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I’ve heard a lot about condition monitoring recently – why should I be interested?”

Condition Monitoring is generally a good thing to do, helping you understand the behaviour and condition of your machines, with the key benefits being:

• You can be warned of developing faults in advance, to avoid unexpected breakdowns and optimise maintenance planning;
• You can diagnose what these faults are, so maintenance can be prepared and targeted at the right fix with the right spare parts and tools organised in advance – to minimise downtime during the repair work;
• The biggest benefit comes if the condition information is good enough to allow you to adopt Condition Based Maintenance as a strategy – ie moving away from both Breakdown Maintenance and Planned Maintenance which can save your business up to 90% of the costs of maintenance and downtime.

Why am I hearing more about Condition Monitoring nowadays?

There has been something of a buzz about condition monitoring recently, with new technologies being introduced, new companies being founded and other companies being acquired by larger firms, all keen to bring this technology to a wider customer base.

• There is a wide variety of technologies available for condition monitoring:
  • Vibration Analysis (VA) – has been the most common technique up to now. Although this has been in use for 40 years or more, newer aspects include
    • Wireless sensors – avoiding the very high cost of connecting sensors on every bearing on every machine back to a central point; but battery life of these sensors can become an issue;
    • Energy Harvesting wireless sensors – avoiding the need for batteries altogether;
  • Other techniques including
    • Ultrasound
    • Motion Amplification
    • Thermography
    • Motor Current methods – which in addition to condition monitoring can also bring an energy optimisation / carbon footprint angle
  • “IoT” or “IIoT” aka “Industrie 4.0”. There has been an enormous amount of hype around the Industrial Internet of things, based on low-cost sensors communicating data via the internet. Underneath this hype the key elements are:
    • Connectivity to the cloud
      • allowing data from different systems to be viewed together to give a more complete picture;
      • permitting visibility wherever you are, on your phone / pc / tablet.
    • These elements are all being brought together with Artificial Intelligence / Machine Learning (“AI / ML”) to make sense of large volumes of data and turn them into simple conclusions and advice.
      • Cloud processing runs the AI algorithms on a central server, with all the raw data communicated from sensors via internet connections – with possibly large data volumes required;
      • Edge Processing does this locally, reducing data volumes and hence bandwidth requirement, but with potential battery life implications.
      • Learning / Training the algorithms can require very large volumes of data, either using historic records or taking a significant time before good results are delivered.

Model-Based Voltage and Current Analysis (MBVI) – a technology that combines the best elements of all of these categories

MBVI systems such as those from Faraday Predictive provide comprehensive machine information including:

• Condition Monitoring –present and predicted status up to 3 months ahead;
• Of the entire machine – motor, transmission, driven machine, and sometimes process;
• Diagnosis of the widest range of fault types – mechanical, electrical, load, speed;
• Information on energy consumption, energy cost and energy waste
• Flexible architecture - cloud based or local or stand-alone – avoiding comms bandwidth issues
• Installed in switchgear
  • Single set of sensors
  • Out of harms way
  • Can monitor inaccessible machines
  • Minimal cable runs
  • No issues about battery life

How can I evaluate which system is going to work well on my equipment?

Each different manufacturer has their own approaches to this but for example Faraday Predictive offer a service using their portable kit, to assess the condition of a handful of customers machines.  This provides a convincing demonstration of how well the system works on your particular machines.

For more information contact  This email address is being protected from spambots. You need JavaScript enabled to view it., +44 333 772 0748

 Drainage specialist offers flood resilience checklist to protect businesses sites

Businesses and householders need to urgently review the condition of their drainage systems as the extremely dry summer weather increases the risk of flash flooding, warns Kevin Moon, Managing Director of drainage and wastewater specialist Lanes Group plc.

The record summer heatwave has left ground baked so hard rainwater cannot soak away and is likely to rapidly build up through surface water run-off to cause localised flooding, with logistics and retail parks, factory sites, and schools often most at risk.

Water that would, in normal conditions, percolate into the ground will also surge into surface water drains and sewers that might not be able to cope with the sudden surge, said Kevin Moon.

