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Life is a series of priorities…
Business life, like life in general, is all about priorities. We all have them. Some things are fundamental to our very survival thus the impetus to complete them is paramount and easily resolved whilst others are what we like to call ‘nice to have’ but not essential. The latter often get placed in pending and never see the light of day! Whatever our priorities, there are always some things in business life which are non-core to our everyday productivity but which, by their very nature, are essential to complete either because they have a direct impact upon our income or worse, because they fall under some form of regulation and therefore have to done whether we like it or not. One of the more obvious and most topical priorities in the latter category is the much hated tax return! We all have to do it – but it is invariably deferred until the point when the deadline can only be met with several late nights and a lot of cursing on the part of the individual responsible! Yes – we’ve all been there! Another category of priority is that which we feel sure would be good for the business if we only had time to look into it. That much publicised Research & Tax Claim that colleagues tell you is ‘well worth claiming even if you don’t think you do traditional R&D’ is one of them; or maybe it is trawling the insurance market to improve on what you are sure is an over-priced existing policy!
The fact is, there is a host of none-core business related activities which are either essential to or would significantly improve the business if only we had more time to do them!
Regulatory Affairs
“If a Trade Association does nothing else – it should act as a voice for its industry amongst politicians and senior government decision makers!”
Lord Sir Digby Jones
When Lord Sir Digby Jones spoke those words he captured the essence of why many trade associations were conceived. Indeed, many associations do little more than lobby Government and there is no doubt that such activities should be a staple membership service for any body claiming to represent the best interests of its members.
In the past few years the BFPA has steadily increased its activities in this area and with the arrival of their current CEO who spent a period of secondment to the UK Cabinet Office whilst with BAE Systems, the lobbying activities of the Association have increased exponentially. An article by the BFPA CEO, (see below) captures the essence of this argument and also addresses the all important question – Can we really make a difference?
“We can make a difference – we just have to go about it in the right way…”
BFPA CEO, Chris Buxton emphasises the importance and benefits of lobbying Government.
If there is one thing that a Trade Association should undertake to achieve, it is to “work effectively to represent the sectors interests at all levels of the legislative and regulatory process.” So states the Trade Association Forum (TAF) in describing the model Trade organisation. As a CBI sponsored body acting as the ‘trade association for trade associations’, TAF is well placed to make such judgements and defines what is widely accepted as best practice in the Association world.
Unfortunately, all too many trade association members are sceptical as to the likelihood of ever being able to influence the regulatory process and consider such lobbying activities on the part of their trade association as at best, ineffective and at worst – futile. However, such scepticism, whilst understandable, is ill-founded. During an earlier period in my career I was fortunate enough to go on secondment to the UK Cabinet Office from what was then my current employer; BAE Systems. Amongst the many things that I learnt from the experience was the fact that undertaken in the correct manner, (i.e. with empathy and constructive professionalism), lobbying is not only effective but is an essential element in the smooth running of any democratic Government and is actively sought-out by Government regulators and Whitehall civil servants alike. As lobbyists we are ‘pushing on an open door.’ But such engagement has to be undertaken properly to be successful.
In effect, lobbying is a form of selling. One party is trying to convince the other of the benefits of its policy or views. It is a process of persuasion. As any good Sales person knows, success comes from understanding the needs of their customer; that is; being able to empathise with the recipient of the messages that are being delivered! Too many lobbyists, especially the smaller, less well informed organisations do not follow this simple principle and then complain that lobbying is ineffective.
Essentially, there are three fundamental steps in this process:-
1) Clearly identify your customer (in the case of lobbying this is the person or people that can actually implement the changes that you are seeking),
2) Understand him/her (i.e. determine their drivers), and understand how their organisation works, i.e. the policy-making process.
3) Tailor the lobbying proposal in such a way that it addresses the key attributes and expectations of that customer. (Whilst accounting for the political as well as the economic impacts of the proposal.)
The most important of these steps is the first. Too many lobby groups secure a meeting with a Minister but neglect the team of civil servants who will actually develop, influence and implement the relevant government policy. Like any good sales process, the lobbyist needs to identify the ‘decision making unit’ and engage with all of the influencers in the policy making process – up and down the echelons of Government. Another mistake often made by lobby groups is to believe that they can ‘go-it-alone’. Such arrogance is misguided and naïve. There are thousands of different trade associations in the UK and regulators are invariably under pressure from a plethora of different lobby groups, each with a different issue. Consequently, they are constantly trying to ‘keep all of the people happy all of the time’, invariably with insufficient resources – an impossible aspiration. In this kind of environment it is imperative that a given industry speaks with one coherent and ‘loud’ voice if they are to be heard above the background noise. By ‘loud’ we invariably mean with a view that represents as large a number of individual voters as is possible! In politics, votes speak volumes in every sense of the word! No one individual, organisation or company will successfully change the regulatory landscape on their own. That is why the BFPA has joined forces with the Engineering and Machinery Alliance, (EAMA), an alliance of twelve like-minded trade associations, all in the engineering sector but most importantly – with common regulatory issues and aspirations. Collectively, they represent thousands of individual employees across well over a thousand companies. Representation on this scale can begin to influence the voting landscape thus politicians are more inclined to listen. This weight, augmented by experience of government policy-making and a professional approach to engaging with the regulators at all levels, positions EAMA and BFPA as one of the key stakeholders with whom Government engages when determining policy.
Can BFPA or EAMA claim sole credit for a whole tranche of regulatory changes? Probably not – no one organisation can, but we can claim to have been critical and major influencers in the development of a significant range of regulatory processes which will and already have, had a major impact upon UK Engineering firms – including BFPA members. The policies that the Chancellor announces in the annual budget are not formulated in isolation. They are developed in conjunction with credible and established lobby groups such as EAMA and the BFPA. Topics upon which we have already been active have included Capital Allowances, Small business rate relief and property rates, improved access to finance, the new Business Bank, fuel duty, late payments, R&D Tax Credits and the all-important issue of skills and training – to name but a few. More recently and most notably we have been successful in securing an exclusion of waste hoses and associated PPE from the hazardous framework directive saving the industry and our members £18 Million pounds a year. [INCLUDE LINK TO PRESS RELEASE]
The BFPA Mission is essentially to help our members improve their businesses. In other words, to help members sell more products and services. Some of the services that we offer achieve this aim directly through cash discounts on none-core business services or web-based advertising channels but our ability and commitment to speak on behalf of the industry in the ‘corridors of power’ is perhaps one of the least well recognised and most important services that we offer. ‘Together we stand – divided we fall!’
