Unscheduled downtime is a negative contributor to any company’s bottom line. It impacts production, sales, customer satisfaction, and of course company revenue. Senior management in most organisations would recognise it as an issue and yet it appears as though unscheduled downtime is simply thought of as a phenomenon that has to be accepted and happens in every industry across the entire world.

According to a recent report by Siemens in 2023, unscheduled downtime costs Fortune Global 500 companies a staggering 1.5 trillion dollars in lost revenues, or about 11% of their annual turnover.

Unplanned downtime occurs across every major industry. As one insightful commentator put it, ‘Unscheduled downtime is an equal opportunities problem’. It is estimated that over 80% of companies have experienced at least one unplanned downtime in the past 3 years. Of all the companies polled, 70% did not have a full knowledge of when important pieces of equipment were due for scheduled maintenance or replacement. Of course, the cost of an unscheduled breakdown varies according to the industry, the length of stoppage and the remedial costs. But one fact is certain; the cost of breakdown goes way beyond the cost of replacing the components. Some reports put the average cost of unplanned downtime at $250,000 per hour and $2 million per event. With so many companies operating on a basis of JIT, then damage to supply chains and reputation must be considered and can prove more costly than the simple loss of production. As a result of this, more companies than ever before have ‘zero unplanned downtime’ as a number one goal.

One of the key challenges to any maintenance manager is identifying potential breakdowns before they happen. In recent years many tools have become available to assist engineers to predict failure in key items of plant hence enabling preventative maintenance to be carried out before catastrophic failure takes place. Thermal imaging cameras are capable of detecting hot spots in gearboxes and bearings whilst more recently, through quantum leaps in technology, acoustic cameras have saved companies huge amounts of revenue by detecting faulty components and inefficient operating systems.

FLIR Teledyne, formed in 1978 is a world leader in the development and marketing of thermal and acoustic imaging cameras. Since then, they have supplied almost every industry around the world with market leading cameras and instruments representing the latest technology.

Building on the highly successful Si124 launched in 2021, FLIR are pleased to announce the launch of a new acoustic imaging camera, the Si2. With an improved frequency range of 2 – 130kHz the camera can detect minute leaks from air systems, ensuring maintenance can be carried out at an early stage before production is adversely affected. Those hard-to-reach areas of plant, such as elevated compressors or simple transfer lines are no problem for the FLIR Si2 with it’s built in lighting system and huge 100+ metre detection range.

Over the years, many production plants have simply accepted compressed air leaks as ‘the norm’ and at best, a minor irritation. But as any production director will know, with energy costs continuing to escalate, compressed air is expensive. A well known compressor manufacturer has estimated that the average leakage rate is about 25% with some plants losing about 80% of their compressed air through leaks. Any air or gas escaping through leaking joints is a false economy and directly impacts the bottom line.

To make life easier, the FLIR Teledyne Si2 camera not only detects leaks in air systems, but thanks to built-in advanced software actually calculates the financial implications of the identified leaks.

To find out more about the FLIR Teledyne Si2 acoustic camera and other products in the extensive FLIR Teledyne range of predictive monitoring tools please contact your local agent or distributor.

www.flir.com

WearDetect IoT combines Gill’s market leading oil debris sensors with Gill’s new IoT data platform to provide seamless equipment oversight for confident asset management.

Gill’s WearDetect oil debris sensors reduce unplanned downtime by continuously monitoring ferrous wear debris in lubricating oil to give the earliest maintenance warnings. This real-time condition monitoring, right in the heart of the equipment, is made all the more powerful when combined with the ability to collect, visualise and analyse that data using the Gill IoT Platform.

WearDetect IoT also allows alerts to be configured from multiple assets and multiple locations and sent straight to your PC, phone or other device, providing insight into gearbox and rotating equipment health, at your fingertips.

• Enhanced data collection & analysis – data assimilated from remote sensors in one simple-to-use platform.
• Remote monitoring and control – remote asset oversight enables timely maintenance.
• Scalability and flexibility – additional sensors can be added to the platform enabling systems to meet changing requirements.

WearDetect IoT offers:

• Real-time condition monitoring – live updates, alerts and machine wear data insights direct to your device.
• Precision sensing – WearDetect employs advanced solid-state sensors (no moving parts) to detect both fine and coarse ferrous wear debris.
• Trending data for predictive analysis – the Gill IoT Platform allows data visualisation for clearer insights supporting informed decision making.
• Instant alerts – user specified alarms ensure users are aware of changes as soon as they occur.
• User-friendly intuitive interface – easy data access and setting configuration puts the user in control.