He added: "This could make flooding risks worse and result in flooding happening in unexpected places. Rainwater could also be combined with sewage, creating a serious hygiene risk as well as property being flooded.

"Businesses should consider these risks as part of an urgent review of their business continuity plans at a time when extreme weather events are likely to put extreme strain on their sewer systems.

"Making sure that site drainage systems are as in a good condition as possible, in terms of being free of debris that can disrupt water flows and reduce capacity and in good repair, should be a priority in situations like this."

Lanes Group is the UK's largest drainage and wastewater specialist. It helps thousands of businesses across the UK protect their properties through planned and reactive site drainage cleaning and maintenance services.

The company also delivers sewer unblocking, repair and rehabilitation services for many water companies, including Thames Water, Severn Trent, Northumbrian Water and Scottish Water.

Lanes is urging businesses to consider 7 urgent issues when carrying out a site drainage resilience review:

1. Is your property location at particular risk of localised flooding?
2. Do you have an accurate and up to date map of your site drainage system and assessments of its condition and capacity? These can only be obtained by a drainage specialist carrying out a full site CCTV drainage survey.
3. Is the planned preventative maintenance schedule for the property's drainage system up to date? Has the drainage system been cleaned in the last 12 months?
4. Are you already experiencing any problems with your drainage system? Does water pool on surfaces around your property after it rains? Do sinks drain and toilets flush properly?
5. Are water courses around your property in optimum condition? Are storm culverts serving your site regularly inspected and cleaning?
6. Has there been any extensive building carried out recently that might affect your site drainage system?
7. Do you have emergency preparations in place if a flood occurs? This may include access to an emergency response service from a reputable drainage specialist and plans to protect assets and deliver services from a different location.

Periods of extreme heat and low rainfall, as experienced across the UK in July and August 2022, can create a "perfect storm" of circumstances that can make flooding risks much worse.

Extremely dry conditions, especially in areas with clay soils, causes the ground to heave, damaging buried pipes.

This has already resulted in an increase in water main bursts, just at a time when drinking water is at its most precious. In some cases, it has resulted in flash flooding.

On Sunday morning, August 14, thousands of homes had water supplies disrupted in the West End area of Southampton after a water main burst, flooding a road and many gardens.

The week before, a wall of water 4ft high flooded a large area in Islington, North London. Two adults and two children had to be rescued, as the flood water created two sink holes and damaged 50 properties.

Just like mains water pipes, sewer pipes can also be affected by the seasonal contraction and expansion of clay soils, resulting in pipe joints being displaced, pipes cracking or even collapsing.

Climate change will result in areas with clay soils further north in the UK being affected by this type of ground movement for the first time. This has significant implications for the maintenance of structures and underground assets.

During prolonged periods of dry weather, tree root systems grow more aggressively as they search for water and nutrients, increasing the risk of root infestation of drainage pipes.

This can result in pipes becoming partially or even fully blocked by root mass, an occurrence that may only come to light when the rains return and the blockage results in localised flooding.

During long periods of dry weather, flow rates in sewers are reduced, allowing heavier, solid material and debris washed into the system to build up, compromising its capacity.

Again, this is only discovered when the rains return and a sewer surcharges, with water coming to the surface, or it backs up into properties, causing an internal sewage flood.

Kevin Moon said: "The continued abuse of combined sewers, with people flushing items like wet wipes and sanitary products down toilets, and disposing of fats, oils and grease down sinks, also has a worse effect at times like this, because the material isn't flushed through the system by regular rainfall.

"Businesses need to consider all these factors over the coming days and weeks as they review the resilience of their drainage systems in the light of heightened risks of flooding.

"They should also bear in mind that statistics show that most businesses that go through the shock of an extreme flooding event at their property do not survive the experience, even if they are insured. The disruption caused is too severe."

Lanes Group: www.lanesfordrains.co.uk

The benefits of protecting our nation’s water distribution networks from corrosion far outweigh the problems faced by those featuring inadequately applied, or even missing, protection. Selecting and applying the right system can help to prevent the need for costly and time-consuming remedial works in the future.