A SELECTION OF RECENT AND CURRENT BFPA LOBBYING ISSUES
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Innovation for growth
Key rationale: OEMs demanding supply chain innovation and companies taking on new lines and services
Topics:
- Building depth in additive manufacturing
- Mass customisation
- Exploiting the Internet of Things and modeling in both the factory and wider supply chain
- Mass customisation
Innovation for efficiency
Key rationale: essential in the drive for re-shoring and re-industrialisation
Topics:
- Manfacturing automation (note: also contributes considerably to innovation for growth)
- Global best practice, capability and capacity self-assessment benchmarking for continuous improvement in productivity
Enabling initiatives
Key rationale: to enhance collaboration across the value chain – both with original equipment manufacturers (OEM) and between SMEs – and communication, the image of the sector and improve the record on equipment and skills investment
Topics:
- Technical and business skills development, possibly through a trade association sponsored national academy
- Small set of competency/technology based innovation centres focused on SMEs but linked to the Catapults
- Fiscal and taxation environment
- LEPs: local delivery opportunities for strengthening supply chain economics
- IP protection services
- Profile of UK machinery makers and component manufacturers in education, and with OEMs and Government
It is recommended that the implementation study adopts a four-stage approach to strategy development over a period of eighteen months.Stakeholder discussions early in the implementation study will segment the proposed projects prior to confirming the approach and resource allocation. Projects will be segmented as:
EAMA giving support and input to initiatives already running
- Focused EAMA effort required to ensure members’ needs are met.
- New territory in which EAMA will take a lead (initially)Support will need to be sought for this work in the first half of 2015.
KEY STAKE HOLDERS AND PARTNERS IN THE GOVERNMENT AFFAIRS ENVIRONMENT:-
– The Engineering & Machinery Alliance (EAMA)
– ORGALIME
– CETOP
– The Trade Association Forum (TAF)
– PNEUROP
– The British Bankers Association (BBA)
– The CBI
– The British Standards Institute (BSI)
– The Government Department for Business Innovation & Skills (BIS)
– UK Trade & Investment (UKTI)
– Local Government
ORGALIME:-
Orgalime is the Brussels based lobbying organisation for all engineering sectors. It is not a UK organisation but a pan European body funded by engineering organizations from all over the EU. It is headed by a Britain, Adrian Harris and no individual TAs can belong. The UK members are BEAMA, GAMBICA and EAMA. Membership of one of these bodies allows access to Orgalime and its activities.
Much of Orgalime’s work is in monitoring the flow of new legislation and regulations coming from the European Commission and preparing position papers and lobbying on behalf of its membership. Most of the time it is trying to stop more regulations on undertaking impact assessments on existing regulations. It is a very vociferous organisation and battles very hard against the tide of proposals which seem to come in never ending waves from the Commission and/or Parliament. It has fought successfully on behalf of its constituents on many fronts i.e. delaying the revision of the Machinery Directive, watering down the impact of REACH on use of industrial chemicals and helping to get capital equipment such as processing and packaging machinery excluded from the first implementation of WEEE (Waste Electronic and Electrical Equipment Directive). They have a useful website which has up-to-date briefing documents and details of legislation passing through the EU commission etc.
Orgalime is a vital source of information regarding EU activity and co-ordinates much useful lobbying on behalf of the whole engineering sector.
The equivalent for the Compressed Air community is PNEUROP.
Contact:- Adrian Harris, Tel. 00322 706 82 35, Email: secretariat@orgalime.org or website www.orgalime.org
CETOP:-
CETOP www.cetop.com is the acronym of Comité Européen des Transmissions Oléohydrauliques et Pneumatiques. CETOP is the European Fluid Power Committee. It describes itself as:-
“The communication platform for fluid power in Europe. The international umbrella organisation for national fluid power associations in Europe.”
Through the 18 national associations which are member of CETOP, all well-known companies in Europe belong to the European Committee. Many of these companies are leading fluid power manufacturers and major players in the international markets.
CETOP represents more than 1,000 companies – mainly manufacturers, but also some distributors – with almost 70,000 employees and a market value of about 13 billion EURO. These account for a very high proportion of companies active in these fields – 80-90% in most countries. CETOP cooperates with ISC – the International Statistics Committee with the aim of getting global Fluid Power Statistics, following commonly agreed definitions and nomenclatures. The following associations belong to ISC: CETOP (Europe), CHPSA (China), FPSI (India), JFPA (Japan), NFPA (USA), and TFPA (Taiwan).
The BFPA has been and continues to be very active in CETOP. Indeed, through its direct involvement CETOP authored a comprehensive set of recommended academic criteria for training in Fluid Power. (CETOP levels one two and three.) The BFPA CEO attends the CETOP Assembly meetings and sits on the EU Marketing Commission. BFPA technical consultants continue to be active on the technical commissions and committees.
The Trade Association Forum (TAF):-
The business sectors that individual trade associations represent may be unique but the organisational and policy issues that they face are not.
Since its formation in 1997, the Trade Association Forum has been encouraging the development and sharing of best practice among UK trade associations and promoting the role of effective trade associations to government, industry and the wider public. The current BFPA CEO is a Board Director of TAF.
Through the Directory the Forum provides comprehensive links to information on UK trade associations and the business sectors they represent.
The Forum provides its members with a range of services and activities designed to assist them in the strategic development and day to day running of their organisations but is not a policy setting body.
Funded by its members, the Forum is an incorporated body operating with guidance from a Board of Directors consisting of trade association representatives. The Forum is based in Waterloo.
Manager: Linda Cavender : 020 3170 0898
Events & Sponsorship: Jocelyn Rudnick: 020 3170 0898
Finance & Benchmarking Officer: Peter Cload : 020 3170 0898
Benchmarking Officer: Richard Fairclough : 020 3170 0898
PNEUROP:-
Pneurop is the European Association of Manufacturers of Compressors, vacuum pumps, pneumatic tools and allied equipment, represented by their national associations. Pneurop members are national associations representing more than 200 manufacturers in eight EU member states in Switserland and Turkey. The European market for the sector exceeds twenty billion euros.
Pneurop speaks on behalf of its members in Eu and international forums regarding the harmonisation of technical, normative and legislative developments in the fields of Compressors, Vacuum pumps, pneumatic tools and allied equipment. It is the preferred EU alliance for the British Compressed Air Society BCAS.
The British Standards Institute (BSI):-
BSI Group, also known in its home market as the British Standards Institution (or BSI), is a multinational business services provider whose principal activity is the production of standards and the supply of standards-related services.
BSI Group was founded as the Engineering Standards Committee in London in 1901. It subsequently extended its standardization work and became the British Engineering Standards Association in 1918, adopting the name British Standards Institution in 1931 after receiving its Royal Charter in 1929. In 1998 a revision of the Charter enabled the organization to diversify and acquire other businesses, and the trading name was changed to BSI Group.
The Group now operates internationally in 150 countries. The core business remains standards and standards related services, although the majority of the Group’s revenue now comes from management systems assessment and certification work.
BFPA is the external secretariat for 500 of the 7000 standards for which BSI is responsible. This is a key work stream for the organisation and a clear differentiator amongst other trade associations.
All formal standards are developed with a period of public enquiry and full consultation. They incorporate the views and expertise of a very wide range of interests from consumers, academia, special interest groups, government, business and industry. As a result, standards represent a consensus on current best practice.
Standards are designed for voluntary use and do not impose any regulations. However, laws and regulations may refer to certain standards and make compliance with them compulsory. For example, the physical characteristics and format of credit cards is set out in standard number BS EN ISO/IEC 7810:1996. Adhering to this standard means that the cards can be used worldwide.
