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Working with Fluke’s new online CO₂ emissions calculator, the LeakQ™ creates detailed air compressor leak reports from images captured by Fluke ii900 or ii910 acoustic imaging cameras.

Eindhoven, Netherlands. 30 June 2022: Fluke, a global technology leader in the manufacture of compact, professional electronic test and measurement tools and software, has today launched a new CO₂ emission indicator to the online LeakQ reporting tool. In addition to the existing estimated leak size and costs, this new feature adds a third element: the estimated electricity related CO₂ emission in relation to the identified leaks.

Maintenance engineers and sustainability managers who work with compressed air and gas distribution systems every day can be unaware of exactly how much gas and energy is wasted due to small leaks in the system. For compressed air applications, LeakQ used in conjunction with Fluke’s online CO₂ emission calculator enables users to quantify the financial value and environmental impact of detecting and fixing leaks in the system by creating detailed reports from images that have been captured using the Fluke ii900 Industrial Acoustic Imager and ii910 Precision Acoustic Imager.

Environmental impact

Approximately 90% of all processing companies use compressed air in some aspect of their operation, such that it is sometimes referred to as the fourth utility. It is estimated that if there were no maintenance systems in place at all, the losses due to leaks in the network would be between 25-30%. Whilst desirable, it is highly unlikely that any plant will achieve an 100% leak free compressed air system.

Compressing air is an energy intensive process and as such any leaks in compressed air systems mean a significant proportion of the electricity used by a compressor to compress the gas should be perceived as energy waste. Due to the energy intensive process, and the potential environmental impact of electricity production, the ability to quantify the environmental and financial value of maintenance is helping companies drastically reduce their energy (costs) use and carbon footprint.

Detailed leak detection

Typical leaks to focus on are quick connect leaks in a joint or interface that isn’t threaded, open end leaks in large holes or open-ended pipes, threaded coupling leaks via metallic threads or weld cracks, and leaks in rubber, flexible and plastic hoses and pipes. Standard leak detection tools only measure dB on a narrow frequency band but LeakQ carries out an automatic scan of the full frequency spectrum and captures the actual frequency range that the leak is generating. This makes estimations far more representative of the real leak rate than those that are achievable using more traditional measuring tools.

Report generator

To develop a report and estimate the potential costs of leaks, the user simply transfers inspection data from the ii900 or ii910 to a computer, where they can be dropped into the online LeakQ report generator. The user then inputs the operating variables such as gas type, pressure, cost of electricity and System Specific Power ratio, which is a measure of compressor efficiency. The report generated will include a summary of all the leaks listed as well as their estimated individual and annual volumes, costs, and emissions. Leak images are also inserted into the report which can be shared as a PDF or downloaded as a .CSV file for importing into existing maintenance systems. A feedback option enables users to relay their experiences directly back to Fluke so that the company can continue to make the leak detection tool better and easier to use.

Prioritising maintenance

Tako Feron, Global Product manager Acoustic Imaging at Fluke said: “Being able to prioritise, quantify and cost leaks in such a simple way is a game-changer for maintenance engineers who will be able to see the full financial and environmental impact of even the smallest leak in a compressed air system. Having the ability to reduce electricity usage is clearly a major bonus at any time but particularly in this challenging climate regarding the cost of energy. At the same time, it is essential to minimise leaks in compressed air systems if we are to meet our crucially important sustainability targets.”

Feron adds: “It’s estimated that around 90% of companies use compressed air in some aspect of their operations and the majority of this is generated on site. That means it is down to the user to keep the costs of compressed air as low as possible and the LeakQ™ leak detection reporting tool provides an extremely powerful means of helping them to achieve that goal.”

Learn more about the LeakQ™ report generator here.

MARL’s  677 series LED panel indicator lamp is a resilient, high-performance, British-made indicator used in some of the most challenging conditions on land, sea and air.

MARL, based in Ulverston in Cumbria, designs and manufactures long-lasting, robust products which have proved their worth over more than four decades.

