1. business and industrial
2. chemicals industry
3. adhesives

Official Loctite® Customer Magazine
How to secure a 15 m
tall rock devouring giant – heavier
than a dozen jumbo jets
Read more on page 18 – 21
no. 1/09
10
at work | no. 1/09
The next generation of gasketing.
Providing more flexible solutions.
Read more on this topic on page 10
Editorial
|
3
Dear Readers,
have you ever wondered how to drill a hole into a mountain? If so, the story of Martin Herrenknecht and his
rock-eating submarines might interest you. Maybe you were the kind of child who took grandpa’s mechanical
alarm clock apart to see how it works? In this case, Rudolf Neumayer and his Tear Down Centre could be just
what you were looking for.
What we would like to do in the first issue of “Loctite® at work”, our new customer magazine, is to take you on a
journey
behind the scenes of some of the world’s most successful and sophisticated high-tech companies. This is why
we gave this issue the title “Reliability at work”. We want you to share our fascination when we look over the
shoulders of engineers constructing the world’s largest tunnel boring machines destined to drill the way through
the Alps or building propellers that move tankers and cargo ships through the ocean.
We believe that curiosity and an interest in how things work are the basis for creativity and innovation, two values
that Henkel and the brand Loctite® stand for. That’s why in the first issue of “Loctite® at work” we are putting the
spotlight on two out of the many companies that embody those values, to show how they can impact on the
practice and the success of a business.
In our Trend Report, we will track the evolution of energy over the last 150 years and give an outlook on how the
future of this most important resource of all might look like. And of course, with Henkel and Loctite® you'll ride
shotgun in the Dakar Rally with the Loctite® brand.
So, lean back and enjoy the ride.
Cédric Berthod
Vice President
Loctite Industrial Group
Henkel Adhesive
Technologies EMEA
Yours sincerely,
Cédric Berthod
4
Content
4
6
11
12
6
Highlight: Dakar 2009
Come along to the bivouac and learn more
about the heroes of the Dakar.
Reliability Report 1: Berg Propulsion
Marine propulsion systems. High tech and
maximum precision, hand made. Breathtaking
technology from Sweden.
RD&E insights
Adhesives aren't invented. They are carefully
developed. Read more to find out how.
Advanced Technologies
The Tear-down process provides insights and
creates new options.
14
14
18
22
23
18
Side Glance
Energy – the breath of civilisation.
Reliability Report 2: Herrenknecht
Tunnel boring technology from Germany.
How does Loctite® provide design support?
Handy Hints
Insights online – the new web-platform from
technicians for technicians.
Outlook
Some of the topics for the next issue of Loctite®
at work.
at work | no. 1/09
4
| Highlight
Live from the 2009 Dakar Rally
Meeting the Loctite®
“Desert Knights” in the
Copiapo bivouac
A cloud of dust on the horizon. A VW Touareg
approaching at breathtaking speed. The towering
mountains and dunes of the Atacama desert rising up
all around Copiapo, in the northern part of Chile. The
Copiapo – Copiapo special is a pretty tough challenge:
476 kilometers of the steepest dunes, deep sand and stony
tracks. According to the drivers it‘s the toughest one in the
history of the Dakar.
The Touareg whizzes by only a metre away at top speed,
the air filled with the powerful roar of the new turbo-diesel
engine, a sound that makes every off-road fan‘s heart beat
faster. Next the field of competitors arrives hot on the heels,
in rapid succession: the great Mitsubishi, Hummer and
BMW X-Raid desert racers. And then, following a short
distance behind, the monster trucks rumbling by, making
the ground shake. Thick clouds of dust have engulfed the
terrain. The Atacama desert is said to be the driest in the
world, with places where it hasn‘t rained for 400 years.
Conditions for the drivers are tough: Rough terrain, difficult
navigation, extreme temperature differences and, most of
all, the dry and dusty conditions, push all competitors to
the limit. Vehicles are continually subjected to hard shocks
and flying stones, the steep dunes demand the highest
level of performance from the engines.
