pipework system was modified. At the same time, a variable speed booster set was supplied as the most cost-effective replacement for the existing pumps.

The booster set significantly improved the system, helping it to provide more consistent pressure with increased efficiency, and reduced power consumption.

In both these cases, ERIKS know-how helped to identify positive energy-use

reductions and cost savings above and beyond the customers’ expectations. Having the expertise to get to the root cause of the problems, and the solution-neutral capabilities to offer the most effective solutions for the customers’ needs, meant significant performance-, energy- and cost-efficiencies.

SEARCHING FOR CLOSURE

You and the



The Rexnord solutionHaving studied the customer’s requirements, ERIKS identified a coupling from the Rexnord® Thomas® XTSR range, which offered the perfect solution.

n Rexnord Thomas XTSR71 couplingn Size: 1298

n DBSE: 175mm and 180mm (two supplied)

n ATEX II 2GD c T6 compliant

n API610 compliant

n IS014691 certified

n Spark reduction construction

PumpCouplingMotor

FORGET MARRIAGE GUIDANCE. THE KIND OF COUPLE COUNSELLING OFFERED BY THE ERIKS CENTRE OF EXCELLENCE FOR COUPLINGS MAKES SURE THAT ANYTHING BROUGHT TOGETHER, STAYS TOGETHER – INCLUDING ERIKS AND REXNORD, THEIR COUPLING SUPPLIER PARTNER.

Supporting the supportersThe ERIKS Centre of Excellence for couplings and drives is staffed by a highly experienced team.

But as well as bringing their own industry experience to bear on the problem, the team have been specially trained by application engineers from their supplier partner: coupling manufacturer and process and motion control specialist, Rexnord®. This gives them exceptional capabilities in solving coupling and drives problems of all types, across all industries and applications. And this particular problem was no exception.

The team brought their know-how and passion for technology to bear, and provided the Service Centre with an improved solution to offer the customer.

Upping the anteERIKS’ expertise and experience, broad range of suppliers, and solution-neutral approach means the product and solution proposed is always the one that’s best for the customer, not just for ERIKS.

In this case, a close look at the specification led the Centre of Excellence to suggest a more up-to-date, higher specification Rexnord unit [see box-out], which offered a number of advantages.

The Rexnord Thomas® XTSR71 is the latest update to the well-known Series 71 of all-metal, torsionally stiff, disc couplings. And it’s a coupling which, when operating within its design parameters, is designed for infinite life. More than a coupleThe new coupling provided the customer with numerous benefits compared to their original specification.

The Rexnord Thomas XTSR71 is smaller than the original coupling, which means it also costs less. And being lighter, it puts less strain on the bearings in the drive – helping to extend their service life – and reduces the overall power consumption needed to drive the pump assembly.

Compliant with ATEX II 2GD c T6, the coupling is not only approved for Gas and Dust explosive atmospheres, but also for T6: the toughest temperature class for the group and category. In addition, it is constructed using Monel (copper-nickel alloy) bushes, which offer a high-level of spark reduction.

The design of the XTSR71 has been optimised to reduce the coupling’s mass and increase bore capacities. It also provides component modularity, together with integrated rigidising for balancing, and improved corrosion protection.

Easy to ownWith the new coupling installed, the customer has discovered a number of other advantages and benefits which make it an easy product to own and run:

1. When replacement of the Centre Member Assembly (CMA) is required, the unit can simply be “dropped out” of the pre-assembled part and replaced. This means there’s no need to set-up the pump and motor alignment each time the coupling is serviced.

2. The flexible nature of the coupling means it can accommodate a certain amount of misalignment between the pump and electric motor, which helps to protect the bearings and prolong the life of the whole system.

3. The coupling’s modular construction means the CMA can be kept as a separate spare part, enabling very quick replacement.

ERIKS ultimately supplied the customer with two units. One has a 175mm, and the other a 180mm, DBSE. All service parts – common to both couplings – have also been supplied, comprising hubs, disc packs, adaptors, and nuts, bolts and washers.

By providing a coupling with a high-efficiency design, easier maintenance and infinite-life design, the ERIKS Centre of Excellence has given the customer a comprehensive solution which meets all their needs – and for a lower purchase price than they expected.

In other words, the perfect marriage of efficiency and cost-effectiveness.

COUPLE COUNSELLING

When a very large, international petrochemical company had coupling problems, they turned to ERIKS’ Grimsby Service Centre for guidance. They called on the expertise of the couplings Centre of Excellence, to ensure a quick, cost-effective solution.

Refining the answerThe petrochemical company needed a coupling to fit between a motor and pump on one of the many pump drives at their refinery. This type of “spacer” coupling is

used in all petrochemical process plants, on the majority of their pump drives.

The location and application meant it had to be not only API610 (American Petroleum Institute standard) compliant, but also ATEX approved and non-sparking. When they contacted ERIKS, the customer suggested a possible unit and also provided a detailed specification, including hub and bore sizes and Distance Between Shaft Ends (DBSE) dimensions.