Mounting through an 8.1mm hole, the 677 series is sealed to IP67 - weatherproof, vandal-resistant, and durable to shock and vibration, providing a reliable status indication solution for all types of applications.

The 677 series is the panel indicator of choice for American company Asphalt Zipper® in its road grinding and milling machines.

An Asphalt Zipper spokesperson said: "We needed LEDs to indicate the state of functions on our machine. After looking around, we found MARL’s 677 series. These LEDs hold up really well in our high vibration application. They are easy to see even from far away and in the sun. They also endure rain, sun, grease and impacts, and keep on working. Using the 677 series LEDs was a great decision and we haven't looked back."

For more information or to enquire about our products, contact our team:

T 01229 484625

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Pipe rehabilitation specialist Lanes Group plc has lined a main production waste pipe at a shampoo factory.

Ultraviolet liners have been installed in the 300mm diameter process pipe at the plant in South Wales.

The highly-sustainable no-dig project was designed to ensure the pipe will function to a high standard for decades to come.

Kyle Burgess, Area Development Manager for the Lanes Cardiff depot, said: “This was a good example of how no-dig pipe renovation technology can be of great help to our industrial clients.

“There was no real option to excavate and replace the pipe because of the need to maintain production and the high cost of such a solution.

“Lining the pipe was, by far, the best approach and Lanes had the technology and expertise to deliver it efficiently and effectively.”

The client, which manufactures shampoo for a global brand, commissioned Lanes to carry out the work as part of its planned and preventative maintenance programme.

It wanted to be sure process effluent could not escape from the concrete pipe into the ground.

The company also wanted to stop groundwater getting into the pipe, which would needlessly increase the volume of waste water being processed, adding to costs.

A team from the Lanes national pipe rehabilitation and lining division carried out the work, supported by drainage engineers based at company’s Cardiff depot.

Lanes has extensive experience in lining production pipes across a huge range of industrial sectors, including food and drink, chemicals, water treatment, and pharmaceuticals.

Working over two days, four separate ultraviolet liners were installed from manhole to manhole along the 181m pipe.

Overpumping was put in place, with water taken from upstream chambers and discharged into downstream ones through 6-inch and 4-inch hoses.

In this way, each section of pipe to be emptied and lined in turn, while allowing full production to continue at the factory.

The lining was carried out to the client’s selected specification, with 3mm thick plastic UV cured in place pipe (CIPP) liners installed.

Lanes uses the latest, most efficient, UV lining technology and can insert liners into pipes with diameters that range from 100mm to 1600mm.

Each liner is made up of layers of glass reinforced plastic (GRP) and resins containing a catalyst that reacts to UV light.

The liner is pulled along the pipe with a winch, then inflated with compressed air, pushing it against the pipe wall.

A UV light array, made up of a series of powerful UV lamps on wheeled trollies, is then pulled along the pipe to harden (cure) the resin layers in liner.

The power of the light array and the speed with which it is travels through the pipe is set by the system’s computer control system.

During the lining process, two lateral pipes leading into process effluent pipe had to be reopened. This was achieved using a remotely controlled robotic cutter.

UV CIPP lining is one of the most sustainable ways to rehabilitate industrial wastewater pipes, and can provide high levels of chemical resistance where it is needed.

Unlike hot water CIPP lining, UV lining does not create large volumes of waste water that needs to be disposed of at specialist sites.

Also, the UV lining process takes up less space and can be completed more quickly, reducing the risk of disruption in factories where continuous production is essential.

Teams from Lanes Cardiff provided CCTV drainage survey and jet vac tanker support for the project.

A post-lining CCTV survey demonstrated to the client that the liner had been installed correctly to the required quality standard, with a design life of 50 years.

www.lanesfordrains.co.uk

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GM Ramos Arizpe Assembly in Mexico has chosen LOBO for its new plant paint shop.

The Chevrolet Blazer manufacturing plant has several production lines that require maintenance. Like many tasks of this nature, access to the awkward area is needed 24 hours, seven days a week.