That day the stage finishes at the Copiapo bivouac, the
northern most point of the rally. The “Desert Knights” –
Henkel engineers, better known as the “Loctite® Charlies”,
at work | no. 1/09
are also ready for action: Jean Gaborit from France,
Célio Renato Ruiz and Demetrio Santos from Brazil. The
Dakar Service Center, set up as a common platform for
Euromaster, BF Goodrich and Loctite®/Pattex, is easily
visible from a long distance. Loctite® banners are snapping
in the wind – and the red Renault truck is parked in its
slot. It is fully loaded with products for repairing all kinds of
vehicle damages: Teroson plastic repair and window glazing
adhesives, Pattex Power Tapes, and the indispensable
threadlockers, sealants, retaining compounds and instant
adhesives from Loctite®, used for maintenance and overhaul
of the mechanical assemblies on engine and gearbox.
Just now, as dusk is falling, the Henkel Team is busy,
working at full steam: many of the drivers coming “home”
– mainly the private competitors not accompanied by a
service armada of their own – urgently needing support
to get their vehicles going again for the next day. “There
were several difficult situations during this rally where
my machine was quickly back in shape thanks to the
Loctite® Team‘s professional repair service. This
helped me save valuable time when every ­minute
counts”, says Miran Stanovnik, a Slovenian KTM
rider in the top 20, sponsored by Loctite®
since 2005.
Right now there are three bikers
dragging their fairings to the
Loctite® service tent, where
Célio Renato Ruiz and
Highlight
Demetrio Santos are busy doing a plastic repair on a BMW
body part. Their daily work and many exciting insights into
the heart of the rally are documented on the Loctite® live blog
www.dakaradventure.com
t­hreaded assemblies such as motor mounting bolts remain
safely and reliably locked – all the way to the finish line”,
is Jean Gaborit‘s expert advice. This is truly “Reliability at
work”, or, using rally parlance: “Dakar proven!”
Chief Charlie Jean is nowhere in sight. I finally discover him
with the Hummer team! Robby Gordon‘s box-shaped race
vehicle is almost completely disassembled, sitting on the
repair stand like a skeleton. Jean is explaining to the chief
mechanic how to use Loctite® 243, a medium strength
threadlocker that is capable of withstanding severe
vibration but allows parts to be dismantled whenever
required. “You need only a few drops to make sure that
VW – The new Dakar
winner
Innovative solutions for racing
champions
Hummer H3 in action
Loctite® repair area in the
bivouac
The Dakar winners
The rally finished successfully on 18th January, with a great
winners‘ ceremony in the heart of Buenos Aires.
A double victory in the car category makes VW the new
hero of the Dakar: Both Giniel de Villiers and Mark Miller
maintained their lead after Carlos Sainz‘ withdrawal from
the race, and they were more than enthusiastic: “For sure:
this is the toughest rally in the world - and we had the
best marathon team in the world! I am overwhelmed by
the surge of feelings at the finish line”, as de Villiers put it in
moving words, “I am proud to be part of it, proud of what
the team has achieved” . And his team colleague, second
placed Mark Miller, adds: “De Villiers is a great champion.
He deserved to win! For me as an American it‘s a dream
to finish the rally in second place, and finish as the
best American. Our team did a fantastic job.
We will gather new strength from this
victory!”
Third position was claimed
by Robby Gordon driving
a Hummer, the eye
catching race car
from USA with
rear mounted,
7.0 liter V8 engine. He lost ground to VW as a result of
several roll-over crashes during the rally. In the interview
he stated: “Our only goal was to make it safely across the
finish line. And we did. The rally was an incredibly tough
challenge. We will now work on improving the chassis to
get an even better result next year”.