Rather than simply and blindly following the instructions, the Grimsby Service Centre contacted the Centre of Excellence, for expert advice both on the specification and the suitability of the unit the customer had suggested.

The know-how and expertise of the team at the Centre of Excellence meant they could propose a solution that was better in more ways than one.



WHICH ARE MORE ENERGY-EFFICIENT – ELECTRICAL OR PNEUMATIC COMPONENTS? WHAT ADVANTAGES DOES ONE TECHNOLOGY HAVE OVER THE OTHER? MANY EXPERTS BELIEVE THAT THE IDEAL SOLUTION IS A COMBINATION OF BOTH. HOWEVER, THIS IS A SITUATION WHERE PREJUDICES OFTEN PREVAIL OVER FACTS. A COMPARISON IS THE IDEAL WAY TO ENSURE CLARITY.

Energy efficiency depends on the application. “This must be clearly defined before a user chooses the drive technology – electric or pneumatic or a mixture of both,” explains Roland Volk, energy efficiency consultant at Festo. But what does this mean in concrete terms? Only a direct comparison of two identically sized drives – one electric and one pneumatic – is able to clearly show the benefits of each technology. In our comparison, motions are performed from point A to point B. This results in very different energy consumption values.

Task 1: Moving and holdingIn the case of motion without additional process force, an electric drive consumes only one-third (25 Ws) of the energy that a pneumatic actuator needs (78 Ws). For the function ‘pressing with process force’, both drives roughly consume the same amount of energy, i.e. between 20 and 30 Ws. If, however, the drives are required to hold a certain position, the energy consumption of the electric drive shoots up to 247 Ws. This is more than 22 times as much as the energy consumption of the pneumatic drive (11 Ws).

The pneumatic drive benefits from the fact that it requires energy only for the brief

moment in which pressure is built up. The holding process itself can be carried out completely without any fresh compressed air supply and there are thus no energy costs. The electric drive, on the other hand, requires electricity constantly in order to remain in the desired position. The longer the holding process, the higher the energy consumption of the electric drive compared to the pneumatic one.

Task 2: GrippingA comparison of electric and pneumatic grippers produces similar results. The comparison shows how finding the right solution depends on a clear definition of the application. If we consider the energy consumption during the gripping process, a pneumatic gripper is superior to an electric gripper in applications with long cycles and with few gripping operations. A pneumatic gripper requires pressure only once for continuous holding. After that, no more pneumatic energy is required for the duration of the holding operation. An electric gripper, which needs electrical energy for the entire holding operation, can be more energy efficient than a pneumatic gripper only if the application consists of short cycles with a large number of gripping operations.

The application decides The benefits of electrical components are particularly evident in motion tasks involving high speeds and long stroke lengths. Electric drive technology is generally used more energy efficiently when the requirements are for flexible positioning, variable motion profiles or high speeds. If, on the other hand, simple, robust handling or high power density is important, pneumatic drive technology offers numerous advantages.

The Total Cost of Ownership shouldalso be taken into account when decidingwhich drive system to use. Pneumaticdrive systems are between 8 and 10 timescheaper to purchase than electric drivesystems. Depending on the stroke lengthand cycle time, the operating costs maybe higher than those for electric drives.However, amortisation times of more thanten years are certainly possible.

Energy efficiency pays offEnergy consumption in production is influenced by factors other than the choice between pneumatic and electrical technology. Users can obtain concrete results using the Festo model calculator.

For example, a company with a three-shift operation and a compressor output of 160 kilowatts can reduce its operating costs by 16% simply by using vacuum generators that operate according to the venturi principle and have an integrated air- saving circuit.

www.festo.com/energy_calculator

The secret is in the mix: The most energy-efficient solution will often be a combination of electric and pneumatic drive technology, as in the case of many of the ready-to-install handling systems from Festo.

THE RIGHT CH ICE

Roland VolkInnovation and TechnologyManagement at Festo

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Energy efficiency measures1 Reducing pressure level 2 Reducing pressure drops 3 Reducing flow rate 4 Correct sizing 5 Reducing energy consumption 6 Reducing leakages 7 Reducing weight 8 Reducing tubing length 9 Recovering energy 10 Air-saving circuits 11 Reducing friction 12 Switching off power

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festo.com/energysavingfesto.com/energyefficiency



THE SEVEN DEADLY WASTESIF YOU – LIKE MANY BUSINESSES – ARE STRIVING TO REDUCE OPERATIONAL COSTS, PERHAPS TIM WOOD CAN HELP. BUT THAT’S NOT A PERSON; IT’S A WAY OF REMEMBERING THE SEVEN DEADLY WASTES YOU NEED TO DEAL WITH.

In most of the Lean business principles you may already be adopting – like Lean Six Sigma, the Visual Workplace, the Five S’s and Kaizen – a key principle is to reduce waste. And the seven most common areas of waste are Transportation, Inventory, Movement, Waiting, Over Production, Over Processing and Defects or TIMWOOD, for short. With over 50 years’ experience across numerous industries, SMC can help you not only address TIMWOOD and reduce waste, but also add value, simply by looking at one of the easiest areas for action: compressed air.