Maintenance areas exist directly above the plant shop conveyor systems, and production downtime must be kept to a minimum. Work at height maintenance processes must be controlled and fall under strict OSHA compliance regulations.

The fast no tools assembly features of the LOBO System are a perfect fit - hence the trial. Moreover, LOBO can be configured quickly and efficiently into any shape or size. Engineers are product trained by LOBO, which adheres to OSHA and delegates are tested at the end to maximise safe use.

GM Wentzville in St Louis, Missouri, has been a successful LOBO customer since 2015, so the concept is not new. LOBO was used for general maintenance activities in and around pipework, robotics, and cabling throughout the production lines.

Boyd Wells, UAW Safety Director at GM Wentzville, Missouri, said, "Thank you for coming to our plant and giving us the training to use the LOBO system properly. We have used your system in various parts of our plant where aerial lifts cannot access. The different configurations and ease of use are what makes your system so appealing. 

I found that our skilled trades workers like the system because it gets them to places they otherwise could not get to and provides them with a sturdy platform to work from. The cost of your system is another appealing part due to the cost of renting traditional scaffolding. I would say we have recovered the cost of your system versus what we would have had to pay to rent scaffolding.

The updated training you gave us further enlightened us on the many uses and new ideas on what can be done with the LOBO system. I know we will use the system more often now that you have opened our eyes to the different uses. In addition, your training covered the aspects of the OSHA standard and GM's policies on guard railing, work platforms and accessing these areas. We have implemented an inspection process now and will be able to train our employees further.

With safety being the overriding priority within GM, I know your system should be in every GM plant. Because I know without it, our workers would be working harder and not smarter".

LOBO Systems CEO Robert Bokros says, "LOBO is a game-changer; it will reduce costs and reliance on outsourced scaffolding contractors and will increase safety with our detailed training process".

www.lobosystems.com

Over the next six months, the Lifting Equipment Engineers Association (LEEA) will be launching a new suite of training courses as part of the Association’s Academy 2.0 Project. EUG (End User Guidance) will be the first course to arrive, on 7 July 2022  – Global Lifting Awareness Day #GLAD2022. EUG will be available via LEEA’s website, leeaint.com, as an open link accessible by all. Also on this day, the ILE (Introduction to Lifting Equipment) course will be available to LEEA members in the ‘Members area’ of leeaint.com.

On 2 August LEEA’s all new Foundation Certificate training course – FOU (Global), will be available to all members on subscription. This course is available in English, Arabic, Bahasa, Brazilian Portuguese and Simplified Chinese. FOU (Australia) will also be introduced, which is essentially the same as FOU (Global) but with regional variations. Online examinations will be available for FOU Certificate training in all languages stated.

LEEA’s all new Lifting Accessories Diploma training course, LAC (Global), will be available to all members on subscription on 5 September. Replacing the previous ‘Lifting Equipment General (LEG) Diploma’, the course is available in English, Arabic, Bahasa, Brazilian Portuguese and Simplified Chinese. In addition there will be LAC (Australia), LAC (NZ) and LAC (USA) courses. These will replicate LAC (Global) but with regional variations.

With all courses available on LEEA’s new e-Learning platform, members can carry out their training when they want, how they want and for as long as they want. The platform is suitable for any device and has an offline study capability with auto-sync updates once back online.  LEEA has made a substantial investment into a technology upgrade In its Huntingdon training centre, making e-learning a real option for learners. Now equipped with high tech cameras, speakers, microphones and other equipment enabling, LEEA staff can hold classes with delegates from across the world and deliver training via Zoom with maximum effectiveness.

Andrew Wright, Deputy CEO at LEEA, said: “Five years ago, I delivered a presentation to the Associations’ Annual General Meeting (AGM), which was held during the LiftEx 2017 exhibition in Telford. I spoke of constraints in the current LEEA Academy, and a range of opportunities that LEEA’s Learning and Development team would be working to deliver for our membership in the future. This included a state-of-the-art learning management system, incorporating a new suite of Certificate and Diploma level training courses; training courses available in languages other than English; online examination and a digital TEAM card. These new courses listed here are fulfilling the goal laid out at the AGM. In addition our digital TEAM card is now being produced and holders will begin to receive their new cards shortly.”