Marc Coma secured victory in the motorcycle class. Second
and third positions went to Frenchmen Cyril Despres
and David Fetigne. Chilean motorcycle rider Francisco
Lopez finished fifth and was celebrated as a national hero
by his compatriots and ardent local fans.
Loctite® KTM bikers Miran Stanovnik, Annie Seel and
Norman Kronseder successfully mastered the tough
challenge and reached positions 13, 76 and 82.
Loctite® triumphed in the truck category! Another double
victory was achieved in the truck competition with Russia‘s
Team Kamaz , supported by Loctite® since 2007. The two
front runners fought a spectacular fight, finally decided by
Vladimir Chagin‘s tire damage. Firdaus Kabirov finished just
30 seconds ahead to win overall victory.
Henkel – Official
Partner to the
Dakar Rally
First time
participation: 2005
Team: "Loctite
Charlies": Service team
with 3 – 6 international
engineers
Brands: Loctite®,
Teroson, Pattex
Products: Adhesives,
Sealants, Surface
Treatment
Major applications:
Threadlocking,
Gasketing, Sealing,
Retaining, Plastic
Repair, Windscreen
Replacement, Glass
Repair, Instant Bonding
at work | no. 1/09
|
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6
| Reliability
Reader recruiting
Report 1Reader
High-tech from
Sweden
The rays of the morning sun reflect on the calm surface of the sea, before they
reach the white lighthouse that has been operating for more than a hundred years.
The small sailing boats are quietly bobbing up and down in their moorings, wooden
houses with the characteristic low roofs line the waterfront and the cries of the
seagulls are the only sounds that the wind carries.
Production in Öckero
at work | no. 1/09
Berg Propulsion headquarters
Propeller blades ready for assembly
High precision meets high-tech
ReaderReliability
recruitingReport
Reader
1
What sounds like the beginning of a bad novel or a holiday
brochure for travellers with a taste for maritime nostalgia,
actually describes the location of a modern production plant:
The island Öckerö, off Sweden‘s West coast, is home to the
ship propeller manufacturer Berg Propulsion, one of Sweden‘s
leading high tech companies.
Ensuring reliability with Loctite®
at work | no. 1/09
|
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8
| Reliability Report 1
Cleaning the hydraulic pipes with
Loctite® 7063
Locking & sealing the threads with a
single product – Loctite® 638
Assembly of the pipes – securing it
with Loctite® 243
The hydraulic system is embedded
into the shaft
Loctite® 243 – securing the
propeller´s steering mechanism
End cap fixing on hub shaft with
Loctite® 243
A dowel pin controls the propeller
blades. Secured by Loctite® 243
After only one hour the system has
to withstand 70 bar of oil pressure
Reliability
at work
Customer:
Berg Propulsion,
Sweden
Task:
Securing hydraulic
­systems to assure
reliability for 25 years
and more
Products:
Loctite® 243
Loctite® 638
No room for error
From modest beginnings, the company was founded as
a shipyard for fishing vessels in 1912, Berg Propulsion
has developed into a multinational company constructing
propellers for all kinds of vessels. Tankers, containers,
cargo ships and luxury yachts, to name just a few, all rely on
the experience and the craftsmanship of Berg Propulsion.
The demands placed on the reliability and durability of
Berg‘s CP (Controllable Pitch) propellers are enormous:
Once the propeller is fitted to the vessel, alterations
become extremely difficult and the propellers are in use
for 25 years or more. There is no room for error, because
the safety of the ship and the vessel depend on the quality
of the product. Money is another aspect; every day that a
ship has to remain in the dock for repairs costs the owner
between 15 and 20 000 $ a day, explains Berg‘s Managing
Director Anders Christoffersson. (see interview)
Family businesses gone global
Technological progress has made its
mark on every aspect of life, and the
manufacturing process at the plant on the
idyllic island of Öckerö is no exception
to this rule. A lot has changed since
Johann Wiktor Berg manufactured
the first CP Propeller for a
wooden fishing vessel in 1929;
one of those changes is the use
of Henkel‘s Loctite® products.