Where’s your air going?The first steps towards saving waste with compressed air can be made in your compressor room. Here you can identify:

n what type of compressors you have

n how they’re run and

n how compressed air is used on site.

After all, there’s little point upgrading your compressor room if all you’re doing is more efficiently feeding the compressed air inadequacies across your business.

You can support Lean principles such as Total Preventative Maintenance,

by monitoring your compressed air usage and what’s going on in the compressor room, on the ring main and at machine level. Once compressed air gets out into the factory, usage monitoring is lost, which can be an issue when department budgets are set without knowing current actual performance.

Simple two-colour digital air flow monitoring sensors can be fitted in the ring main or at machine level and fit in perfectly with the Visual Workshop key principle of Lean – allowing operators to spot issues quickly, either in line or at machine level – additional digital or analogue outputs allow data to be captured and monitored in real time by control systems.

One recent innovation; Automatic Leak Detection Systems (ALDS), fitted to machinery during the build stage can also help to drive down energy costs. These systems show in real time where a machine is suffering from compressed air loss, so the maintenance team can decide whether a repair is needed immediately or at the next maintenance interval.

More ways to saveSomething as apparently simple as air offers a surprisingly large number of different ways to save money.

For example, vacuum systems are often ignored when looking for compressed air savings. Unless you have a vacuum pump running, a vacuum generator uses compressed air to generate a vacuum using the Venturi principle. This can be inefficient and expensive, as a vacuum generator may continue to consume compressed air even after the product is gripped.

However, the latest vacuum generators shut off as soon as a vacuum is made, saving up to 90% on compressed air consumption.

Air blowing – typically used for cooling, drying, moving, orientating and rejection of a product – is another area where energy savings can easily be made. Continuous air blow through a simple tube can cost over £2k a year, but optimising air blow equipment to the application can reduce costs considerably.

As energy consumption is part of your sustainability drive you may be interested to know that there are now alternative technologies to stop pneumatic filtration products going to waste in landfill sites, or help you meet a CSR “ Zero Landfill” commitment. Although single-use bag filters are common in manufacturing, unique alternatives including “wobble plate” filtration system for fluids, with a reusable filter element eliminate the need for bag filters, and saves on landfill.

Saving the best saving until lastFor the biggest tangible saving in compressed air usage, all that’s required is to make sure you’re using the correct pressure setting for your application.

Reducing output pressure by just 1 bar can save around 7% of the electricity cost used to generate the compressed air.

However, it’s essential to carry out all necessary preparation work before turning down line pressure. If you have failed to adopt basic good practice – such as fixing known air leaks, reducing pressure drops, and optimising vacuum and blow-off systems – machines may not operate correctly with reduced pressure.

If some equipment needs higher pressure in comparison to other applications, consider a point-of-use air booster removing the need for a whole network to run at an elevated pressure.

Choose to saveWhen you adopt Lean principles, it’s not just the cost of buying a product that you should consider. Only around 15% of the purchase price is reflected in a product’s Total Cost of Ownership (TCO), so you also need to look at the cost of energy to run the equipment, as well as warranty and procurement expenses. There are a number of online selectors that can help with this along

with advice from technical specialists from ERIKS and SMC, good advice pays dividends.

John TurnerIndustries Development Manager at SMC

SMC products that cut your energy costsSMC’s two-colour digital air flow monitoring sensors can be fitted in the ring main or at machine level, to measure flow rates from 0.5 l/m up to 12,000 l/m. The two-colour digital display and the digital and analogue outputs allow data to be captured and monitored in real time.

Automatic Leak Detection System (ALDS) installed at the build stage helps minimise energy costs.

The highly efficient SMC ZK2 vacuum generator can save up to 90% on compressed air consumption.

To optimise air blow efficiency, an SMC KN Blow Nozzle, VMG Blow Gun or ZH Air Amplifier Unit can reduce costs considerably.

The SMC unique “wobble plate” filtration system for fluids, with a reusable filter element eliminates the need for bag filters.

If some equipment needs higher pressure in comparison to other applications, an SMC series VBA point-of-use air booster could be installed.

To make this easier, SMC has a range of product selection software tools to help you select the most cost-effective and energy-efficient products available.

Just visit www.smcpneumatics.co.uk to start choosing, start saving, and start achieving your compressed air KPIs.

Cheaper than air?Sometimes the simplicity of compressed air is not available, and sometimes it’s seen as less cost-effective to use than other methods. For both these situations, SMC has developed an extensive range of stepper and servo motor actuators, including linear, rotary and gripper drive models.

These simple SMC controllers for the stepper drives units even allows non-technical staff to set-up and commission the actuator – freeing technical engineers to concentrate on more challenging issues.