At Winn & Coales (Denso) Ltd, we recommend our Denso P1 System™ for the protection of ferrous pipes, joints, and fittings.  Fully compliant with P1 Civil Engineering Specifications for the Water Industry (7th Edition), our easy-to-apply system consists of a primer (Denso Paste™); mastic (Denso™ Profiling Mastic), to fill any voids and create a smooth profile; and petrolatum tape (Denso Tape™) wrapped with a 55% overlap When administered correctly, the system offers long-term, effective protection from corrosion and can be applied on site before assets are buried. This method was recently utilised by Morrison Water Services on behalf of Thames Water at Kempton Park Water Treatment Works where the team protected 32 flanges, joints, and 4 x 1000 mm valves with the Denso P1 System.

www.denso.net

Air and fluid power specialist Thorite has appointed Gregg Blyth as Business Development Manager for the North East region, as part of its national growth strategy.

Gregg has more than 20 years’ experience in sales and business development and a wide breadth of knowledge, having previously worked for companies including Nike, Yell UK and, most recently, JTI (Japan Tobacco International).

He will be based at Thorite’s North Shields branch, in Orion Business Park – one of the company’s ten regional Trade Counters.

Thorite is the UK’s leading independent supplier of air compressors, air tools and pneumatic and fluid power process products, supplying over 70,000 products from more than 100 global brands.

A key objective for Gregg will be to promote Thorite’s comprehensive aftermarket offering, including compressor servicing and maintenance, air purity testing, air leak detection and energy saving solutions.

Gregg said: “I believe there are many opportunities to develop and grow the North East region for Thorite. I’m looking forward to learning, progressing, and developing as an individual in my career within a more technical and challenging sector.”

Thorite Sales Director, Mark Yates, said: “Our one-stop shop service with 360 aftermarket support is central to our plans to achieve £10 million growth over the next five years.

“We have a strong customer base in the North East and I’m delighted that Gregg is joining us to enhance our services in the region.”

Rising energy costs and more stringent legislation guiding sustainable practices is spurring companies to re-evaluate processes and seek new tools and technologies to reduce waste and overcome challenges in today’s industrial environments.

Eindhoven, Netherlands. 8^th August 2022: Fluke, a global technology leader in the manufacturer of compact, professional electronic test and measurement tools and software, today shares the top three trends that are enhancing operational efficiency in today’s industrial environments.

Challenges posed to industrial operations managers by the pandemic have now been superseded by the rising cost of energy, and the need to deliver on net zero ambitions. As the price of energy continues to increase, the need to reduce costs and deliver on shared sustainability goals intensifies for small-to-medium sized enterprises through to large corporations.

Paul Feenstra, Vice President Fluke EMEA, at Fluke said: “We are working together with our customers to help drive new initiatives to improve operations, increase efficiencies, and take reliability to a new level in the 21^st century.”

• Reducing energy costs with upgraded technology and cloud-based data monitoring

Approximately 90% of all companies use compressed air in some aspect of their operation, such that it is often referred to as the fourth utility. Recent developments in industrial acoustic imaging technology have enabled the fast identification of leaks in compressed air systems used in industrial and manufacturing environments. Fluke’s ii900 Industrial Acoustic Imager features an array of microphones, providing visualisation of sound field within an expanded field-of-view and on a distance of up to 70 meters, that enables maintenance teams to visually locate air leaks very quickly and accurately in compressed air systems.

Beyond the improvement of rugged handheld tools, monitoring practices are also evolving with the use of internet-connected instruments. Analysis and data is captured on a cloud platform allowing operators to monitor the key performance indicators (KPI) of compressed air systems including energy, electric power, flow, pressure and leakage flow. Fluke’s LeakQ™ Report Generator creates detailed air compressor leak reports from images captured by Fluke ii900 or the ii910 Precision Acoustic Imager and calculates the energy savings once the leaks are repaired.

• Using data to deliver predictive maintenance

For generations, maintenance professionals have used preventive maintenance to avoid equipment failures and turned to reactive maintenance when assets failed. With the emergence of Industrial Internet of Things (IIoT) technologies, maintenance professionals can now connect tools, software and sensors to collect, store and analyse multiple data sources in one place. The pandemic accelerated investment in technologies that make remote monitoring possible. The technology enables reliability and maintenance teams to meet up-time requirements no matter how fluid on-site staffing might be. The trend for remote monitoring will continue, with small scale operations turning to remote condition monitoring services.