Berg Propulsion and Henkel, the
All the blades are
assembled and the
propeller is ready
for use
at work | no. 1/09
global leader in adhesive technology, have a lot in common:
Both started as family businesses with an emphasis
on high-quality products and both have developed into
successful companies operating on a global scale.
Henkel had the opportunity to observe the production
process at Berg‘s island plant. The gigantic propeller,
with a diameter of more than 9 metre, dwarfs the men
standing next to it. The shining bronze propeller blades
appear almost menacing in their shining perfection. At every
stage of the manufacturing process Loctite® products have
an important role to play: The threads of hydraulic pipes
responsible for controlling
the individual
blades
Reliability Report 1
are retained with Loctite® 638. They have to withstand
pressures of more than 70 bar, which equals twice the
force the blades will have to bear on the ocean.
Developing tailor-made solutions
The adhesive sealing has to be hermetical after
an hour, because then the hydraulic pipes are
embedded into the shaft. Another example for applied
technological progress is the production of the
spacer that protects the propeller‘s control units. The
spacer is fitted to the units with 4 screws, locked with
Loctite® 243. “Loctite® increases the reliability of our
products. We co-operate closely with Loctite‘s technical
department during the development and the production
process” says Christofferson.
Anders Christofferson, Managing Director Berg Propulsion Technology AB
What is your position at Berg Propulsion? I am Vice President of our
technical division Berg Propulsion Technology. And we are developing Berg’s
products of tomorrow.
Lars Andreasson, from Loctite‘s Industrial Engineering
department explains: “We can assist the customer by
calculating the pressures the product has to withstand, for
example. It‘s a form of team-work. Our goal is to assist the
customer by developing tailor made solutions.”
You use Loctite® threadlockers and thread sealants to secure assemblies in
the hydraulic system and in the propeller hub. Can you tell more about the
specific requirements applying for these areas? The requirements which our
systems must meet are that they have to be sealed, and this applies especially
for our hydraulic systems, they have to be pressure resistant. Then in our threaded
assemblies we have to lock the bolts and screws against vibration loads.
The manufacturing process of ship propellers has come
a long way. What is interesting to note about it, is the fact
that there is something like a conspiracy theory about
the origin of the technology. There is a possibility that the
Englishman Francis Smith, who took credit for the invention
was actually preceded by the Austrian enthusiast Josef
Ressel. Unfortunately, however, that issue wasn‘t resolved
in Ressel‘s lifetime and he never received the credit that in
retrospect appears to be due to him. While technological
progress is unstoppable, like the co-operation of Berg
Propulsion and Henkel on idyllic Öckerö shows, issues with
intellectual ownership seem to be here to stay.
In which way can Loctite® be of help in those situations? Loctite® increases
reliability of our products.
Why do you use Loctite® products in this application? This gives us a quick and
easy assembly.
Which products do you mainly use? We use threadlockers 243 and 2701, for
retaining it is 638 and 603.
Which benefits do you get, besides the technical reliability? We can reduce
inventories for mechanical locking devices and we have fewer item numbers, which
gives us big savings in warehousing
Why is reliability so important for Berg Propulsion? Reliability is important as Berg
has safe and dependable products. Our customers expect ship propulsion systems
with highest availability at all times. If there is some failure in the propulsion system,
the boat can no longer earn money. And in this case, we talk about high amounts of
money. This varies from 15 – 20 thousands US Dollar per day. This is not unusual.
Do you make use of Loctite‘s technical service today? Yes, we use Loctite®
technical support daily in form of calculations and application solutions. Then, we also
get ongoing product training for our technicians and engineers.
Do you know more about the brand Loctite®, e.g. the history or the other
product ranges? Yes, concerning the history I know that it is a company from the
50-ies, and we’ve started to use Loctite® in 1964. It was a colleague, Erik Berg, son
of the founder of Berg Propulsion. He was in England and came home with a Loctite®
product as replacement for the locking washer. And it worked. Since then we have
used Loctite® products and other products; those we know among others are your
lubricants and flexible adhesives and instant adhesives.