As the UK’s National Standards Body, BSI is responsible for producing and publishing British Standards and for representing UK interests in international and European standards organizations such as ISO, IEC, CEN, CENELEC and ETSI. Formal British Standards are titled BS (for British Standard) XXXX[-P]:YYYY where XXXX is the number of the standard, P is the number of the part of the standard (where the standard is split into multiple parts) and YYYY is the year of publication.
BSI produces standards on a wide range of products, services and processes; from nuts and bolts to sustainability, risk, business continuity management and nanotechnology.
BSI produces British Standards, and, as the UK’s National Standards Body, is also responsible for the UK publication, in English, of international and European standards. BSI is obliged to adopt and publish all European Standards as identical British Standards (prefixed BS EN) and to withdraw pre-existing British Standards that are in conflict. However, it has the option to adopt and publish international standards (prefixed BS ISO or BS IEC).
In response to commercial demands, BSI also produces commissioned standards products such as Publicly Available Specifications, (PAS’s), Private Standards and Business Information Publications. These products are commissioned by individual organizations and trade associations to meet their needs for standardized specifications, guidelines, codes of practice etc. Because they are not subject to the same consultation and consensus requirements as formal standards, the lead time is much shorter.
BSI Group is the world’s largest certification body. It audits and provides certification to companies worldwide who implement management systems standards. BSI also provides a range of training courses regarding implementation and auditing to the requirements of national and international management systems standards.
It is independently accredited and delivers assessments for a wide range of standards and other specifications including:-
- ISO 9001 (Quality),
- ISO 13485 (Quality management systems for medical devices)
- ISO 14001 (Environment),
- ISO 50001 (Energy management systems),
- OHSAS 18001 (Occupational Health and Safety),
- ISO/IEC 27001 (previously BS 7799 for Information Security),
- ISO/IEC 20000 (previously BS 15000 for IT Service Management);
- PAS 99 (Integrated Management),
- BS 25999 (Business Continuity),
- Greenhouse Gas Emissions Verification,
- SA8000 (Social Accountability) and
- Food Safety standards and specifications, including ISO 22000.
- AS9100, AS9110, AS9120 Aerospace
- EU Emissions Trading System (EU ETS)
BSI certifies approximately 60,000 locations in over 124 countries and operates across the UK, CEMEA, Asia Pacific (including Japan and China) and the Americas.
Subsequent to an acquisition in 2006, BSI also offers a web-based integrated management system software service called Entropy Software, which specializes in helping large organizations manage risk and compliance issues.
BSI Group also offers a range of training services on how businesses can implement and audit management systems effectively.
BSI also publishes standards-related books, CD-ROMs, subscription products and web-based solutions as well as providing training on standards-related issues.
Within Testing Services, BSI’s best known product in the UK is the Kitemark, a registered certification mark first used in 1903. The Kitemark – which is recognized by 82% of UK adults – signifies products or services which have been assessed and tested as meeting the requirements of the related specification or standard within a Kitemark scheme.
BSI also conducts testing of products for a wide range of certifications, including for CE marking. CE marking must be applied to a wide range of products intended for sale in the European Economic Area. Frequently manufacturers or importers need a third-party certification of their product from an accredited or ‘Notified’ body. BSI holds Notified Body status for 15 EU Directives, including construction products, marine equipment, pressurized equipment and personal protective equipment.
BSI also conducts testing for manufacturers developing new products and has facilities to test across a wide range of sectors, including construction, fire safety, electrical and electronic and engineering products.
Within Healthcare, BSI provides regulatory and quality management reviews, and product certification for medical device manufacturers in Europe, the United States, Australia, Japan, Taiwan, Canada and China. It is the market leader in the USA, the world’s biggest healthcare market
The Government Department for Business Innovation & Skills (BIS):-
The Department for Business, Innovation & Skills (BIS) is a ministerial department of the United Kingdom Government created on 5 June 2009 by the merger of the Department for Innovation, Universities and Skills (DIUS) and the Department for Business, Enterprise and Regulatory Reform (BERR).
Of all of the Government departments it is the one that is most relevant to the business of the BFPA along with its associated export agency UKTI. (See below).
The department is responsible for UK Government policy in the following areas:-
- business regulation and support
- company law
- competition
- consumer affairs
- corporate governance
- employment relations
- export licensing
- further education
- higher education
- innovation
- insolvency
- intellectual property
- outer space
- postal affairs
- regional and local economic development
- science and research
- skills
- trade
- training
It is the first ‘port of call’ for all items relating to business and provides specific services relating to:-
- General guidance for business
- Find guidance on jobs and pensions
- Learning about export control
- Identifying business finance and grants
- Export support
Significantly BIS also houses the Better Regulation Executive (BRE) who provide support for industry engaging with Government on poor or inappropriate regulation. The current BFPA CEO was a part of the BRE during his secondment to the Cabinet Office and therefore has a selection of good contacts within the department.
Key staff appointments following the May 2015 Election were as follows:-
- Secretary of State for Business, Innovation and Skills, and President of the Board of Trade – Rt Hon Sajid Javid MP
- Minister of State (Trade and Investment) – Rt Hon Francis Maude (jointly with the Foreign and Commonwealth Office)
- Minister of State – Anna Soubry MP**
- Minister of State – Nick Boles MP (jointly with the Department for Education)
- Minister of State – Ed Vaizey MP (jointly with the Department for Culture, Media and Sport)
- Minister of State – Jo Johnson MP
- Parliamentary Under Secretary of State – George Freeman MP (jointly with the Department of Health)
- Parliamentary Under Secretary of State – Baroness Neville-Rolfe DBE (jointly with the Department for Culture, Media and Sport)
UK Trade & Investment (UKTI):-
UKTI was formed in May 1999 as British Trade International, comprising two parts: Trade Partners UK (for export) and Invest UK (for inward investment – FDI). In October 2003, the former department name and two inner departments merged and became UK Trade & Investment to simplify the outward recognition of the organisation, and possibly to reduce confusion with the two departments. UKTI reports jointly to the Foreign Office and the Department for Business, Innovation and Skills.
Aims:-
To support its aim to “enhance the competitiveness of companies in Britain through overseas trade and investments; and attract a continuing high level of quality foreign direct investment”.
UK Trade & Investment offers services to British businesses wanting to gain access to global markets through export, and foreign based firms wanting to invest in the UK as a base to expand globally. Under agreement Trade & Investment organisations for Scotland, Wales and Northern Ireland respectively Scottish Development International, Wales Government, Invest Northern Ireland are able to access UKTI services and provide support for those companies who are located in their individual countries.
Structure:-
UK Trade & Investment is an international organisation with headquarters in London and Glasgow in Scotland. Across its network UK Trade & Investment employs around 2,400 staff and advisers, including overseas in British Embassies, High Commissions, Consulates and trade offices, and regional offices in the nine English regions.
The delivery of many UKTI regional services within the United Kingdom is contracted out to other organisations. Traditionally this was a role played by the local Chamber of Commerce, but more recently contracts have been awarded to “bodies which are closer to government.” The British Chambers of Commerce (BCC) argued that the effect of this change was to “take trade services from a single roof which employers knew and understood [and] spread them among many different organisations.” In Devon, Cornwall and Somerset, UKTI regional services are now delivered by Serco, which also provides services to local government and the private sector in the following areas: home affairs, defence, science, nuclear, health, education, welfare to work, and IT. In China, the China Britain Business Council, another private body, is the provider.