Artificial intelligence (AI) and machine learning (ML) have held the promise to quickly identify trends and adapt quickly to changing operational conditions. Software armed with prescriptive analytics is finally meeting up with modern condition monitoring hardware to spark a revolution in the use of AI/ML in maintenance operations.

Now a new race has emerged to pair that hardware and software with ML and AI algorithms. Companies, like Fluke, are working to combine technologies so that the software can identify trends, recognise data patterns and make specific recommendations for equipment maintenance.

• Digital SI speeds integration of critical equipment measurements

The accelerated uptake in digital measurement solutions for industrial applications can save time and money, whilst facilitating a shift towards predictive maintenance for systems. Although modern measurement digital devices are typically not fit-and-forget solutions, the increase in digital measurement solutions paves the way for verification technologies that can help to reduce the maintenance burden on personnel, without compromising on accuracy or reliability.

Digital SI (International System of Units), an initiative created as part of the industry 4.0 revolution, relates to the creation of a globalised system to transmit calibration certification information electronically. This is critical as the exchange of data and the data itself are the basis of highly automated industrial processes. The system ensures measurement traceability from all calibrations performed and enables sharing of information in a paperless manner. This speeds up the integration of measurements that can be performed using critical test equipment as part of an integrated factory enhancing maintenance efficiency and plant efficiency.

“The tests we have faced within the last 24-36 months is delivering a growing awareness among top management that fundamental changes in maintenance best practice need to occur in order to protect the bottom line,” said Paul Feenstra.  

“This is music to the ears of progressive industrial managers who have been advocating for investments to improve efficiencies and reliability of systems. Now is the time to make the case to adopt innovative technologies, tools, and processes to ensure your company maintains a competitive edge and thrives in this new environment.”

For more information about Fluke’s specialist products and services, go to: https://www.fluke.com/en.

Crossflow Energy Company is utilising bearings supplied by R.A. Rodriguez (U.K.) Limited to help revolutionise the world of wind power. The KDM slewing ring with external gear is helping Crossflow to widen the adoption of ‘small wind’ technology and open up a wealth of market opportunities with the potential to be as commonplace as solar in everyday renewable applications.

Offering a unique way of bringing affordable, reliable power to many parts of the world which rely on small-scale diesel generation to meet growing essential power needs, Crossflow’s hybrid energy solutions leverage the company’s know-how in maximising renewable energy capture from a combination of wind, solar and battery storage. Reducing reliance on fossil fuels and their damaging consequences, these solutions incorporate Crossflow’s patented resilient wind generation and ‘2 in 1’  Eco Tower system.

In its development process, Crossflow has addressed historical challenges associated with harnessing wind power, such as high turbulence and veering winds, plus past limitations with reliability, noise and vibration. However, in order to develop successful product solutions, the company relies on high-quality engineering components, including bearings.

“We needed very large bearings to fit around our wind turbine towers,” states Rebecca White, Commercial Director at Crossflow Energy. “Rodriguez was one of the few companies that had slewing rings in the required size. We also needed robust and resilient bearings to take the force of incredibly strong wind loads.”

Crossflow looked at three or four different vendors but, in the end, R.A. Rodriguez (U.K.) Limited was the only supplier which had the right type of bearing – in the right specification – ready to go off-the-shelf: the KDM.H.A.1155.00.10 slewing ring with external gear. Slewing bearings consist of an inner ring and an outer ring, one of which usually incorporates a gear. Both rings typically feature an attachment hole, which allows for optimised power transmission between adjacent machine components.

“The bearings we scrutinised from some other suppliers wouldn’t have stood up to strong wind loads on a continuous basis,” says Rebecca. “In contrast, the Rodriguez bearings are durable and match the characteristics of our low-maintenance turbines. Furthermore, we’ve received great support from Rodriguez since the outset. They’ve cleared up any issues right away; it’s been a really helpful, consultative process.”

The KDM slewing ring is now an important part of a new product design from Crossflow Energy.