Typical applications include:

• Industrial machinery – centralising wear data for rotating equipment allows maintenance professionals to pinpoint issues and minimise downtime.
• Automotive production – visualising wear data provides clearer and earlier maintenance insights on production lines with numerous loaded gearboxes.
• Cranes – heavily loaded critical gearboxes in hard to access locations benefit from remote wear monitoring.
• Wind farms – supports wind turbine gearbox monitoring and proactive, data-informed maintenance scheduling.

All Gill products are solid state, with no moving parts for minimal maintenance and low cost of ownership.

Gill Sensors & Controls is an established leader in the design and manufacture of advanced measurement sensors. Gill specialises in providing cutting edge products for level sensing and real-time ferrous wear detection, delivering market-leading performance and reliability. 

Gill is based in the UK with facilities including R&D, manufacturing, sales and customer support but also sells across the world through a long-established base of highly experienced distributors.

www.gillsc.com

Enerpac announces the LGH3100 synchronous lock grip system delivering up to 100 tons of hydraulic force for pulling medium to large size wheels, sprockets, bearings and other similar shaft-mounted parts. The puller’s self-centring closing "Lock-Grip" system moves all jaws simultaneously, allowing a single operator to safely handle removal of large wheels, bearings, and couplers with ease.

Removing large, shaft mounted, components that may have become seized and corroded can be challenge for maintenance operators. Dangerous practices such as torching, cutting and hammering are liable to damage expensive parts leading to maintenance delays and extended equipment downtimes. The 3-jaw LGH3100 Lock-Grip Puller gives operators the ability to detach heavy and stubborn, large shaft mounted components efficiently and without damage.

The 100 ton lock grip puller is mounted on an ergonomically designed rolling cart with a low centre of gravity that minimises the physical effort needed to position and operate the puller. The cart features large industrial castor wheels and pockets for use with a forklift. The hydraulic pulling power is provided by the onboard Enerpac ZE3-Series electric two stage pump and remote operating control pendant.

Removed components are captured and held securely within the synchronous locking jaws. With a maximum reach of 1219 mm, the smooth action, hydraulic scissor lift on the LGH3100 cart provides effortless centre height adjustment from 698 mm to 1679 mm. When both space and budgets are tight, the 3-jaw LG3100 is easily converted into a 2-jaw, 70 ton capacity configuration, avoiding the need to use valuable budget on a separate 2 jaw puller.

“The LGH3100 Lock-Grip Puller is the safe and productive way to remove large shaft mounted components without damage,” says Diego Rossi, Commercial Director Rail Markets EMEA, Enerpac. “The combination of a smooth action scissor lift, synchronized grip jaws and an intuitive operator station creates a stable and efficient pulling tool, allowing a single operator to remove, for example, large wheels, bearings, and couplers with unmatched ease.”

For more information on the Enerpac LGH3100 Lock-Grip Puller, visit www.enerpac.com.

The recent supply by Hoist & Winch of a bespoke electric-powered winch to a UK building products company is allowing the safe and smooth lifting and lowering of a large telescopic export chute that loads heavy-goods vehicles (HGVs) with a media byproduct from the customer’s production process. Importantly, raising and descending takes place in a level and precise position thanks to adjustable turn-buckle jacking screws.

Conceived by Hoist & Winch, one of the UK's leading lifting equipment companies, a 400 V three-phase Haacon wire rope winch providing a swl (safe working load) of 1,500 kg sits at the heart of this innovative solution. The advanced winch offers a special triple rope lead-off design that raises and lowers the export chute via one vertically and two horizontally orientated diverter pulleys. A purpose-made frame and bolted connections facilitate mounting of the winch to the steel floor, ensuring level rope pay-off from the winch drum to the three diverter pulleys serving the system.

The final wire rope connection to the export chute is via adjustable turn-buckle jacking screws and swivelling eye bolts, a design that not only provides accurate chute levelling adjustment, but also extends the service life of the wire rope by eliminating any twisting action.

Winch control arrives courtesy of a switchgear enclosure and a two-button, single-speed, hard-wired pendant control station located remotely in an environmentally protected operating cubicle. Environmental protection is vital due to operating temperatures of over 40°C in summer months, as well as excessive dust in the atmosphere and surrounding work areas.