THE NEED FOR INDUSTRY TO REDUCE ENERGY USE IS NOT GOING AWAY ANY TIME SOON. TWO POSSIBLE SOLUTIONS, AS ROB JENKINSON, DIRECTOR CORPORATE SUSTAINABILITY FROM SKF EXPLAINS, ARE THE BEARINGS THAT REDUCE FRICTION IN ELECTRIC MOTORS AND MOVING FROM TRADITIONAL HYDRAULIC OR PNEUMATIC ACTUATION TO ELECTRO-MECHANICAL LINEAR DRIVES.

Automating energy-savingAs industrial processes have become increasingly automated, as part of thepush to improve energy efficiency, linear drive technology has come under intense scrutiny.

Traditionally, most linear drive systems have been pneumatically or hydraulically driven. But in many applications, electro-mechanical systems are beginning to replace them.

Pneumatic and hydraulic systems do still offer a number of advantages – depending on the specifics of the application and the operating environment – but electric cylinders:

n require less ancillary equipment

n are cleaner

n are more reliable

n demand less machine downtime for cleaning and maintenance and, most importantly

n are more energy efficient.

Hydraulic systems typically require around 40% more energy than electric cylinders, while pneumatic systems may require up to 90% more energy due to the inherent inefficiency’s in these systems. This is due to the energy losses inherent in compressed air systems such as the rejected heat, piping losses, the leaks etc. Likewise in hydraulic systems – converting from electrical energy to pressurised hydraulic fluid energy incurs losses which are avoided with the direct mechanical link from the motor to the actuation rod in an electromechanical actuator.

Facts about frictionElectric motors are an energy expensive component. They consume a total of approximately 1.36 trillion KwH per year in the EU and USA alone, so increasing their efficiency represents a massive opportunity for industry.

One way to do this is to reduce friction.Reducing friction in the rolling bearings used in motors will reduce the amount

of energy required by the motor itself. Specially-engineered rolling bearings can significantly lower friction, resulting in impressive energy savings. Lower friction also means the bearings run cooler than a basic-design bearing, which extends bearing life due to the improved lubrication properties at lower temperatures.

Good for business and the planetReducing energy use – which in turn can decrease greenhouse gas emissions – and minimising air and water pollution, can all deliver cost benefits in the short term, by reducing running and maintenance costs. In the long term, emphasising green credentials to customers and potential customers can only help to win business and increase customer loyalty.

In the even longer term, saving energy helps to reduce emissions and that’s not just good for business – it’s good for the planet too.

SKF BeyondZeroIn 2005, SKF launched a new strategy for reducing environmental impacts, called SKF BeyondZero. The strategy drives actions to reduce the impacts of SKF suppliers as well as SKF’s own operations (reducing the negative impacts), while in parallel developing solutions with our customers that help them do the same (increasing the positive impacts).

The SKF BeyondZero portfolio spans SKF’s five platforms of bearings and units, seals, lubrication systems, mechatronics, and services, across every industry in which the company is present. To be included in the portfolio, a solution must deliver or enable significant environmental performance improvements.

Two examples of products within the SKF BeyondZero portfolio with wide-ranging applications in any manufacturing business are SKF CASM electric cylinders, and SKF Energy Efficient bearings.

SKF CASM – an electromechanical solution for linear drives – can provide energy savings of up to 90% compared with pneumatic systems* – resulting in important cost savings and reductions in environmental impacts.

SKF Energy Efficient (E2) performance-class bearings also offer dramatic improvements over other options. Specially engineered and manufactured to reduce frictional moment by 30% or more beyond SKF’s already efficient standard bearings, the reductions can be even more dramatic when compared with other manufacturers’ bearings.

Available in a wide variety of bearing types, SKF E2 bearings run 5-30°C cooler than SKF basic design bearings, depending on operating conditions. SKF E2 Y-bearings have been designed for applications in which reduced energy usage is an important concern. Under normal operating conditions, they also have a considerably longer grease service life than a standard SKF Y-bearing, helping to reduce lubricant consumption.

* Swiss Federal Office for Energy

As energy awareness evolves, matures, and combines with increasing environmental consciousness, more businesses are realising that energy use reduction can be about being

green as well as staying out of the red. As we are all becoming more environmentally conscious, manufacturing industry seeks ways to make their activities greener to match our expectations as consumers. On top of this,

there are increasing regulatory requirements on businesses – in the UK for example - the Carbon Reduction Commitment (CRC) to the Energy Savings and Opportunity Scheme (ESOS).

As a result, reducing the amount of energy used, increasing the energy efficiency of applications and components, and therefore reducing their carbon footprint, is now a top priority for many businesses.

Some more forward-looking businesses are going further still, taking action not simply to reduce the negative impacts of their own

operations, but to accentuate the positive by putting a focus on developing products and solutions which help their customers by providing or enabling significant environmental performance improvements.

In other words, reducing or eliminating your own operational negative environmental impact is only the first stage. Delivering positive environmental benefits to your customers is an even more effective second stage.