What do you think are the most important characteristics and benefits of
Loctite® products today? Loctite® products have a lot of benefits. But the most
important one for us is reliability and the technical support which Loctite® gives us.
at work | no. 1/09
|
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10
| RD&E insights
The stories behind inventions tend to have
something romantic, something co-incidental about
them: Archimedes allegedly had his big idea in the bath
tub and Einstein is said to have been sunbathing in the
park when the special theory of relativity occurred to him.
If you listen to Martin Smyth and Peter Wrobel from the Henkel
Technology Centre in Dublin, however, there seems to be little room
for the picturesque co-incidents that make for a good urban myth about
inventions.
No room for myths
It rather seems to be an efficient, well-organised process that leaves very little to chance.
“We have something called Single Customer Project, which allows us to react very quickly
to customer needs,” says Smyth. In this particular case, a customer needed an adhesive
that cured on nickel-plated substrate with an extreme speed. The initial screening phase
took about a month. After another month, during which three employees of the centre in
Dublin devoted themselves full time to the project, the first prototype was ready. “It met 90%
of their requirements, but it needed some fine-tuning,” says Smyth. By that point, market
research had already shown there was a broader market for Loctite® 276, the new addition
to the Loctite® product family.
Co-adapting to industrial evolution
Peter Wrobel’s story is an example for a more long term project. It was a 2 year
process that led to the development of Loctite® 5188, a flange sealant aimed primarily at the
automotive industry. “We are basically co-adapting to the evolution of car engines,” says
Wrobel. “There is a shift from steel to aluminum in the industry, and accordingly, we
constantly improve Loctite® sealants in order to work well with that material.” Before Mr. Wrobel
and his team embark on such a project, though, there needs to be a solid business case. “If a
successful commercial application seems less than probable, we don’t go into the lab,
because that’s very cost-intensive,” explains the team-leader. Wrobel is a trained chemist, but
he has acquired a good feeling for the business side of things through customer visits. While
there is still a place for the coincidence and the power of the subconscious, after all success
and failure is still down to people, individuals with their strengths and weaknesses, innovation
depends today on to a large extent on exact planning and efficient use of resources.
RD&E insights
The evolution of new adhesives
Peter Wrobel, Senior Development Scientist,
Automotive Product Development Dept.
Henkel Technology Centre Europe
at work | no. 1/09
RD&E insights
High-speed threadlocker
Achieving fast fixture on passive metal substrates – such as nickel- & other plated
surfaces ­– is quite a challenge for an anaerobic threadlocker, especially if requirements
also call for good sealing performance and high strength, as well as very good thermal and
shock resistance.
Finding the optimal solution: Loctite® 276, one of the latest innovations to come out of the Henkel
R&D labs, meets all of these requirements. Originally developed in as little as two months within the scope
of Henkel's so-called Single Customer Project in reaction to an urgent customer need, the product was finetuned to give an optimal combination of characteristics for the market environment. And, there could be no compromise
where performance was concerned, because a high production output is one of the key criteria.
Reliability
at work
Benefits – Overview:
• Provides locking and
sealing
• Ideal for gas pipes,
valves & connectors
• Allows higher
production output
Mission accomplished: Loctite® 276 is a high-strength anaerobic threadlocker that achieves fast fixture even on
passive metal substrates. It provides locking and sealing of threaded assemblies. It cures reliably even at low
temperatures but can withstand up to +150 °C. ­Loctite® 276 carries the European gas approval according to EN 751-1.
Available in 50 ml and 250 ml bottles.
Flexibility – a challenge in gasketing
Loctite® 5188, the first anaerobic gasketing material
offering excellent flexibility even after heat aging, can be
used for many applications in the automotive and industrial
area. Typical applications include metal-to-metal flange
assemblies such as gearboxes, housings, covers, etc.