Incorporating new ‘smart’ technology, the new TEAM Card will enhance security, provide instantly verifiable data when required, and will be instantly updated by the LEEA team when changes occur such as new validation dates, change of employment details, a new photograph and when new qualifications are added.

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EEMUA Industry 4.0 webinar – Free and Open to All on 7 July – Live online – 14:00-15:45 UK time / 15:00-16:45 Amsterdam / 08:00-9:45 Houston – – Experts from Radio Data Networks and the University of Bristol explore: robotics developments; sensor design and use for a ‘control and quality revolution’ in a more connected world – more details and registration at  

#Freewebinar #roboticsdevelopments #connectedsensors #industry4.0 

The British Compressed Air Society (BCAS) has elected two new board directors, to further strengthen its representation of small to medium compressed air distributor members.

Wendy Hayward, Managing Director of Aircare Compressor Services Ltd and Dean Horn, Sales Director at Wearside Pneumatics Limited have now joined the team, with a remit to help enhance the range of services and support provide to distributors, which comprise over 50 per cent of the society’s membership base.

Wendy Haywood

In 1994, Wendy joined Aircare Compressor Services Limited (Aircare), which at that time was a fledging family business set up by her father Brian in 1991.  Then, only four-people strong and operating from Brian’s family home, Aircare presented diversity, opportunity, and scope for Wendy in a new industry.  Wendy became Managing Director of Aircare in 2010 and the business now operates from branches in Corby and Nottingham, with x employees.

Said Wendy:

I am excited by the challenge.  Distribution is a thriving compressor sales channel in the UK, comprising many small to medium businesses that have built up impressive customer portfolios and technical knowledge over the years.  However, as SMEs they face numerous challenges, such as staying abreast of legislative and regulatory change and ensuring staff are trained and developed continually - all while managing their own business and employees.

I hope that with my 30 years' experience in distribution I can bring first-hand experience of these challenges to the board and work with the team to further support our distributor members

Dean Horn

Dean has been working in the compressed air industry since 2006, holding numerous roles for Wearside Pneumatics, include office management, branch management and latterly as Sales Director.

Said Dean:

After more than 16 years in the industry, I felt it was time to give something back and am delighted to have this opportunity to help further support our distributor network. 

BCAS has an excellent reputation for providing timely and accurate information, backed by industry-leading training to its members; helping them to stay compliant and safe.  I am hoping to provide insight on how this information can be tailored further to support distributors, especially around the areas of energy-reduction and legislative compliance.

Vanda Jones, BCAS Executive Director concludes:

We send a warm welcome to Wendy and Dean and congratulate them on their new appointments. 

The British Compressed Air Society is committed to helping compressed air users operate more efficiently, compliantly and safely, so it is essential that we communicate effectively with all our members. 

From providing guidance on mitigating health and safety risks, to implementing compressed air energy saving initiatives during a time of unprecedented price increases, our distribution members have a key role to play in shaping the future of our industry.  We look forward to working with Wendy and Dean to better support our members in these challenging times.

FireAngel specialises in advanced fire, carbon monoxide and home safety technology and has achieved numerous safety industry firsts, deploying over 70 million products, and holding over 80 granted patents. Behind the scenes, its engineers Usha Hedge, Kirty Nagar and Swathi Kamble are helping the company to revolutionise the fire safety space. 

Despite the growing demand for tech talent, it’s still a male-dominated area with around three in ten roles filled by women. Why do you think there are so few females in tech? 