Rob JenkinsonDirector, Corporate Sustainability at SKF

ENVIRONMENTAL IMPACTS

BEYONDZEROGOING

ON



The most widely used method of extraction involves large exhaust air systems to remove the air, with high-tech membrane filter systems to remove the mixture of aerosols and paint from the air first. This incurs high costs not only for supplying the clean air, but also for the downtime and labour involved in cleaning the filters.

Now a new solution eliminates downtime and reduces associated costs too.

Non-stop cleaningThe new RECLAIM process from Keller Lufttechnik uses a new type of filter, which can regenerate during operation – so there’s no need to stop the painting process. And it saves energy too.

The system works by using fabric filters pre-coated with PTFE, and an auxiliary filter layer of limestone powder. The limestone powder absorbs and bonds with the adhesive aerosols of the overspray, to prevent the filter clogging up and quickly becoming unusable.

However, the system also goes further to save energy, time and costs.

Weight sensors located under the dust silo detect the degree to which the pre-coating material is saturated with overspray. As long as a pre-defined total weight – consisting of pre-coating and powder – is not exceeded, the mixture previously blown off the filter plates can be blown back on.

When it resettles on the filter the limestone powder and paint overspray mixture forms a new auxiliary filter layer. This continues until the weight exceeds the pre-defined limit, at which point the overspray-saturated limestone powder is removed from the system, and new limestone powder added.

And all this takes place automatically, with no downtime required in painting operations.

Energy-saving airThis innovative technology cleans the air so effectively that up to 95% of the extracted dirty gas can be returned to the paint booth as pre-conditioned clean gas – saving significant amounts of energy.

In fact, compared with paint booths without this technology, energy costs are reduced by as much as 50%.

If a paint booth requires 1,000 cubic metres of air per hour, which has to be supplied from the outside and heated, it uses around 60 megawatts of energy per annum. Assuming a suction rate of 16,000 cubic metres per hour, if the amount of air supplied from the outside can be reduced to just 5% – instead of the usual 100% – then savings of over £40,000 can be made every year.

Painting green and blackBy reducing energy use, the new air filtering technology for paint booths contributes to a more ecologically-friendly painting process.

At the same time, it helps to significantly reduce costs for the operator – helping to maintain a healthier bottom line as well as a healthier planet.

INDUSTRIAL PAINTING INEVITABLY PRODUCES LARGE AMOUNTS OF OVERSPRAY. THIS CONTAMINATES THE AIR OF THE PAINT BOOTH, BUT CAN’T BE RELEASED INTO THE ENVIRONMENT. SO THE AIR HAS TO BE EXTRACTED, CLEANED, AND REPLACED WITH FRESH, CLEAN AIR. IT’S AN ENERGY-INTENSIVE PROCESS AND A COSTLY ONE TOO. BUT NEW AIR TECHNOLOGY HAS BEEN DEVELOPED TO SOLVE THE PROBLEM.

LET US AND SAVE ENERGY

Complete control from FestoA sophisticated automation solution such as Keller Lefttechnik’s new RECLAIM process demands an equally sophisticated control system. A key component in this is the CPX-VTSA valve terminal from Festo, which combines a modular electrical terminal (CPX) with a valve terminal (VTSA).

Previously, similar systems have used 2/2-way individual valves, which have lacked a complex monitoring and control function. However, the CPX-VTSA now provides this, to guarantee a smooth process at all times.

Valve choiceThe flow rate of systems of various sizes is regulated by Keller Lufttechnik simply by choosing valves of different sizes on the valve terminal. The individual valves are then precisely adjusted to the required flow rate, using pressure regulator plates.

At the same time, the CPX modular electrical terminal controls all the electric actuators and sensors in the system, via ProfiNet bus nodes. The VTSA pneumatic interface provides the electromechanical connection between the CPX terminal and VTSA valve terminal. A complete pneumatic control chain is connected to the fieldbus using the input modules of the CPX terminal.

Extended service intervalsThe CPX-VTSA controls the pressure regulators for adjusting the pressures and flow rates in the RECLAIM system, as well as controlling vacuum exhausting of the pinch valves. This optimises transport parameters, and helps to extend service intervals.

In addition, peak load regulation stabilises the compressed air system; active consumption rate monitoring helps to reduce compressed air consumption values; and there is actuation of exhaust-free fluidisation valves without raw gas return flow.

To find out more, visit festo.com/catalog/vtsa

This month’s debate This month’s debate


DECIDING WHETHER TO REPAIR OR REPLACE A PUMP IS RARELY A BLACK AND WHITE ISSUE. ANDY CRUSE, FROM ERIKS PUMP DIVISION, DEFINES THE KEY DECISION MAKING CRITERIA FOR PUMP USERS AND OFFERS HIS VERDICT ON THE REPAIR OR REPLACE DILEMMA.