                                                                                                                                                            Continued ……

The new winch system, which replaces an original obsolete solution that had reached the end of its service life, offers a number of further beneficial features to the customer, many relating to safety. For instance, the winch has a pressure roller to ensure secure retention of the wire rope on the drum. This capability is particularly important in the event of a slack wire rope, which might occur due to accidental over-lowering of the chute on to the HGV bed, for example.

Further safety-oriented features include an inverter controlled winch motor to provide very smooth and slow speed control, and grooves in the winch drum to ensure even and secure wire rope winding.

Notably, the scope of supply provided by Hoist & Winch was extremely comprehensive, as Andy Allen, Director of Hoist & Winch, explains: “We provided all pre-installation survey work to ensure correct alignment of the winch, diverter pulleys and associated equipment. In addition, we performed installation commissioning and load testing, all field wiring and the issue of a LOLER (Lifting Operations and Lifting Equipment Regulations) Thorough Examination Report for the complete system, including diverter pulley support steelwork. We take our responsibilities very seriously in all customer projects, ensuring the delivery of robustly engineered, high-performance solutions that are safe, reliable and fit-for-purpose.”

Delivered on-time and on-budget, the installation took place over a two-day plant shutdown. Hoist & Winch also provided thorough operator training on topics such as winch operation and control functions, as well as daily maintenance checks.

Visit www.hoistandwinch.co.uk for further information and to view recent case studies.

Hoist and Winch Ltd

Unit 20, 11B Arrow Business Park, Alcester Employment Park, Arden Road, Alcester, B49 6HN

Tel:  08450 171126                  

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.

web: www.hoistandwinch.co.uk

Hi-line Industries, a UK-based leader in the design, manufacture and installation of energy-efficient compressed air purification equipment, has established a new Technical Division that further elevates the level of support available to its valued nationwide distribution network. With highly qualified and accredited technicians, Hi-line’s Technical Division uses an unbranded fleet of vehicles whenever the need arises to provide support for a third party.

As an ISO9001-accredited UK manufacturer of class-leading air filters, adsorption dryers and air treatment ancillaries, Hi-line is a major supplier to the compressed air industry. One of Britain’s largest stockists and a proud member of the ‘Made in Britain’ campaign, the company has a responsibility to support its extensive distribution network, which includes compressed air service companies, compressor OEMs and local industrial suppliers/agents.

Hi-line’s new Technical Division employs only experienced compressed air treatment service personnel, with engineers trained in all aspects of compressed air and gas generation. Every technician is ACRIB (Air Conditioning and Refrigeration Board) registered and an approved ‘safe refrigerant handler’ in accordance with REFCOM (Register of Companies Competent to Handle Refrigerants). The company is also affiliated to BCAS (British Compressed Air Society) and works in association with DEFRA (Department for Environment, Food and Rural Affairs).

To support its broad portfolio of class-leading solutions for the compressed air industry, Hi-line’s Technical Division offers an extensive list of services. The servicing of compressed air dryers made by Hi-line and other manufacturers (refrigeration and desiccant models) is clearly a core activity - involving tasks such as filter element replacement, desiccant changes and condensate separator maintenance - but there is plenty more to Hi-line’s new service offer.

For instance, the company can provide air treatment total care agreements, energy audits (compressed air flow analysis), breathing air analysis, leak surveys, compressor data logging (with reports) and dewpoint measurements. In addition, the company has a long list of retrofit services available, including the ability to add dewpoint control to any make of dryer via the company’s high-capability AEMS (Automatic Energy Management Systems). Hi-line can also update dryer analogue control to touchscreen panels and provide dial-in retrofits for digital monitoring. Even pipework installations and modifications (including hygiene-grade stainless steel pipes) are no problem for the company’s Technical Division. Importantly, discretion is a priority whenever required.

“Many of our products are ‘unbranded’ at the request of compressor companies and other OEMs,” explains Hi-line’s Managing Director Steve Smith. “To support these products, we have an unbranded fleet of vehicles and can even adopt plain overalls and customer service report sheets upon request. Whatever your service requirement, we have discreet, well presented and qualified engineers to support compressed air treatment equipment made by Hi-line and others.”