Anaerobic gasketing technology has revolutionized flange
sealing of rigid flanges in the automotive industry, and the
assembly of heavy equipment. Anaerobic sealants remain
liquid when exposed to air, but cure when the metal parts
are assembled and the adhesive is confined between
mating flanges. OEMs and subsuppliers have long been
enjoying the technical and economic benefits of anaerobic
gasketing materials, and Loctite® 5188 takes this
technology to a new level.
The use of aluminium to produce light-weight
automotive castings has gained wide acceptance, and
Loctite® 5188 meets the flexibility requirements
of these modern concepts. The product is
designed to function in the most demanding
applications. It has very
good adhesion
to metal
surfaces, especially to aluminium, and provides immediate
low pressure sealing. Resistance of the cured product
to thermal and chemical stress is excellent. It provides
elongation to compensate for micro-movements resulting
from vibration, pressure and temperature changes. Because
Loctite® 5188 allows flanges to come together with
metal-to-metal contact, tolerances can be more
accurately maintained, and the correct clamp load
is ensured throughout the life of the assembly.
Loctite® 5188 has improved oil tolerance, allowing
it to seal through slight oil contarmination. To suit
all needs, the product is available in three sizes:
2 l bag-in-box, 300 ml cartridge, and 50 ml accordion.
Reliability
at work
Benefits – Overview:
• Suitable for lightweight design
­flanges
• Can tolerate
­micromovements
on highly stressed
flanges
• Ideal for e
­ ngine
compartment
­applications
at work | no. 1/09
|
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12
| Advanced technologies
Tear Down analysis
improving industrial processes
Have you ever felt the urge to take a washing machine
apart to see how it works? Or an oven? A fridge, maybe?
If your answer to any of the above questions is yes, you
will probably envy Rudolf Neumayer: Because that’s what
he does for a living. The friendly Bavarian lightens up when
he starts talking about taking things apart.
Rudolf Neumayer
Manager of European
Technical Service and
Engineering, Henkel, Munich
“Taking things apart” is not his official job description, of
course. Rudolf Neumayer is Manager of European Technical
Service and Engineering for Henkel in Munich. He works
out of Henkel’s Innovation Centre in Munich and is part of
an interdisciplinary team of specialists that is responsible
for what Henkel calls the “Teardown Analysis”, also known
as taking things apart.
Tearing it down
What is the rationale behind such an analysis, apart from
the sheer joy it seems to bring to the people involved in the
activity? A Tear Down analysis is a form of Value Engineering,
i.e. the attempt to look at each
component of a
finished
at work | no. 1/09
product, to see whether the value of the product can be
enhanced or the cost of manufacturing can be cut.
“Value Engineering or Value Analysis was conceived in the
early 1940s by Lawrence D. Miles while he was employed
by General Electric, a major defense contractor which
was facing the scarcity of strategic materials needed to
produce their products during World War II, according to a
paper published by the International Value Society in 2007.
From those humble beginnings, Value Engineering has
come a long way. One of the paths the development of
the method has taken is the Tear Down Analysis practiced
by Neumayer and his team. “In the last 3 years, we have
worked on over 60 projects with a broad range of major
international companies,” explains Neumayer. Since the
customers enter a very confidential relationship with Henkel,
giving access to manufacturing sites and construction
plans, it is understandable than Neumayer guards their
identities very carefully and refuses to even hint
at them during the interview.
Advanced technologies
|
Teamplay and interplay of our various technical specialists at the ETS in Munich brings all relevant facts and figures on the table.