Business and University leaders work with UKTI as “Business Ambassadors”. They promote the UK internationally and highlight trade and investment opportunities. They focus on helping small and medium-sized enterprises (SMEs), which sometimes face greater barriers to accessing global markets than larger businesses.
UK Trade & Investment brings together the work of the Foreign & Commonwealth Office (FCO) and the Department for Business, Innovation and Skills (BIS). It draws staff and associated administration funding from both parent departments, but has its own stream of programme funding, for which the Chief Executive is directly responsible as accounting officer. The UK Special Representative for International Trade and Investment works as part of UKTI to promote British business and produce.
UK Trade & Investment has Public Private Partnership agreements with the Federation of International Trade Associations under which they contribute market research and other reports on GlobalTrade.net.
UK Trade & Investment has an arms trade branch called UKTI DSO (UK Trade & Investment Defence & Security Organisation).
An important activity of UKTI for BFPA is the fact that it runs the Trade Access Program (TAP) which provides funding through Accredited Trade Organisations (ATO’s), for UK companies wishing to undertake business in overseas territories. The main contacts for the BFPA are in Glasgow and are Ron Archibold and Janet Tingle. The current BFPA CEO has close relations with both parties. The BFPA is not currently an ATO. There is a need to establish whether or not there is sufficient demand amongst the membership to merit seeking ATO status. To do so would also facilitate a small revenue generating facility through management fees associated with taking members overseas.
Local Government:-
UK Local government is subject to extensive lobbying, which is reasonable given the greater importance of the local public sector in large welfare states. Most of the scholarly attention has understandably been focused on lobbying at the national level. Contrary to common misconceptions, generally local representatives seeking re-election are contacted more frequently by interest groups. Interest groups target their lobbying activities toward politicians who are members of the relevant council committees, and they exert stronger pressure on members of the executive board and active representatives who perceive themselves as influential. Interest groups tend to be more active in the richer local governments. The demands of the residential population also impact weakly on lobbying efforts. Recent Government efforts to decentralize a number of initiatives e.g. The local Enterprise Partnerships (LEP’s) that replaced the Regional Development Agencies (RDA’s), and spread the cost of policy implementation have meant that there are a number of localized initiatives and opportunities that merit BFPA attention and by implication, that of its members. However, only the very largest of trade associations can afford the overhead of focusing on local issues on behalf of an individual or small group of members. They can however, provide guidance to members on how they might undertake their own local initiatives. A topical example of this is the Government Business Growth Accelerator program which is implemented at a local level through approved parties operating under a policy framework dictated by central government. The BFPA therefore needs to remain aware of locally implemented initiatives and advise where possible, members in taking their own action should they wish to allocate the necessary resources.
Can we seriously influence Brussels? The BFPA position:-
It is widely recognized that a large proportion of UK legislation is dictated by EU law. However, determining the exact amount has eluded many pundits. Sometimes a figure of 70% is used — including in February 2014 by Viviane Reding, the Vice-President of the European Commission — but this is actually the percentage of EU laws that the European Parliament (elected representatives of each EU country) and the European Council (representatives of the governments of each EU country) have had an equal say on. The rest are either decided solely by the Council, or with Parliament giving the Council consent to them being passed. In other words, it’s the percentage of EU law that the UK-elected politicians to the European Parliament have as much say on as our national government! Either way, it is safe to say that any trade association meeting its member obligations has a duty to try and engage with Brussels. The challenge arises in that lobbying the EU is a very resource intensive and expensive process. The situation is further complicated in that not only is the structure of Brussels complex but it only allows lobbying via a number of recognised bodies and organisations. Each of these bodies tends to specialise in a given group of sectors. They also carry what is usually an expensive membership subscription. The BFPA, through its membership of EAMA; (see above), is a member of ORGALIME, an EU lobbying organisation with a focus upon the Engineering sector. EAMA members still find staying abreast of the activities of ORGALIME a challenge but for a small Trade Association such as the BFPA it is the only realistic way of having (a) any knowledge of what is coming down the EU regulatory pipeline and (b) having any influence on it. The current BFPA CEO is an EAMA Board member and as part of the 2015 strategy will continue to engage with ORGALIME as much as is realistically possible. However, it will not be a major thrust in the activities of the BFPA in the short term and will act primarily as a source of information on the activities of Brussels and the extent to which they will impact upon the membership. There is also a close connection between the Technical and Standards committees managed by the BFPA and the relevant EU departments in Brussels. These activities also overlap with CETOP – see below under Strategic Partners.
A View of the primary political influences in the BFPA Market by the BFPA CEO – Chris Buxton:-
1) Renewed Government focus upon manufacturing & specifically engineering and other Science Technology, Engineering & Mathematics (STEM) subjects.
Since the ‘fall from grace’ of the finance sector in the 2009 crash the UK Government has recognised that a successful economy depends upon trade and manufacturing. This has given impetus to a tranche of new initiatives aimed at supporting the Engineering and manufacturing sector at all stages in the supply chain. Much of this focus has tended to be biased towards the Aerospace and automotive sectors where Government believes it can realise the best returns for what are limited resources but this nevertheless has a positive impact on all suppliers to these sectors and related areas. In 2014 they published an industrial strategy; (www.gov.uk/government/uploads/system/uploads/attachment_data/file/306854/bis-14-707-industrial-strategy-progress-report.pdf) which developed specific strategies for what have been ten sectors; specifically:-
- Aerospace
- Agricultural Technologies
- Automotive
- Construction
- Information Economy
- International Education
- Life Sciences
- Nuclear
- Offshore Wind
- Oil and Gas These sectors have been underpinned by the identification of five cross-cutting themes:-
- Technology
- Skills
- Access to Finance
- Procurement
- ‘Other issues of cross-sectoral significance ‘
The result is a two dimensional matrix strategy in which each of the primary sectors has been given ministerial sponsorship and a number of specific initiatives to further their cause. Recognising that many sectors (including that of the BFPA) do not naturally fall into the primary industries identified in the government strategy, BIS has agreed to provide support on a case by case basis for other sectors willing to undertake their own initiatives and ‘dove-tail’ their strategies into that of the Government. BFPA in conjunction with EAMA has undertaken one such initiative for the Engineering and machinery supply sector. This initiative is still in the early stages of development and the BFPA CEO sits on the steering group managing it.
2) Access to funding
For some years access to funding for companies in the manufacturing sector has been a major issue – especially in the SME sector where risk of non-repayment of loans is highest. Consequently much work has been undertaken by organisations such as the BFPA in lobbying government to put the finance sector and banks under pressure to reduce or remove what were widely accepted to be disproportionate terms of business. One consequence of this inflexibility has been that many companies have found alternative means of funding their activities and with the return to healthy economic growth many now have strong business pipelines and no longer require the kind of support previously required from their banks. In essence, the tables have turned somewhat and banks are now seeking to repair their reputations as unco-operative and parasitic institutions and become much more business friendly. Whilst we shall never see a return to the old personalised banking of the sixties and seventies many banks, notably Lloyds have made significant progress in this aspiration and with the support of government there are now a number of new sources of finance available from both the banks and a number of government departments. E.g.