Further information is available from: Hi-line Industries Ltd,

Green Street, Burton on Trent, Staffordshire  DE14 3RT

Telephone: 01283 533377                                           Fax: 01283 533367              

e-mail: This email address is being protected from spambots. You need JavaScript enabled to view it.                      www.hilineindustries.com

Rubis Terminal has become the latest company to join EEMUA, the international membership body for companies that own and operate industrial facilities or that are significant purchasers or users of engineering equipment and materials.  

Rubis Terminal is a leading major independent provider of industrial liquid bulk products and gases, operating 15 terminals across France, Spain, Belgium and the Netherlands. It provides flexible, reliable, and responsible solutions, handling a wide variety of products across the fuel, biofuel, chemicals, and agrifood sectors.

Hugues Baillet, Technical Director of Rubis Terminal commented: “Joining EEMUA is a strategic move for Rubis Terminal to enhance our commitment to safety, efficiency, and regulatory compliance within the industry”.

Deovonne Ferreira, EEMUA’s Head of Membership, added: “EEMUA is well placed to support Rubis Terminal in its commitment to sustainability and being part of the global route to Net Zero – the EEMUA membership is expert, is engineering focused and technology neutral, working across industry boundaries developing and sharing engineering expertise and good practice in tackling the engineering issues needed for industrial assets to operate efficiently, safely, and in compliance”.

EEMUA: www.eemua.org

Rubis Terminal: https://www.rubis-terminal.com

A Fusion of style and performance - built for active work in the Spring.

Snickers Workwear’s new range of lightweight Mid-layers are crafted for full flexibility on site and optimal comfort.

Built for active work, they’re fully flexible and can be worn as an outer layer when it’s warmer or a mid-layer when it’s a bit cooler.

They’re full of handy technical features and innovative fabrics to tame the wind, plus brand new energising colours to brighten your spring-time workday.

Choose from new street-smart styles such as the Windblocker Half-zip Hoodie or the Lightweight Flexiwork Mid-layer Jacket. There’s also a new Windproof Soft-Shell Jacket for women.

Whatever Snickers Workwear Mid-layer you choose, you can be sure that they all have body-mapping designs for a great fit, outstanding functionality and long-lasting comfort – all day, every day.

Getting more information on the Snickers Workwear clothing range is easy. You can call the Helpline on 01484 854788; check out www.snickersworkwear.co.uk or email This email address is being protected from spambots. You need JavaScript enabled to view it.

Unique, Tested and Certified to Exacting International Standards^[1] with longer-lasting impact protection.

In what is probably the most ground-breaking Work Trouser and Knee Guard innovation, Snickers Workwear has launched the world’s first built-in, certified kneepads which are completely integrated into a pair of Snickers Workwear’s premium stretch Trousers.

Delivering low-profile impact protection, the AllroundWork, Stretch Trousers with Capsulized™ Kneepads are an innovative combination of cutting-edge sportswear technology coupled with well-established workwear know-how. They’re ideal for craftsmen and women on site; for people in logistics and warehousing; industry, engineering and maintenance who are constantly on the move and want the continuous protection of welded-into-place Kneepads.

Designed and engineered in partnership with YBC®,^[2]  the Capsulized™ kneepad components comprise six protection layers that work with each other to dissipate the energy created by the impact of working on your knees or through bumps in the workplace.

https://www.snickersworkwear.com/campaign/capsulized

They deliver effective durability combines with penetration protection, as well as additional impact absorption, pressure release and enhanced comfort.And, as is typical of all Snickers Workwear clothing, these stretch Work Trousers with the lightweight Capsulized™ kneepads will provide in-place ergonomic protection all day, every day.

^[1] Tested and Certified according to EN 14404 for Type 2, Level 1 Knee Protection, https://www.snickersworkwear.com/list/protective-standards/en-14404-knee-protection .

^[2] YBC®, The Contour Experts, https://ybc-protection.com .

Air Power East's Secret Weapon Against LeaksChallenge

 Air Power East, a family-run business with over 30 years of experience as a premier distributor of Atlas Copco, specializes in providing high-quality compressed air systems to various industries across East Anglia. Under the leadership of Jason Sewell, the company has established a strong reputation for delivering reliable and efficient solutions.

However, they faced a significant challenge in ensuring their systems were completely leak-free, a concern shared by their clients, including an agricultural manufacturer managed by Paul Musgrove. Jason highlighted the issue, stating, "Customers have been asking us to make sure that we can prove something that's completely leak-free."

