Measuring devices are critical equipment in your process and plant. Correct measurements are essential in ensuring the quality of your product. Therefore, it is vital that these devices are regularly calibrated to ensure they are operating as they should.

Calibration involves checking the measures taken by a device and comparing these against a traceable reference to ensure they are accurate.

Why calibrate?

• Product quality
• Economic reasons
• Safety
• Environmental reasons
• Regulatory requirements

Even the best instruments drift over time. With key decisions often based on these instrument readings it is essential that you can be confident they are accurate.

How often should you calibrate your instruments?
Each instrument Is different. Key factors that will help decide the appropriate calibration interval include:

• The manufacturers recommendation
• Past experience
• The interval currently being used for existing instruments
• National standards

 

Device vs Loop Calibration
Device calibration focuses on one specific device. The device is calibrated at install to create a benchmark and is periodically checked for accuracy.

Individual Calibration:

Loop calibration involves looking at the performance of the entire loop and all its components including the sensor, transmitter, wiring, input card etc. These all work together to measure the process parameter.

Loop calibration:

 

The other key step in the calibration process is the documentation of the results. EAS provides calibration certificates for all work done ensuring that your paperwork is all up-to-date.

It is essential that calibrations are carried out by trained skilled professionals like the Electrical & Automation solutions (EAS) team.  If you need an instrument calibrated or want to discuss setting up a calibration timetable, get in touch with the EAS team today on 07 834 0505.

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Static electricity can cause serious problems within the manufacturing environments from product quality issues to worst case scenario sparks being generated risking fire and explosion.

What causes static electricity?
Static electricity is caused when two materials rub against each other. Typically, the surface of every material has both protons(+) and electrons (-), with their charges being balanced; meaning the overall object has a neutral charge. However, when two objects rub against each other, the charges are separated and an electron or proton can move from one object to the other, resulting in each object becoming either positively or negatively charged. These objects will then attract (or repel) other objects.

So why is this a problem?
If two objects with a different electric potential are placed close together and if the voltage difference is sufficiently high, a spark can occur. Sparks can cause a serious risk of fires and explosions especially in environments where there are flammable materials or in environments where there is a lot of dust or fine powders.

While the creation of a spark is the most serious result of static electricity, static electricity can also interfere with the production process in other ways such as:

• dust contamination
• products clinging to each other
• contaminants getting into product
• plastic sheets not separating properly
• potential damage to machinery
• shocks to operators

What factors affect the creation of static electricity?

• The weather
  The dryer the air the greater the static build-up. Controlling the atmosphere in your production facility can reduce the risk of static electricity build-up.
• The type of materials being used
  Some materials are more readily charged than others. For example, materials such as acetate will gain a charge very readily whilst glass will gain a charge less readily.

• Repetition
  Repeated actions such as constant friction or separation will increase the level of charge found on a material. For example, a plastic web moving over a series of Teflon rollers will increase its surface charge after every roller.
• Battery Effect
  The combination of many charged items can lead to extremely high charges. For instance, individual sheets of plastic with relatively low surface charges when stacked together can generate extremely high voltages.
• Change In Temperature
  As a material cools down it can generate charge.

Controlling static electricity
While the generation of static electricity cannot be stopped, its accumulation and dispersal can be controlled through:

• correctly designing machinery, pipes and filtration systems
• bonding and grounding of equipment
• humidity control
• additives – antistatic additives can be added to liquids such as fuel to increase conductivity and reduce electrostatic build-up
• Material, flooring and clothing – conductive flooring, shoe soles and clothing can help dissipate static charges from a person as they walk or move around
• the introduction of Ionisers to your production line.

What are Ionisers
Air Ionisers make the air sufficiently conductive to dissipate static charge. Whatever static charge is present on objects in the work environment will be reduced and neutralised by attracting opposite polarity charges from the air. Because it uses only the air that is already present in the work environment, air ionisation may be employed even in cleanrooms where chemical sprays and some static dissipative materials are not usable.

Some ionisation devices require airflow to operate properly and may incorporate fans in their design.

Static electricity is an invisible hazard in many production environments. If you would like advice on steps to protect your plant from static electricity, get in touch with the EAS team today on 07 834 0505 or [email protected]

Electric motors have been around for centuries, becoming more refined and powerful over the years. Their role is to convert electrical energy into mechanical energy used in everything from your household appliances and computers to powering mega factories around the world.

The first motors were developed as far back as the 1740’s, however due to the challenges in generating the high voltages they needed for operation, these motors were never used for any practical purposes.

DC motors made a rise through the 1830’s, running up to 600 revolutions per minute, they powered basic tools and presses.

By the 1880’s the modern AC electric motor was taking shape, able to be adapted to many applications.

Today there is a wide variety of electric motor options for your plant. Key factors to consider when making your selection include:

• Input power source
• Environment – will the motor be operating in areas where it would be at risk or dust or water contamination or extreme temperatures. Is it located in a Hazardous Area?
• Motor specifications – the weight, size, shape can all have an impact on the suitability of the motor for the job.
• Motor performance – the speed and torque, starting/stall torque and the load profile will all impact on whether the motor is the right fit. A motor that has not been matched appropriately will cause significant damage to the machine, likely resulting in stalling or failure.

The EAS team can work with you to help take the guesswork out of choosing the right motor for your application.

To ensure the longevity of your motor, maintenance is also a key consideration. Over their lifespan of your motor, both mechanical and electrical inspections should be carried out to help identify issues such as:

• High resistance connections – Terminal box
• Winding contamination
• Rotor bar faults
• Bearing Housing
• Motor Feet
• Base-plate/Foundations
• Motor Insulation

The importance of including these checks as part of your preventative maintenance plan have been proven by the Cooper Bussmann brand which found that old age was responsible for only 10% of the failure of electric motors.

The most common causes of motor failure are actually:

Source: A.Bonnett & C. Yung

In addition to regular checks on your motors some early warning signs for motor failure may include:

• Motors tripping circuit protection
• Hot motor housing
• Excess vibration noise
• Increased operating costs
• Reduced torque
• Oil leakage at bearing seals
• Rust

Ignoring these warning signs may lead to costly repairs and downtime for equipment. Getting a qualified and experienced electrician you can trust in to diagnose these issues is paramount for safety and the lifespan of your motors and equipment.

If you would like advice on the best motor selection for your machines, or if you would like maintenance or repair assistance, get in touch with the EAS team today on 07 834 0505 so we can work together to find the best solution for you.