- The Advanced Manufacturing Supply Chain Initiative (AMSCI)
- The new Regional Growth Fund initiative (RGF)
- The Growth Accelerator Programme
- The R&D Tax Credit system (hmrc.gov.uk/ct/forms-rates/claims/randd.htm)
- Funding Circle (www.fundingcircle.com )
- The new business bankwww.gov.uk/government/uploads/system/uploads/attachment_data/file/203148/bis-13-734-building-the-business-bank-strategy-march-2013.pdf Business banking insight website
- Lloyds SME engagement strategy (Business Finance Guide now available)
- whilst the Governments ‘Business is Great’ campaign and website now offer a selection of related services at:-www.greatbusiness.gov.uk/
- Another very good source of information relating to access to funding is now available at:www.gov.uk/government/uploads-sme-access-to-finance-measures
3) Prompt / late payments:-Like access to funding, late payment regimes and disproportionate terms of business, particularly amongst tier one suppliers in the manufacturing and engineering supply sector have long been the catalyst for complaints and lobbying initiatives. The Government recently undertook a public consultation on the subject and the CBI is developing a policy document on the subject as part of a new lobbying initiative. BFPA contributed to the consultation exercise and are involved in the associated CBI workshop. The problem is not easily addressed as any robust action puts the customer relationship at risk and SME’s, particularly those at the lower end of the supply chain, are loath to be too stubborn or proactive. Nevertheless, the BFPA continues to work on this topic and Government interest in the subject can only help. Threats to instigate a ‘name and shame’ policy would appear to be having some effect but there is still a long way to go and government are afraid of upsetting the larger companies so close to an impending election. Perhaps one of the more encouraging developments was the publication of the Governments new Small Business, Enterprise and Employment Bill in June 2014, which includes a number of clauses relating to companies having to publish their payment practices whilst smaller companies now have greater rights to invalidate contractual terms that are disproportionately restrictive or quite simply, demonstrably unfair.
4) Skills shortages
With improvements in access to finance, the UK skills shortages in the engineering sector have long since been the primary obstacle to business growth. The statistics are well known:- 80% manufacturers are experiencing recruitment difficulties and two-thirds of those say this is because candidates lack technical skills:
– 146,200 job vacancies (22%) in 2013 were unfilled because of inadequate skills, compared with 91,400 (16%) two years earlier. (UKCES SURVEY)
– 100,000 STEM graduates are needed a year just to maintain the status quo (The Royal Academy of Engineering)
– In the UK some 23,000 engineers are graduating every year. (But India is producing eight times as many, and China 20 times as many.)
– 830,000 graduate-level STEM experts and 450,000 technicians will be needed by 2020 Government is seeking to address this problem with a number of new initiatives:-
– Instigation of the UK Commission for Employment & Skills
– Established University Technical Colleges (UTC’s) www.utcolleges.org – New £30M fund to secure supply of engineers and boost number of women in sector
– New support for apprentices (Trail blazer initiative)
– Raft of new NGO initiatives such as Engineering UK
– The Talent Retention Scheme. (TRS) This list is not exhaustive and the plethora of apparently un-coordinated initiatives in this area, many spawned from well-meaning, semi-private organisations frustrated by government inaction does little to provide clarity.
5) Export
Inward investment into the UK economy created or secured more than 112,000 jobs in 2011 to 2012 according to UKTI’s inward investment report for 2012 to 2013. The government wants to double the UK’s exports to £1 trillion by 2020 and attract more inward investment in UK infrastructure projects. A challenging target in language!
They claim that; “We are determined to remain one of the top countries for ease of doing business, by providing more support for British businesses to export their goods and services, and reducing corporation tax to competitive levels.” A worthy aspiration.
One of the steps that they have taken includes the establishment of a government department called UK Export Finance.
UK Export Finance supports exports through a range of products and services. These include guarantees to banks for loans used to purchase UK exports and insurance against non-payment. Its remit is to complement and not compete with the export insurance and finance available from the private sector.
In 2011 UK Export Finance broadened its business domain and product range to provide support for exports sold on short terms of payment. It offers a Bond Support Scheme and an Export Working Capital Scheme and, to help smaller exporters access the right support, it operates a network of regional Export Finance Advisers.
UK Trade & Investment (UKTI) offers services to businesses who are looking to or already exporting overseas. They also help overseas companies who want set up and invest in the UK.
International trade advisers are able to provide advice on a range of UKTI services to UK companies, including financial subsidies, export documentation, contacts in overseas markets, overseas visits, e-commerce, export training and market research. They are located in over 40 local offices around the country. UKTI also has sector specialists who can provide support to specific industries. Companies can book a face to face meeting with a trade adviser.
UKTI trade teams located in embassies, high commissions and consulates work with companies to identify overseas opportunities or the right contacts and potential partners in a specific country though the Overseas Market Introduction Service (OMIS) although much of the data in the OMIS reports is derived from the sector Trade Associations and they are not inexpensive.
UKTI’s Passport to Export is an assessment and skills-based programme that gives new and inexperienced exporters the training, planning and ongoing support needed to succeed overseas. Passport to Export also helps companies to research and visit selected markets.
The Tradeshow Access Programme (TAP) provides grants to help businesses who want to take part in overseas trade exhibitions and increase their knowledge about markets.
Experienced exporters are able to apply for the UKTI Gateway to Global Growth scheme which offers a 12 month programme of specific support focused on their needs.
UKTI’s Export Communications Review gives companies advice on language and cultural issues to improve their competitiveness in export markets.
UK companies can get free independent advice on how to carry out marketing research through UKTI’s Export Marketing Research Scheme. It can help them decide if they should export to a new market and how best to deliver products and services. It can also provide financial support for a marketing research project in certain circumstances.
UKTI established the UK Advisory Network in 2007 so government and the private sector could work closer together on giving help to investors setting up in the UK. The network gives companies easier access to private sector expertise.
The government is also simplifying and reducing corporation tax to encourage inward investment. The current rate of corporation tax is 21% making it the fourth lowest in the G20. The government is lowering the rate of corporation tax to 20% in 2015 which will be the joint lowest in the G20
Through their UK networks overseas, the Foreign and Commonwealth Office provides information to UK businesses to help guard against risk when operating overseas. They also offer timely political and economic updates which highlight key factors in emerging markets and help businesses identify and pursue new opportunities.
The Foreign and Commonwealth Office is establishing a new government-owned company, the British Inter-governmental Services Authority (BISA), to help the UK benefit from government to government contracts with other countries.
BISA has been specifically set up to manage these contracts and help facilitate and deliver opportunities for British companies across the entire supply chain, from major prime contractors to SMEs. It is not yet trading but in 2014 it is expected to grow into a fully operational company, with its own chief executive and board. More information can be derived from Jolyon Welsh, Head of Government to Government Contracting, FCO, by email at jolyon.welsh@fco.gov.uk
The FCO’s Business Charter, published in 2011, shows how Foreign & Commonwealth Office (FCO) resources can meet the needs of British business. It is part of the FCO’s work to create lasting prosperity for the UK, explaining the specific contribution that the FCO makes to support business across the world.