Concurrently, Paul Musgrove was seeking an effective way to manage and maintain their compressed air systems, with a specific focus on reducing energy waste and operational costs, emphasizing the need to "save money where we can, especially with energy prices as they are."

This dual challenge called for an innovative approach to maintain Air Power East's commitment to quality and efficiency while addressing the specific needs of their clients.

Solution

To address the intertwined challenges, Jason reached out to Baseline-RTS, an independent supplier of training and predictive maintenance equipment. They introduced Air Power East to the FLIR Si124 camera, an advanced acoustic imaging tool, capable of accurately detecting air leaks. Jason explains, "We sat down and did a bit of market research on a few different models and then came to the top. So, we contacted FLIR to come along and show us the Si124, and we've loved it ever since."

The Si124 is a lightweight, one-handed tool designed to quickly locate pressurized leaks in compressed air systems or detect partial discharge from high-voltage electrical systems. It is equipped with 124 microphones to produce a precise acoustic image that visually displays ultrasonic information. This image is transposed in real time on top of a digital camera picture, allowing users to accurately pinpoint the source of sound. The Si124 camera can detect issues up to 10 times faster than traditional methods, even in loud industrial environments. Additionally, it is compatible with FLIR Thermal Studio suite for offline editing, analysis, and advanced report creation, and it can help facilities save money on utility bills and delay the expense of installing new compressors.

Results

The use of the Si124 camera brought about transformative results. Jason explained the camera's effectiveness: "We've managed to walk around with the customer, showing them exactly what we're finding on our screen. And if we do find any small leaks, we can rectify them and then we can prove to the customer that their system is leak-free." This approach not only heightened the efficiency of the compressed air systems but also solidified customer trust in Air Power East's services.

Quantitative results underscore the Si124's impact. The camera enabled the detection of leaks amounting to approximately 100 cubic feet per minute (CFM), which is roughly 50 liters per second. This translates to about 18.5 kilowatts of compressor power, leading to substantial energy and cost savings, particularly in light of rising energy prices.

Conclusion

Air Power East's adoption of the FLIR Si124 camera to address the complex challenges in compressed air systems illustrates the power of innovative technology in industrial settings. The successful detection and rectification of air leaks not only enhanced operational efficiency but also led to considerable energy and cost savings for the agricultural manufacturer. This case study demonstrates the effectiveness of advanced tools in solving intricate industrial problems and highlights the importance of technology-driven solutions in optimizing industrial processes.

SPP Pumps Ltd (SPP) and Rodelta Pumps International BV (Rodelta) have agreed a strategic alliance between two of the world’s most established and respected pump manufacturing brands. Founded on almost 150 years of continuous product development and improvement, the agreement combines SPP Pumps’ ISO accredited and sustainable manufacturing expertise with Rodelta’s renowned R&D capabilities.

Established in the UK in 1878, SPP has grown into a leading designer and manufacturer of centrifugal pumps and associated systems, backed up by a worldwide spares and service network. Founded in 1946 in the Netherlands, Rodelta offers a technology driven product range, with an especially strong reputation for intrinsically safe pumps in potentially hazardous atmospheres.

Together, SPP and Rodelta’s pumps and systems are trusted globally for their reliability and low life cycle costs in safety-critical applications such as: process industries; water and wastewater treatment; fire protection; power generation; construction; mining; and other large industrial plants. 

Through the formation of a joint Process & Chemical Solutions division, SPP-Rodelta will focus primarily on oil, gas, petrochemical, biofuel, hydrogen and carbon capture markets; supported by a network of knowledgeable, responsive teams in Europe, the Middle East, North America and East Asia.

Robbie Graham, business development manager for the new Process & Chemical Solutions Division, commented: “I am delighted, after months of careful planning, to be formalising the longstanding cooperation between SPP and Rodelta. By combining best in class capabilities from both companies, we can now offer the latest in pumping innovations, such as our API 610 12^th edition compliant OH2, OH3 and OH5 ranges, via a genuinely global sales and support network.”

In particular the alliance is responsible for developing and introducing new products to complement the Rodelta range of API 610 (12^th edition) pumps; meeting the stringent safety and quality standards of the energy sector, where unplanned downtime is not an option. More specifically, this API compliant portfolio includes the ETL range of close coupled OH5 pumps, which provide improved energy efficiencies, reduced weights and smaller footprints with more user-friendly installation and maintenance than traditional alternatives.

www.spppumps.com/markets/process-chemical/