Value
engineering
Tear Down
analysis
Enhanced
product
value
Dreaming of windmills
What he does talk about is in what way
he and his team have achieved some quite
stunning results on some of the projects: Adhesives,
aka glue, are something else that Rudolf from Bavaria
seems to feel passionate about. “It is a problem that in
many vocational trainings, people aren’t taught enough
about the possibilities that modern adhesives open up,”
he says in English. Surprisingly, his English sounds a lot
more polished and difficult to place than his German. The
fact that he is responsible for the whole European area
and speaks English most of the time seems to have taken
its toll.
Lower
production
costs
And what kind of machine would he like to tear down
next? “A windmill would be nice,” he says, with a dreamy
look in his eyes…
“To give you an example: For a major customer (we only
deal with customers that do mass-production, otherwise
our process wouldn’t make any sense) we managed to
replace a step in the production process of his washing
machine by using Loctite. That way, the production has
become cheaper and the customer was able to fit a
larger drum inside the washing machine. So, it’s good for
everybody: Good for us because we have new customer
for Loctite, good for the manufacturer because they raise
their margin, and good for the consumer because they get
a larger drum,” he explains enthusiastically and it is hard
to disagree with him.
And it doesn’t stop here, at least not for Rudolf:
“We have only just started, we have just scratched the
surface of what’s possible,” he says and his eyes gleam.
at work | no. 1/09
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14
| Side Glance
Energy – the breath
of civilisation
With every breath we take, according to Traditional Chinese Medicine, we receive
our share of Chi, the universal energy keeping us alive. Normally we are not aware of
breathing. Normally we are also not aware of the energy, equivalent to 120,000 TWh,
produced and used each year around the world to keep our society alive, except
when our cities stay dark, oil becomes too expensive or there is no gas for heating.
at work | no. 1/09
Side Glance
Watt – the man who brought the dawn of endless
opportunity
In 1776 James Watt installed the first industrial standard
steam engine. This was the dawn of our modern,
technology-driven society that soon became inseparably
linked to and dependent upon a continuous and growing
supply of energy. From these very first days, energy
production and transport became a global network, as
unobtrusive as it was reliable, always available and ready
to work. The impact energy has on daily life, the way
energy characterises society becomes apparent when
malfunctions occur; only when cities remain dark, or when
oil, gasoline or natural gas run short or become unavailable
do we fully understand our lifestyle’s dependence on
energy. Without an energy supply there is no mobility, no
media, no information technology, no commodities nor a
food supply; medical care and hygiene is reduced instantly,
and in the worst-case-scenario there is iciness.
others
USA
21
18
Africa
India
3
4
Middle East
5
Latin America
Japan
Share of world energy
­consumption 2007,
17
5
China
­percentages.
Source: BP
5
6
16
Russia
EU
Sources and uses of energy
For more than a hundred years, the world’s energy
consumption has increased rapidly. Today the demand
for energy is nearly twenty times greater than in 1900
and twice as big as in 1970. Of the energy consumed
globally, 58 % is produced by oil and coal, 24 % by natural
gas, and 18 % by biomass, renewable energy and atomic
power plants. In the distant past, coal was a less-thanideal solution for those who could not afford wood and
had to use these putrid, smoking stones for cooking and
heating. But the growing demand for metal, and James
Watts’ steam-engine paved the way to a coal-driven era.
Soon large cities like London, Boston, New York and Berlin
were illuminated by coal-produced town gas. From 1800 to
1850, coal consumption grew from 10 million tons (mt) to
76 mt. In 1900, 760 mt of coal were used in a single year.
In those days, coal covered 90 % of global fuel needs.
(Mtoe)
nuclear power
10,000
hydropower
9,000
8,000
7,000
firewood
coal
gas
6,000
Timeline of energy demand
5,000
by sources.
4,000
Source: Exxon
3,000
oil
2,000
1,000
1860
1880 1900
1920 1940
1960
1980
2000
(Year)
at work | no. 1/09
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16
| Side Glance
A 1.7 kilometre cube in
New York, equivalent to
the world oil consumption
each year.
Source: SDI-Research
The rise of industrial nations would not have been
possible without the combined power of coal and the
steam engine. Even today, coal production is still rising.