UKTI has an ongoing programme of research that looks into the effect of exporting on UK companies across the economy.
UKTI’s publication ‘Bringing home the benefits: how to grow through exporting’ found that for many UK companies the decision to grow through exporting has been profitable. Those companies who venture into new export markets tend to be rewarded both directly through boosted turnover, and indirectly through improved levels of efficiency, innovation and credibility. Early analysis of BFPA member companies suggests that the full export potential in our sector is not being fully realised and there would be merit in exploring this issue further.
Cleanliness Monitoring of Hydraulic Systems
Geoff Grant, MP Filtri UK Ltd., UK and Mike Day, CMS Consultants Ltd., UK.
The extent that solid particles (dirt) affect the performance and reliability of hydraulic systems has been recognized by equipment designers, system builders and users alike, and all are implementing measures to lessen the effects. Fundamental to this approach is the setting of a fluid cleanliness specification and monitoring the achievements of the contamination control measures fitted to the process.
Monitoring the concentrations of particles in the various process fluids is now seen as an essential part of contamination control, whether it is during piece-part production through to maintenance activity in service. Automatic Particle Counters (APCs) are an essential measurement tool as they can quickly and accurately measure the number of particles over a wide size range. It is this accuracy and speed that makes them indispensible in monitoring contamination in service as part of a proactive maintenance regime. APCs are able to detect small but significant increases in the numbers of particles allowing corrective action to be promptly implemented when they rise above a specified level before any serious damage is done to that part of the process. Thus, to reduce the amount of wear experienced by the process or system, the minimum of time must lapse between sampling, the detection of an increase and its correction. This is best done using APCs permanently installed to the system as the data is continuously available.
This paper looks at the requirements for monitoring fluid systems in service and examines the options for integrating APCs into a maintenance regime. It demonstrates the benefits of monitoring on-line with an APC fitted to the system, whether it is with a permanently installed APC or a portable unit. It also gives guidance on how to obtain valid data and detect errors.
Introduction
Research studies (1, 2 & 3) have established that the presence of solid particles (dirt) in the hydraulic fluid is the single most important factor influencing the reliability and life of fluid systems. It has been estimated that between 50 and 70% of failures to plant and machinery were due to dirt in the lubricant. Furthermore the UK’s DTI survey quantified the relationship between the level of reliability of systems and the of dirt level in the system as represented by the ISO 4406 Solid Contamination Code [4]. This relationship is seen in Figure 1. Put quite simply, the lower the dirt level, the more reliable the system and the longer its useful service life.
Figure 1 – Relationship between Hydraulic System Dirt Level and Reliability
Significant improvements in fluid cleanliness has been made in the Fluid Power industry since the DTI survey was carried out some 30 years ago [5] as equipment designers, system builders and users realize the potential benefits to be gained as a result of operating with cleaner fluids. Management of cleanliness has been extended to the manufacturing processes as part of an overall approach to lower the incidence of damage to components during initial operation and so reduce the probability of a failure. This way a long component life is assured. Industry has moved from having to live with contamination to maintaining cleanliness!
It has been stated that cleanliness monitoring is probably the most sensitive of all monitoring techniques [6] and, by virtue of its simplicity, it is probably the most cost effective. For this reason, it is being integrated as a front line technique in fluid management into most operational areas from piece part production through assembly and test, and continued in service. Fundamental to this is the provision of a fluid cleanliness specification and a means of measurement that gives accurate and consistent data so that any significant increase in the level of contamination level is promptly detected and corrected. If the reason is promptly identified and the root cause determined then, the amount of surface wear occurring will be minimized. Thus, the measurement method chosen, should give accurate results in the shortest possible time. Having a succession of false alarms would prove to be both costly and disastrous to the concept of monitoring.
This paper looks at the requirements for monitoring the level of cleanliness in fluid systems, briefly discusses the technique that the authors’ consider to be the most suitable and illustrates this with an example. The paper also details the pitfalls to avoid so that the potential benefits of this form of monitoring can be realized.
Philosophy of Cleanliness Monitoring
Most modern hydraulic systems, both fluid power and lubrication, are now being designed to operate at a specified fluid cleanliness level. This is called the “Required Cleanliness Level” (or RCL) and its importance cannot be over emphasized. It forms the base level that the system filters must achieve and maintain throughout their useful life. Of equal importance, it also should form the basis of cleanliness specifications for all manufacturing processes e.g. machine coolants and wash fluids, system assembly and the flushing process preceding delivery. Further information about RCLs can be obtained in the paper by Bensch [7].
To fully understand the effect of particulate contaminant on components, some knowledge of the wear process is desirable. As it is beyond the scope of this paper to go into this, the reader is advised to read the paper by Needelman [8]. Briefly, contaminant particles that come into contact with surfaces will cause damage to the surfaces through wear, resulting in loss in performance and, eventually, component failure. This happens during all manufacturing process to a greater or lesser extent, even during component piece part machining operations. Thus the dirt particles should be removed from the process at the earliest opportunity to eliminate or minimize the effects and consequential damage.
In service, hydraulic systems are generally re-circulatory such that any wear debris generated will be circulated through the components to potentially produce more wear. This is called “regenerative wear”. If not corrected there will be acceleration in the components wear rates, substantial amounts of surface material will be removed and component failure will be likely in a short period of time. Under these circumstances operation can be unpredictable and unsafe. Even if failure is not experienced, the surface of the component will be so abraded that it may not operate to it’s design performance and will certainly not achieve the desired service life.
The role of filtration in this process can be appreciated by looking at how components wear up to eventual catastrophic failure (Figure 2).
Figure 2 – Particle Generation Rate up to Failure
If the filtration level has been correctly selected for the system concerned, i.e., based upon the contaminant sensitivity requirements of the components and the life and reliability expected by the user, then wear rates will be low and under control. Here low numbers of small particles (< 10 µm) will be generated mainly by fatigue i.e. repeated stress of the surfaces. These are termed “fatigue platelets” and are small, almost two-dimensional particles (i.e. very thin) and their shape means that they can generally pass through component clearances without producing other wear particles. Even when they get caught in a clearance, they are generally easily fractured, producing only small amounts of denting to the other surfaces. This wear mode is very mild (“benign”) and this will ensure reliable operation and long component lives.`
If either the wrong grade of filter is selected or the existing filter has weaknesses such that its performance is seriously reduced, there will be a rise in the contamination level through three body regenerative wear. This causes an increase in both the numbers and the size of particles generated. The wear mechanism changes very quickly from mild fatigue wear to abrasive wear causing larger amounts of material to be removed from the component. Unless this change is detected and rectified, then this regenerative wear will progressively produce even larger particles and eventually the component will fail, often catastrophically.
The aim of more traditional forms of monitoring (vibration, noise, chip detection etc) is the detection of imminent failure so that the component can be taken out of service before failing catastrophically. In most cases the component has to be replaced because it is damaged beyond economic repair. In cleanliness monitoring, the philosophy is completely different. System fluid samples are analysed for any significant increase in smaller particles and actions promptly implemented to correct the situation and bring the wear back into the benign mode in the shortest possible time. This way the aims of reliable operation and long component life will be achieved.