“Previously, our turbines didn’t fit around towers, they sat on top,” explains Rebecca. “In order to open up the potential of ‘small wind’ for the telecoms industry, given that telecoms equipment sits on top of telecoms towers, we needed to utilise bearings that would allow our turbines to fit around towers. We assembled the first KDM slewing rings to our new product in early 2022.”

Crossflow’s self-powered Eco Tower integrates the company’s unique Transverse Axis Wind Turbine and co-hosted telecoms equipment with conventional solar and battery technologies to create a 24/7, self-powered communication mast. Eco Towers provide reliable and affordable energy to the telecoms sector, facilitating 4G/5G connectivity in off-grid rural ‘not spots’ and delivering a far greener alternative to fossil fuel generation.

The KDM bearings, which rotate the blade system to allow the turbine to yaw around the tower, fit all models in Crossflow’s 3.6 kW rated Turbine range, offering both accurate positioning and smooth, efficient rotation.

Concludes Rebecca: “The bearings are a great fit. Tolerance can be a real issue in machine engineering, but we’ve faced no difficulties in that department. Most importantly of all, the bearing’s high-quality material ensures it is sufficiently robust to offer a long service life.”

The varied and specialist services available from Hoist & Winch Ltd have come to the rescue of a cement industry customer that was looking to replace a large rotor used in its production process. Thanks to the design, manufacturing, test, certification and installation services offered by Hoist & Winch, the cement works was able to avoid the long lead times associated with buying original OEM equipment, and successfully complete a highly complex and challenging lifting operation.

In essence, the objective was to lift and replace a large rotor fitted with pivot-mounted hammers that break down the media as part of the cement manufacturing process. Located at the base of a very large production enclosure, a pair of bearing journals provides support for each end of the rotor. Hoist & Winch had to design and arrange manufacture of equipment that would help to lift the worn and replacement rotors in and out of position in a precise manner without damaging any adjacent equipment, including the main drive motor and gearbox.

The cement works last performed this particular maintenance lift to replace a worn rotor in 2010 using a pair of lifting lugs that had since been disposed of. New replacement lugs were only available from the original supplier of the cement production process equipment on a very long lead time, which did not meet the requirements of the customer’s programme.

With a total design weight of 80T, rotor lifting was courtesy of a pair of tandem-controlled 41T SWL (safe working load) wire rope hoists located on monorail beams arranged at 90° to the rotor bearing journal stub shafts.

                                                                                                                                                            Continued ……

Kicking off the scope of work and working closely with a long standing trusted Sub Contractor, Hoist & Winch set about designing two 41T SWL rotor lifting lugs. As the basis for this task, the company used the customer’s drawing of the 600mm diameter rotor stub shaft profile and site photographs of the original lifting lugs. Other assignments here included accurate surveys of the existing hoist runway beam centres and the hoist unit hook profile. Hoist & Winch then produced general assembly drawings for a final dimensional check on site and customer approval of the design concept.

As well as manufacturing the rotor lifting lugs, the Hoist & Winch scope included design and manufacture of a special mandrel that would allow proof load testing of the lifting lugs prior to delivery to site. Each 41T SWL rotor lifting lug had to undergo a test rig mounted, 200% static proof load test. Hoist & Winch also performed non-destructive testing (NDT) involving visual, X-ray and magnetic particle inspection (MPI) procedures, while dynamic load testing of the rotor lifting lugs took place at the customer’s site using the new replacement rotor as the test load in advance of the lifting operation.

After passing all testing requirements, Hoist & Winch issued a LOLER (Lifting Operations and Lifting Equipment Regulations) Thorough Examination Report and Proof Load Test Certificate for the new rotor lifting lugs, along with 3.1b Material Certification for all materials used.

To see the project to its conclusion, Hoist & Winch witnessed the customer’s use of the rotor lugs during a planned plant shutdown for the lifting operation to take place. In so doing, the company also provided standby breakdown cover for the pair of tandem-controlled 41T SWL wire rope hoists.

“This project demonstrates how our diverse and comprehensive portfolio of services can come to the aid of almost any lifting requirement,” says Andy Allen, Director of Hoist & Winch Ltd. “Our professional team has decades of experience in lifting equipment services, for all applications. If your plant has any kind of lifting demand that would benefit from the input of industry experts, our team can help, beginning with a no-obligation discussion about the task in hand.”