Usha Hedge, Firmware Engineer: The gender gap is not as simple as encouraging more women to enter the field or encouraging companies to recruit more women. It’s also an issue of retention. Research by the Global Talent Network, Adeva, found that over half (56%) of women in tech leave their careers at the midway point and the primary reason isn’t because they’re unhappy in their jobs. The timing of this movement is likely connected with a correlation that at this time, a woman also tends to start a family and must balance her career with childcare and new responsibilities. In a field that’s highly competitive and demands 100 per cent of your energy, this can be particularly challenging. 

What has been your experience of being a mother in tech? 

Usha Hedge, Firmware Engineer: I was lucky to be working at FireAngel when I had my first child several years ago. They gave me the opportunity to work flexible hours between home and the laboratory, despite there being no company policy to do so at the time. More managers across the tech world need to support women and have the conversation about flexible working to help diversify the industry. Flexibility and remote working in the recruitment process are two of the most effective diversity strategies noted by the 580 signatories of the UK Tech Talent Charter, a collective designed to share data, best practice, and progress on diversity in the industry. Making this common practice could keep more women in the field.  

What challenges have you felt being a woman in tech and how could this be improved? 

Kirty Nagar, Electronics Design Engineer: As women are underrepresented in the field, it can feel lonely. I think all organisations should have a channel or a group for women working in STEM to interact with other female colleagues to share support and guidance. The experience is similar in education, with a distinct lack of female role models. We need more organisations holding events at universities and schools and more female teachers, so that young women can learn about the opportunities available in STEM and hear from women that have progressed in the career. 

What motivated you to work at FireAngel? 

Kirty Nagar, Electronics Design Engineer: There are only so many companies with such a strong purpose. At FireAngel, it’s not just a matter of safety – but a matter of saving lives and there is nothing more precious. In multiple-occupancy houses, terraced homes, and high-rise buildings, a major fire does not just put a single household in danger but potentially hundreds of lives. I’m proud to work on technology that can help prevent a 999 call because I know I’m helping to protect people, their families, and communities. 

Swathi Kamble, Test Engineer: I like challenging myself and developing new skills and that’s what attracted me to the fire industry. The industry is currently recognising that the Internet of Things (IoT) promises to transform fire safety and having the opportunity to work on these types of projects from scratch to deployment is very exciting. With complex technical challenges along the way, it’s a big learning curve but I find it rewarding to know that I can make a difference to every step of the process. 

Local firms to collaborate on trial demolition job of one of Cumbria’s most iconic structures

A FOCAL point of one of Cumbria’s most iconic skylines is set to be demolished - but not before a team of local experts complete an essential trial run to ensure the job can be carried out safely.

The Pile 1 iconic chimney has dominated the landscape over Sellafield for decades, but it will be brought down in the coming years as the structure is decommissioned.

Ahead of the demolition job, a collaboration of Cumbrian firms plan to construct a replica of the chimney and then use new hydraulic equipment to demolish it to prove that the chosen methods would work.

A planning application has been submitted to Copeland Borough Council to demolish the bespoke concrete ring which will be created to accurately replicate the chimney with the same circumference of 15m, but only 7m in height. The dummy structure will be cut down with a newly developed Hydraulic SPIDA machine designed by ADAPT, a joint venture consisting of companies Doosan Babcock, Atkins and Orano.

The SPIDA structure is being fabricated by Glasgow company Cairnhill Structures. It is planned that the machine and the mock concrete barrel will be transported to Leconfield Industrial Estate, in Cleator Moor, to be tested and commissioned before two rows are cut out as a trial ahead of the actual work at Sellafield.

The trial is being facilitated by engineering firm Forth at the request of ADAPT.  Forth has bases across Cumbria including the proposed trial site at Leconfield.

The trial run is standard procedure within the nuclear industry and is deemed necessary to ensure working practices are safe and sustainable ahead of any demolition work on an active, potentially hazardous, site.

The trial works could last up to two years and, with an average of 30 people required on site each day, it is expected the project will create further job opportunities in Cumbria and also accelerate the plans for regeneration in Cleator Moor.

Graham Cartwright, the projects director at Forth, said: “What we are hoping to achieve with this project is to showcase the phenomenal talent and capabilities of the workforce in Cumbria to complete the required demolition job as part of such a major and landmark project for the local area.