Selection of the Most Suitable Monitor
Planning
The subject of monitor selection is very large as it depends upon the requirements of the user and, to a certain extent, on the end customer(s). Thus selection is beyond the scope of this paper and is reported elsewhere [9]. However the user is advised to spend time evaluating exactly what his requirements are before purchasing a monitor as they sometimes involve considerable capital expense. This may appear obvious, but it is the authors’ experience that users often buy a monitor which appears to be suitable initially, only to have problems later. This is tied up in planning and education. The operator must become familiar with the principle of the device, how apply and use it, and how to interpret the data; the unit is as good as the person who interprets the data! Consideration must also be given on how contaminant monitoring can integrate to the existing system management infrastructure.
Requirements for fluid Cleanliness Monitor
Bearing in mind the strategy stated in Section 2, the product requirement for monitoring fluid cleanliness can be summarized as:
• Needs to be able to measure relatively low concentrations of ‘small’ i.e. < 10 µm
• Needs to measure a wide range of particle sizes and concentrations
• Can present data in an industry acceptable form e.g. to Cleanliness Coding systems such as ISO 4406 or AS4059 [10],
• Is approved by the ISO Committee developing particle counting standards for the Hydraulics industry
• Have proven accuracy and repeatability
• Provides results ‘immediately’ or at least in a short time period so that corrective actions can be effected with the minimum delay
• Can analyze a wide range of fluid types e g. hydraulic, lubrication, wash and solvent fluids
• Have an ‘acceptable’ cost
Size range of Interest
This should be self-explanatory and the instrument must be tailored to the users’ and perhaps the end customers’ requirements. The generally accepted size range of interest in fluid systems is 4 to 70 µm(c) and most Cleanliness Classification systems feature these sizes. However, it should be noted that Component Cleanliness sizes go up to >1,000 µm.
Mode of operation
There are two methods of measuring the cleanliness of the process fluid, off-line and on-line and these are seen graphically in Figure 3
Figure 3 – Mode of Sampling Analysis
a) Off-line is where a sample of the fluid is taken from the system and collected in a suitably cleaned container for subsequent analysis either at the work place or, as is more usual, in a laboratory. The process is time consuming and delays are incurred between sampling, the receipt of the data for examination and then possible corrective action. This can range from hours if the analysis is performed in-situ, to weeks if sent to an external laboratory. This will not be a problem if the process is under control, but it could be disastrous if the contamination level is changing rapidly.
Another problem associated with off-line analysis is that contamination is added in the sampling and handling processes. This can generate substantial errors, give variability in data and, perhaps of greater concern, cause unnecessary corrective actions. The cleanliness levels of modern filtered systems are so high (i.e. very clean) that this extraneous dirt can completely masks the dirt levels in the system [11]. This makes interpretation of trended data almost impossible. Thus, current bottle sampling techniques are no longer satisfactory for cleanliness monitoring.
The benefit of this mode of sampling is that there are a much wider range of techniques and instruments available to the user should they need to find out more about the contaminant profile of the sample to find the root cause of any increase in the contamination level as part of a Proactive Maintenance regime. Examples of these are: Microscopic analysis, Spectrographic Analysis, Infra-red analysis, Wear Debris Analysis etc.
b) On-line is where the instrument is connected directly to the system or process, either to a main flow line or the reservoir, and so eliminates the errors associated with taking bottle samples. It also ensures that the time between sampling and acting on the data is mimimised. There are two forms of this: portable and permanently mounted.
The portable units offer the advantage that one unit can monitor a number of systems at a site and could offer a cost effective solution where a large number of systems need to be monitored, say > 5. However, they do have the following disadvantages:
• The unit has to be flushed every time a connection is made to remove the connection debris that is generated otherwise errors will result and the sample is not representative of the fluid in the pipe. This can take as long as 40 minutes [12].
• A significant fluid volume may be ‘lost’ if the outlet hose is not directed back to the reservoir.
• Cross contamination of fluids may occur if the unit is used on a number of systems with different hydraulic fluids.
• The analysis process is not ‘immediate’ because of the need to go to the location, connect, and flush adequately, and then confirm that the data is correct and consistent.
• The result may not be truly representative of the fluid in the system.
The permanently mounted unit is the preferred option it overcomes the disadvantages of the portable unit namely:
• The data is continuously available so any increases in contamination can be noticed instantly and corrective action can then be promptly implemented.
• Flushing the unit prior to measurement is unnecessary.
• This outlet can be connected back to the system so there in no loss of fluid.
• Sampling times can be easily be increased to reduce variability when monitoring either clean fluids (particle count statistics) or variable generation rates, with no waiting penalty.
This method of analysis does demand one instrument for each system. In the past this may have been beyond the resources of most users and a single portable unit was used to monitor numerous systems on a planned inspection routing. However, the advances in technology have resulted in a dramatic reduction in the cost of these devices so that such investment is no longer prohibitive.
Optimum Means for Monitoring Fluid Cleanliness Levels
Reviewing the requirements for a cleanliness monitor stated in Section 2, it is the authors’ opinion that on-line particle counting with Automatic Particle Counters (APCs) is the technique that satisfies these requirements. Without the development of APCs, much of the research into contamination control over the last 35 years would not have been possible. When used within their limitations, they have demonstrated both accuracy and economy of operation. However, like all particle counting techniques, they are subject to certain limitations and, if not used correctly, can give erroneous counts [11].
APC’s work on the light extinction principle where the particles contained in the fluid interact with a beam of light shining across a narrow sensing passage to reduce the intensity of light received by a detector, (Figure 4).
Fig 4 Principles of APCS
This is achieved by either using light scattering or adsorption principles. The reduction in intensity is related to particle size by calibration. The APC can cater for a wide particle size range, from 0.5 to over 2,000 µm depending on the type of instrument and its application, and they can work directly on-line, in the ‘sip’ mode from low pressure sources or off-line from bottle samples extracted from the system. The ability of these instruments to count and size individual particles quickly and with a high degree of accuracy has meant that they have proved to be indispensable in contamination studies. Such fields of application include filter testing, component contaminant sensitivity testing, monitoring the progress of flushing and general condition monitoring.
Example showing the Benefits of On-line Monitoring
This example shows how continuous on-line measurement enables ‘immediate’ detection of an out of control situation and the prompt implementation of corrective actions meant that the amount of extra wear was minimized. The system studied is the hydraulic system of a machine tool that has a single 6µm filter fitted in the pressure line and operates at 120 bar (1,750 psi). The on-line results of a 3-day period have been extracted.
Very low particle counts are experienced initially (ISO 5/3/1) until the system was topped-up with oil during the night shift (A). The oil was poured in and not dispensed through a filter, and proved to be very dirty. This caused the filter to go into partial bypass. Unfortunately, the blockage indicator failed to function and the increased contamination was only spotted the next morning when the on-line monitor was inspected. A new element was fitted and the system cleaned up very rapidly.
Other increases were evident during the study. The next increase (B) was eventually traced to the presence of air in the system, caused by the pressure line filter being located above the reservoir level, such that the oil could partially siphon out of the filter assembly during periods of inactivity. On start-up, at low pressure, a slug of air was circulated around the system until it was removed by a combination of floatation to the surface and being forced into solution when the system was operated at pressure. This was overcome by fitting a spring-loaded check valve to the downstream side of the filter to prevent siphoning and was performed at the weekend shut down. The next peak (C) was noticed immediately after start up and reflected the dirt that ingressed into the system following the breaking-in of the system to fit the check valve. The APC showed that the filter quickly removed this maintenance debris.