                                                                                                                                                            Continued ……

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

Six Work Trouser families to satisfy every need on site - sustainably.

 Snickers Workwear’s trouser families are suited to any kind of work on site. Delivering maximum functionality, comfort, protection and mobility they’re the products of choice among discerning professional tradesmen and women. For them, sustainable, street-smart, body-mapping clothing are key parts of their product choices.

Hi-tech fabrics, functionality and fit are the hallmarks of these market-leading products. The AllroundWork trousers are ready for any kind of work in any trade. FlexiWork trousers deliver superior freedom of movement. While LiteWork trousers keep you cool, dry and ventilated.

Then there’s RuffWork trousers, reinforced and tough for the roughest work on site. ProtecWork protective wear for hazardous environments and certified High-Vis trousers when personal visibility on site is a priority.

work environments.

Snickers Workwear Trousers also deliver certified protection with the patented KneeGuard System for greater flexibility, comfort and durability. It’s what makes them the optimal choice for craftsmen and women who need to get every job done comfortably and sustainably on site. 

 Getting information on the Snickers Workwear trouser families is eay. You can call the Snickers Helpline on 01484 854788, checkout the website at www.snickersworkwear.co.uk or email This email address is being protected from spambots. You need JavaScript enabled to view it.

The Water Jetting Association has introduced an Audited Member programme giving its members a powerful new opportunity to promote the  standards they set to customers.

The initiative gives users of water jetting services greater assurance that contractors displaying the Audited Member logo meet the WJA’s high standards.

It has been made possible by the introduction of an audit procedure that requires new and renewing members to provide more information and evidence to show services are aligned with WJA codes of practice.

David Malin, Chairman of the WJA Technical Committee, whose members have been overseeing the development of the auding procedure, said: “We’re excited by the opportunities presented by our Audited Member programme.

“It’s going to help the WJA safeguard trusted water jetting standards and, thanks to the quality of the data we’re gathering, will play a key role in helping us to raise them over time.

“Equally important, also, is the opportunity it provides members to promote their services, and make the most of the advantages of being members of the WJA.”

Companies and organisations that use water jetting services, along with regulatory bodies, look to the WJA to set and uphold vitally-important safety and technical standards, said David Malin.

He added: “At the same time, our members join the WJA because they share our values and know customers will be assured by their association with us. The Audited Member programme will help us achieve both outcomes.”

The WJA has now added a range of new questions to its application forms for new members and for companies renewing their membership.

These are designed to extend the amount of information the WJA gathers about the safety and technical standards and processes companies work to, including equipment management and training.

The auditing process is closely aligned to standards detailed in the WJA’s codes of practice – the Blue Code for high and ultra-high water jetting, the Red Code, for use of water jetting in sewers and drains, and the new Purple Code, for pressure washing.

It also requires members and renewing members to abide by the principles laid down in the WJA Charter of Professional Conduct, covering issues that include professional behaviour, competence, incident investigation, and equality.

High and ultra-high pressure water jetting contractors – under the C1 and C1P (Provisional) categories – have been the first to undergo the auditing process. Auditing for members and prospective members in C2 to C6 categories will be rolled out over time.

All members who pass the auditing process will be allowed to display an ‘Audited Member’ logo on their websites, and promote the enhanced status they have achieved to customers and prospective customers.

Development of the auditing system has been led by Jeff Haigh, a WJA Ruling Council member and a qualified auditor.

Under the auditing system, all the new information provided in application forms is being carefully examined. Gaps or inconsistencies are resolved with applicants. Only then can the applications move to the next stage in the approval process.

The WJA also retains the option of carrying out visits to work sites or to company offices as part of the auditing process.

The WJA is grateful for the patience and cooperation of members during the introduction of such a fundamental new programme, said Jeff Haigh. Learning would be fed into later phases of its roll-out.

He added: “This is designed to be a positive process. The WJA wants to support applicants at every stage, sharing information and expertise that will help them with their applications, and to meet the standards we all want to achieve.”

www.waterjetting.org.uk