“It’s about keeping, and creating, jobs locally, and preventing the workforce having to travel to Scotland to complete the project, thus reducing the carbon footprint of the project.

“Working together we can display all the skills needed and it will be a huge benefit to Cleator Moor and Cumbria for the job to be carried out locally.”

Paul Terry, Project Director for ADAPT said: “This proposal will make use of an unused area of the Leconfield Industrial Estate.  It supports our desire to keep things local, reduce travel and use local resources and supply chain wherever possible.

“This innovative project for Sellafield will also bring additional focus to the industrial estate as it starts to make progress with its regeneration plan.”

On completion of the trial work, the site at Leconfield will be cleared and returned to a similar condition to its current state.

Leconfield Industrial Estate, where this work is due to take place, is part of a wider Industrial Solutions Hub (iSH) campus which will enable further collaboration between industry and SMEs, creating employment and helping to regenerate communities across West Cumbria.

Coo l successor with sustainable DNA

Rittal is expanding its smart cooling unit solutions by adding the new Blue e+ S range. Our latest generation of cooling units with their lower output categories of 300, 500, and 1,000 W have been designed for efficiency, ensuring a smaller footprint and lower costs – just like their “bigger brothers.” So it’s a win-win both for users and for our future.

Solutions that reduce our carbon footprint during production are in high demand. But at the same time, these solutions need to be intelligent and communication-enabled so that they can be easily integrated into digitalised manufacturing environments. Seven years ago, Rittal responded to this demand with its Blue e+ range of cooling solutions and launched extremely efficient enclosure cooling units, which provided on average energy savings of 75 percent. Now we have a new generation – the next generation – but still developed with that same design DNA. These new cooling units with their lower cooling outputs of 300, 500, and 1,000 watts called “Blue e+ S” add to the Blue e+ family and bring with them additional smart capabilities. And furthermore, this new generation offers innovative energy-saving features for the production process.

What’s behind this energy-saving and therefore cost reduction is the technology used, combining a heat pipe with inverter-controlled components. The heat pipe works without a compressor, expansion valve, or other regulating elements and so does not need any electrical energy except to operate the fan. Depending on the thermal energy generated in the enclosure and the current ambient temperature, cooling can be performed with the heat pipe alone. The additional compressor cooling only operates if a large amount of heat has to be dissipated from the enclosure or if the ambient temperature is very high. And what’s more – when it does operate, it is far more energy-efficient than conventional units. This is because the compressor and fans possess an inverter-controlled drive, which automatically adjusts their speeds depending on the requirements. As a result, the temperature within the enclosure remains constant, and the energy efficiency is significantly higher than with other more conventional cooling units.

Staying cool all the time

Alongside energy efficiency, another feature also reduces the carbon footprint: The new Blue e+ S series uses a refrigerant with a GWP (Global Warming Potential) that is 56 percent lower than those used in comparable cooling units. Furthermore, instead of the R-134a previously used, the cooling circuit in the new generation of units now runs with R-513A refrigerant.

Smart communication-enabled capabilities

With their additional smart functions, the new cooling units also help in the digitisation process. With a fully integrated IoT interface as standard, the cooling units can be intelligently monitored in digitalised environments and easily connected to Rittal's new Smart Service Portal. This optimises the service processes and increases efficiency through predictive maintenance. As a result, fewer unplanned downtimes occur which all helps to manage the high cost of production, especially with Industry 4.0 processes.

Production-friendly facelift

These cooling units in the lower output classes have also undergone a facelift. Their most striking feature is an integrated coloured LED light strip. This means that warning messages can be immediately seen, even from far away. A display on the front of the enclosure provides additional up-to-date information. Moreover, the cooling units are equipped with the familiar NFC interface, which enables them to communicate with mobile devices that have the Rittal Scan & Service app installed.

For further information on the entire Rittal range visit  www.rittal.co.uk or check out our linkedin page @rittal-ltd-uk