Two aspects are highlighted here. The first is the need to check the cleanliness of the system more regularly as it cannot be assumed that if samples are acceptable from one period to another, the period in between is consistent. It is likely that if either off or on-line analysis using a portable unit had been used the short term increases may be missed altogether and the more long term events (like the above problem of the filter bypass) only picked up after a significant period. If the high contamination level is allowed to remain unchecked, the amount wear and subsequent damage will accelerate. The second is that continuous measurement leads to a better understanding about the dirt generation profile of the system so that improvements in the design or operation can be made when convenient to do so. This is an essential part of a Proactive Maintenance regime.
Factors Affecting the Validity of Cleanliness Data
It was stated earlier that to avoid ‘false alarms’, the data from the unit must be representative of that of the fluid in the system and there are a number of factors that influence the validity of cleanliness data. These are detailed elsewhere [11] but are briefly re-examined in relation to permanently installed APCs:-
Sample Bottle Cleanliness: Not applicable.
Sampling Technique: Not applicable as permanently installed units have a continuous flow, but portable units will require flushing after connection.
Location of sampling point: Not applicable as permanently installed units have a fixed location. Cleanliness levels vary around all systems, so the same location should be used for general monitoring.
Flushing of sampling point: Not applicable to permanently installed units.
Calibration method: Not applicable as a common method is used – ISO 11171 [13].
Coincident particles: Where two or more particles are counted as one and may increase the counts of the smaller sizes. This is a function of dirt concentration and should not be frequent with modern cleaner systems. See also finely divided contaminant.
Saturation of APCs: Caused by high particle counts and is not a problem nowadays as the saturation level of APCs is substantially higher than say 15 years ago and systems are much cleaner.
Duty cycle: Like location, the cleanliness will vary as the system operates. To average out these variations, a large volume should be analysed e.g. 1 litre for ISO 10/8/6.
Other fluids (air, water in oil, oil in water, tramp oils etc): APCs require clear, homogeneous liquids and some fluid contaminants will give erroneous results. The nature of the data with these fluid contaminants is such that these should be easily identified as errors. For instance, water contamination can give a profile of ISO 22/21/21 in an otherwise clean system. Identification of these forms of contaminant is down to the experience of the operator. Note that such contaminants are usually a result of poor housekeeping and a lack of education.
Finely divided contaminant: contaminants that are very small, < 4µm(c) and present in large numbers like products of oil oxidation, spent additives and fatigue particle from some gearbox application, will give unrepresentatively high particle counts through the mechanism of coincidence. These can be identified by large differences in the 1st & 2nd cleanliness scale or code numbers e.g., ISO 18/11/08. Generally the 2nd & 3rd code or scale numbers are not significantly affected. Some non-soluble additive materials e.g. Silicone Anti-foam Additive have a similar effect.
Analysis procedures used: On-line counting provides a consistent analysis process and is not affected by such errors.
Extent of knowledge in the technique: As with any technique, the interpretation of the data is critical to the success of the monitoring function as correct interpretation will lead to correct decision making and vice versa. Therefore it is essential that the operator is correctly trained in both the use of the APC and the interpretation of the data.
Conclusions
The following conclusions are drawn:
• The life and reliability of hydraulic systems is greatly affected by the presence of particulate contamination in the lubricant. The cleaner the fluid, the more reliable the system or process and the life of the components will be greatly increased.
• Cleanliness monitoring of hydraulic fluids is probably the simplest and most cost effective monitoring technique and should be front a line technique in any maintenance regime.
• To achieve optimum system performance, a fluid cleanliness specification should be developed based upon the components’ contaminant sensitivity requirements and the life and reliability required by the specific user.
The system should be monitored regularly, the data compared to the specification and corrective actions promptly implemented if the specification is exceeded. This will ensure trouble free operation, leading to improvements in productivity, product quality, profitability and customer satisfaction.
• Of the techniques available, it is continuous on-line automatic particle counting using a permanently installed APC that can best achieve these requirements and is an essential tool in any Proactive maintenance regime. This method of monitoring has less pit falls than similar instruments used in other ways. It also assists in understanding the dirt generation profile of the system so that improvements in the design or operation can be made when convenient to do so.
• The success of the application of APCs is greatly dependent of the knowledge and experience of the operator and training should include both use of the instrument and interpretation of the data.
References
1. E. Rabinowicz Lecture presented to the American Society of Lubricating Engineers, Bearing Workshop, USA, 1981.
2. UK DTI “Contamination Control in Fluid Power Systems, Vol. 1 Field Studies”, Dept Trade and Industry, N.E.L, East Kilbride, Glasgow, UK, February 1984.
3. J. Potteiger, “Understanding Lubrication Failures”, Uptime Magazine, August/September, 2011, pp 30-31, Florida, USA, 2011.
4. ISO 4406 “Hydraulic Fluid Power – Fluids – Method for Coding Level of Contamination by Solid Particles”, International Standards Organization, Geneva, Switzerland, 1999
5 M. J. Day, & “Developments in Cleanliness Control in Fluid Systems”, Presented at
G. Fincher Workshop on Total Contamination Control”, Monash University, Australia, August 1999.
6 T. Hunt “Handbook of wear debris analysis and particle detection in liquids” published by Chapman & Hall, London 1993, ISBN 1-85166-962-0.
7 L. E. Bensch “Setting target cleanliness levels for hydraulic systems and then monitoring”, Presented at Workshop on Contamination/Filtration- Issues and Perspective”, National Fluid Power Association, Chicago, Illinois, USA, January 1998.
8 W. Needelman “Filtration for wear control”, Wear Control Handbook, American Society of Mechanical Engineers, Book No G001691, 1980.
9 M. J. Day “Hydraulic System Particulate Contaminant Monitoring”, Presented at “ Subsea Hydraulic Symposium”, FMC Kongsberg Subsea AS, Kongsberg, Norway, 13 & 14 October 2003.
10 AS 4059 “Aerospace Fluid Power – Cleanliness Classification for Hydraulic Fluids”, SAE Aerospace, Warrendale, PA, USA.
11 M. J. Day & “Contaminant monitoring of hydraulic systems – the need for reliable data”, J. Rinkinen Presented at COMADEN 97, Tampere University of Technology, Tampere, Finland, 1997.
12 J Rinkinen “Condition Monitoring And In-Line Maintenance Of Oil And On-Line Diagnostics Of Components In Fluid Power And Circulating Lubrication Systems”, Tampere University of Technology publication vol. 661, Tampere, Finland, 2007.
13 ISO 11171 “Hydraulic fluid power — Calibration of automatic particle counters for liquids”, International Standards Org., Geneva, Switzerland, 2011.
BFPA Consultant members are all skilled practitioners in their various fields of expertise. All BFPA Consultants are completely independent of any commercial enterprise and as such will give unbiased opinions and advice.
Please mention the British Fluid Power Association when contacting consultants.
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