CRITERIA #1 CostIn the end most things come down to cost. If the unit price for a new pump is relatively low and is available it can make economic sense to replace. Our view is that single stage pumps up to 15kW, used in light industrial and HVAC, are replace rather than repair, because the cost of repairing failed bearings and seals, for example, is uneconomic for the pump user. For larger and “engineered” pumps it’s a different case altogether. This type of pump is of a more substantial build quality and will lend itself well to a number of maintenance and repair regimes over it’s working life, which is reflected in the price. At this point repair makes much more sense.

THE VERDICTRepair: if you’re using larger or “engineered” products where the main components are cast rather than pressed fabrications.Replace: if your pump is in the “up to 15kW” range and the unit cost of a new pump is relatively low and readily available.

CRITERIA #2 Production disruptionArguably the key criteria for pump users in industry. I know of one pump user who accepted the fact that his pump would only have an operational life of circa six weeks and always kept a spare on hand to quickly plug in and keep production going. It’s not an option I’d recommend, because pump operational life can be subject to multiple variables not just the pump itself, but if repair is too costly in terms of downtime, then it is one way of keeping going.

THE VERDICTRepair: if the pump is in a non-critical production area or a stand-by pump can be quickly brought online.Replace: if the pump is critical to production operations and there is no alternative pump available.

CRITERIA #3 Energy efficiencyThe European Union has been the driving force behind some very significant improvements in pump efficiency in recent years, which has added another criteria to the pump decision making process. The ErP Directive, for example, enforced a Minimum Efficiency Index which identified minimum hydraulic efficiency that all manufacturers must meet, dramatically increasing pump efficiency. A modern end suction pump, for example, is circa 13% more efficient than its predecessors. Pump users need to be calculating how much energy it is possible to save, along with potential payback periods, by upgrading their pumping technology, before making a repair or replace decision.

THE VERDICTRepair: if your pump is modern, high efficiency and ErP compliant.Replace: if you are using old, inefficient pumping technology.

CRITERIA #4 Plant room disruptionAnother big issue for pump users. It’s all very well saying it’s easier to replace a pump rather than repair, but much of the existing pump equipment, already in use, has configurations and dimensions bespoke to the manufacturer and not to a recognised international standard. This can mean that direct replacement is nigh on impossible in some cases. What’s more, old plant rooms often have asbestos lagging around pipework which pump users are reluctant to disturb.

THE VERDICTRepair: if it’s old plant with outdated dimensions and standards and where there is potential for significant disruption and budget constraints, there may well still be savings opportunities to take benefit from thorough modern motor control regimes.Replace: if it is a modern plant manufactured to international standards offering an easy like-for-like swap.

CRITERIA #5 New pump availabilityA criteria that is very much dependent on the pump and its application. For smaller up to 15kW pumps, both manufacturers and distributors keep plenty of ex-stock available on the most popular sizes, which can usually be shipped in 48 hours. Bespoke pumps for process applications with special options, such as seal and material variants, are a different matter entirely, because they are not as readily available and often are subject to long lead times.

THE VERDICTRepair: if the pump is specialist or bespoke and has a long lead time.Replace: if stock is readily available and can be accessed within a short timeframe.

CRITERIA #6 Spares availabilityReady access to spares is a key criteria in assessing whether to repair or replace. For water pumps in light industrial or HVAC, all-too-often the cost of the part, labour and downtime means that any repair or replace calculation comes out on the side of replacement. Process and wastewater pumps are a different case, with manufacturers often making ‘repair kits’ available which have a variety of components that are prone to wear. Obsolescence is another issue. There are plenty of pumps still in the field that are more than 30 years old and which are no longer supported by the original OEM or, alternatively, the cost of spare parts is increasing year-on-year. Pump users need to assess whether continuing with these pumps poses a risk to their operations.

THE VERDICTRepair: if spares and repair kits are readily available or can be reverse engineered.Replace: if the pump is designed for replacement rather than repair and the cost, including parts, labour and downtime, make repair uneconomic.

CONCLUSION Pump repair or replace is not an easy decision, but whilst cost and potential disruption to production are the key criteria, other factors, such as plant room disruption, can lead a pump user coming to the conclusion that, despite increasing spares costs and all the potential for energy saving, there really is no alternative to soldiering on with their current pumps. My advice is to get advice. Often what seems like a pump problem is actually a system issue which the pump is getting the blame for. The only real way to get the best out of your pumps is to step back a moment, assess what the pump is actually being used and whether it is fit-for-purpose, before making informed long-term and strategic decisions.

For more information on ERIKS please visit: www.eriks.co.uk

REPA R OR REPLACE: THE KEY CRITERIA FOR PUMP DECISION-MAKERS

Andy CruseERIKS Pump Division

Time savings Time savings

26 27ISSUE 23 knowhow.eriks.co.uk

The dairy manufacturer had been asked by a number of customers to provide milk packaged on pallets for onward distribution, rather than in delivery cages as they normally did.

Although the production site had no palletising facility, the manufacturer was interested in testing-out palletised delivery. So they decided to investigate adapting a small number of existing lines as a small-scale trial.

Starting smallAn in-house project team was assembled to undertake the task, and came up with a plan.

Their idea was to initially adapt two existing conveyors to enable the palletisation. This would involve adding an extra five metres of conveyor to transport the product into

the chill area, where it could be manually stacked onto pallets by a team of people.

The product could then be pallet-trucked away to automatic rotary arm pallet wrappers.

If this trial system proved successful, and demand volume increased, then a fully automated version would be considered.

So far, so simple.

Hitting the belt - and hitting problemsUnfortunately, the project team’s proposal for belt conveyors attached to a roller conveyor was not a suitable solution. When the product hit the belt it would have fallen over.

Even more frustratingly, getting the capital expenditure agreed for the project took longer than expected, which meant a schedule too tight for the conveyor manufacturer to meet – fatally compromising the required delivery deadline.

For the dairy manufacturer, it was all turning sour.

Getting the creamWith time pressing and no viable solution in sight, it was time to call in ERIKS.

The local ERIKS MRO Specialist quickly put a plan in place which would provide a product solution to the customer’s exact specifications, and meet the customer’s packaging demands. It could also be guaranteed to be delivered on time, thanks to ERIKS’ know-how, and extensive network of trusted, reliable, and high-quality supply partners: the crème de la crème.

Working with one of these – an existing conveyor partner – ERIKS committed to project-manage the design and build of the required conveyors with just a three-week lead time.

All wrapped upWith the initial fabrication underway, the customer decided to add an extra metre to each conveyor. This meant more parts needed ordering against an even tighter delivery window, but ERIKS’ close relationship with the conveyor manufacturer meant the original agreed deadline was still adhered to.

Meanwhile, in addition to the conveyors, two pallet wrappers were required to shrink-wrap the loaded pallets of product.

The customer’s original plan had been to use a type of pallet wrapper with a moving platform for the pallet to sit on as it’s wrapped. However, ERIKS’ engineers pointed out that this was an unsuitable option for an inherently unstable product.

As an alternative, ERIKS suggested the use of rotary arm pallet wrappers. These work on the opposite principle: moving the wrapper around a static pallet, so there’s no risk of the product falling over. The customer agreed to this solution, and ERIKS’ engineers began working in collaboration with an European supplier, to ensure manufacture and delivery of the correct specification equipment to the required two- to three-week lead time.

Know-how, in pintsWhat made life harder for the dairy manufacturer’s own project team of engineers was the need to juggle an urgent one-off project with the demands

of keeping a busy production facility up and running.

ERIKS’ engineers have the advantage not only of unparalleled technical know-how, but also of being able to dedicate a team to a project. This means solutions can be arrived at more quickly, and also releases a customer’s own engineers to concentrate on what they do best. Of course, it remains a partnership, but one where ERIKS can take the pressure off, while the customer can still take the decisions.

In this case, the dairy products manufacturer benefited in two ways.

Firstly: saving the valuable time of their engineers by taking the bulk of the project off their hands. Secondly: saving time on the entire project timescale, by achieving a solution which was designed right, built right, and delivered and installed with a short lead time, right on time. Calling in some additional know-how can save significant amounts of time!

IN-HOUSE EXPERTISE CAN OFTEN SEEM LIKE THE EASIEST AND MOST COST-EFFECTIVE WAY TO GET A JOB DONE. BUT AS A LARGE DAIRY MANUFACTURER DISCOVERED, SOMETIMES THERE’S NO SUBSTITUTE FOR A PARTNER WITH TECHNICAL KNOW-HOW, INDUSTRY UNDERSTANDING AND CLOSE RELATIONSHIPS WITH CRUCIAL SUPPLIERS – NOT JUST TO COMPLETE A PROJECT, BUT TO COMPLETE IT ON TIME.

Rotary Arm Pallet Wrapper - courtesy of Mima-Films.

Best practice Best practice


ALL TOO OFTEN, A DECISION IS MADE TO CARRY OUT AN IN-HOUSE REPAIR TO A PROCESS GEARBOX IN THE BELIEF IT WILL SAVE MONEY. THE REALITY IS OFTEN VERY DIFFERENT.

Simon WhitehouseBusiness Unit Manager Gearbox Repairs

Long lead times, difficult modifications or higher initial costs can all make replacing or upgrading look less attractive than repair. But problems arise, and costs rise, when you choose in-house repairs rather than sub-contracting to a third party.

Because there’s not just one cost to consider, but four:

1. Lost production

2. Removing the equipment from the line or process, and subsequently replacing it

3. The actual repair

4. In-house engineers making repairs, so being unavailable to tend to other parts of the plant (opportunity cost).

Taking any or all of these into account means the longer that plant can run between maintenance intervals, the less the total downtime cost per year of production. And when your gearbox repairs are entrusted to an expert refurbishment house, then the life of the refurbished gearbox will almost certainly be extended and that total cost reduced.

As good as new?To fully realise the benefits of sub-contracting, it’s essential the repair is carried out to a high standard.

In fact, nothing less will do than a gearbox rebuilt to precise manufacturers’ specifications, backed by fully-guaranteed workmanship. This means finding a repairer with the experience and know-how to rebuild industrial gearboxes of all leading types and styles, and able to guarantee the use of only genuine manufacturers’ parts.

The repairer you choose should also offer a comprehensive, lengthy guarantee – and ensure the gearbox is fully tested before it’s returned to you.

It’s your choiceWhether to repair or replace is, of course, ultimately your decision alone, based on the economic viability for your business. But to help you decide, a reputable repairer will always carry out a full engineer’s inspection and provide you with a written assessment before any work is begun.

This not only provides reassurance that you are right in your assessment of the problem, but also acts as a restraint against more work being done – and charged for – than is strictly necessary. And if you choose a repairer who can also offer a full range of replacement gearboxes, then you can expect unbiased, solution-neutral advice.

The overhaul alternativeAnother option for your gearbox is reconditioning and overhaul. Some repairers offer this service, and some can even rebuild obsolete designs to meet the manufacturer’s original specifications.

The scope of the work – and therefore of the repairer’s competence – may include:

n replacement of worn or broken - gears - bearings - seals - shafts

n uprating and modifying designs to suit specialist applications.

The gearbox should then be reassembled and returned in “as new” condition.

Again, prior to any work taking place, the unit should be stripped, examined and written-up in a detailed report for your approval.

ERIKS’ Core Competence Centre (CCC) – Gearbox Maintenance and Repairs.

A refurbishment specialist with close relationships with process gearbox manufacturers, and many years of experience and know-how. Providing a dedicated, 24-hour, quick-response gearbox rebuilding and complete gearbox service unit.

ERIKS’ repairs and rebuilds using only genuine parts from manufacturers such as:

n David Brownn Fenner

n Renold

n SEW

n Flender

n and many others.

Gearboxes are returned fully repaired, serviced and tested, within days as standard, or even on the same day if required (all subject to work requirements and inspection). Every fully-overhauled gearbox carries a twelve-month guarantee.

If you decide a repair is uneconomical, ERIKS CCC Drives facility in the West Midlands carries an extensive range of replacement drive products, and can quickly access more from an extensive supplier base. ERIKS can also supply purpose-made gearboxes, complete drive installations or open drives, or simply uprate an existing gearbox.

30

The Tig

Art on an industrial scale

“ In my lounge at home I have a signed limited edition print of a

Trevor Grimshaw pencil drawing called ‘Church and Chimneys’ which depicts a mid-20th Century industrial landscape in the North of England.

The print is gritty and it divides opinion. Visitors either love it or hate it. I suspect those who hate it see an image of industrial decay. Those who love it see an echo of their own upbringing or early careers forged in engineering and manufacturing.

When the print was first published in 1973 one art reviewer commented: “Where the rest of us turn up our collars and head for home and tea by the fire, the artist has stayed for a further look and found beauty”.

That ‘beauty’ which Grimshaw found in industrial landscapes has now all but disappeared. Modern industry is much more hidden from view. It’s still there, but now it’s located on out-of-town industrial estates with carbon copy business units giving away little of what is going on inside. The smoke from chimneys which characterised much of Grimshaw’s work is now outlawed by clean air regulations.

50 years ago, our great provincial cities of Liverpool, Manchester, Birmingham, Newcastle and Glasgow had skylines dominated by industrial production, which brought industry and its economic benefits, in terms of jobs and wealth creation, much closer to its people.

Some of these industrial structures were iconic. The Longbridge car plant conveyor bridge over the A38 which carried vehicle bodies from the West Works manufacturing area to the South plant for paint and finishing. The cranes of Swan Hunter and Cammell Laird which dominated the Tyne and the Mersey. All provided a dramatic backdrop to everyday life, which artists like Grimshaw used in their work.

Perhaps this loss of iconic industrial structures is why so many people think we don’t manufacture in this country anymore. The truth is that, although car production at Longbridge may have disappeared - along with the A38 conveyor – JLR just down the road is thriving. More tonnage is moved through Liverpool now than in its supposed Victorian ‘heyday’, it’s just that the port itself has moved down the river to Seaforth to enable the massive container ships to dock.

Manchester has replaced textiles with a reputation for advanced engineering. Sunderland has replaced mining with Nissan, whilst Derby is building on its rich railway engineering heritage with its Toyota plant at Burnaston.

Of course, much of this manufacturing expertise is now hidden from view, behind security gates and fencing. Few of us will ever get the chance to tour the JLR factory in Solihull or the Airbus facility at Broughton.

The truth is we should not lament the loss of industry – it’s still there and doing very well. Rather we should mourn the loss of the dramatic structures and scenes which characterised the old industries and which inspired artists like Trevor Grimshaw.

“

ISSUE 22 www.eriks.co.uk/knowhow

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‘Church and Chimneys’ pencil drawing by Trevor Grimshaw

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ERIKS Know+How Issue 23, Energy Conservation

Business

Transcript of ERIKS Know+How Issue 23, Energy Conservation