Due to the increasing demand for energy, especially in
China, coal production was at an all time high of 5.4 bn
tons in 2007 – equivalent to a 1.4 kilometre cubic block
of coal, and an increase of more than 30% within only
five years.
The rise in demand for crude oil started with an ingenious
marketing campaign. To sell more petroleum, J.D.
Rockefeller gave away free oil lamps. So people bought
his oil instead of expensive and rare whale oil. Some years
later, refined oil played a key role in developing the newly
invented motorcar, and oil became the basis of mobility.
From then onwards, a global distribution network was
introduced that included drilling rigs, pipelines, crude oil
vessels, refineries and gas stations. Since 1960, crude
oil has been the most important fossil fuel, covering one
third of world energy consumption. A 60% share of oil
production is used for traffic and transport. In 2008 the
average daily production and use of crude oil was 85 million
barrels (one barrel =159 litres) a day or 31 bn barrels a year,
which is 4933 bn litres or 4.9 cubic kilometres – this would
make a cube with sides 1,68 kilometres long.
Natural gas has been available since the beginning of oil
production, was mainly considered as an unimportant
and dangerous by-product. In the 1980s, natural gas
became established as a basic energy resource for
industrial production, the production of electricity, and for
households. This economic breakthrough was founded
at work | no. 1/09
on the convenience, warmth and cosiness that natural
gas offered as a replacement for coal-produced town
gas. Today, natural gas is still a major fuel for generating
electricity and for residential domestic use. The total
worldwide amount of natural gas extracted in 2007 was
2940 bn m3 – this time enough to make a cube with 14
kilometre-long sides.
However, progress was followed by adverse effects. In
total, burning oil, coal and gas produces 26.100 bn tons
(13.300 bn cubic kilometres) of carbon dioxide a year –
imagine a cube with sides 23.7 kilometres long. This is the
problem of growing energy consumption – nature cannot
recycle all the man-made CO2 and so the atmosphere
is becoming overloaded with this gas. In addition, fossil
resources are limited but in the future there will be a vital
need for these precious raw materials – for synthetics as
well as for life-saving pharmaceuticals and hundreds of
other products derived from crude oil. Dependency on
fossil resources has also become an economic and a
political source of crisis. The Cold War as well as power
games with and between main oil-producing countries
has led to economic imbalances. Long-distance transport
routes, volatile prices, geopolitical instability, trouble spots
and economic dependency on a few energy providing
countries are causing a worldwide re-evaluation of energy
systems.
The breath of the sun – light, heat, wind
In contrast to fossil energy production, atomic energy,
hydro power, biomass and renewable energy represent
only one fifth of world energy production. Nevertheless, the
Side Glance
hope for an enduring and stable energy supply depends
on renewable resources such as the wind, sun, biomass
and water. The reason is obvious; in only three hours the
sun sends as much energy as the whole world needs in
a year.
Therefore only 3 % of the Sahara‘s land area would be
enough to cover the world’s usage of electricity. Only a
fraction of available solar energy is used now even though
solar power capacity increased from 2 Petajoules (Pj) to 13
Pj in the period from 2004 to 2008. In 2008, wind energy
plants, mainly in Germany, the USA and Spain, produced
94.000 MW of electricity. A huge potential remains
untouched. The overall potential of renewable energy
also depends on technical as well as geographical and
economic conditions. Only a fraction of the solar energy we
receive is usable but the figures are still impressive:
Primary energy 100 %
Conversion
in power plants,
refineries etc...
Only a fraction of primary
Conversion loss
22.5 %
transport
energy is used.
Source: Paeger
Private consumtion,
loss of power
5 %
Final energy 65%
Non-energetic
consumption
7.5 %
Useful
energy
Consumer
consumption
36 %
Reliability
at work
Technical Glossary
Type of Energy
Amount of
world energy
consumption
covered
Solar Energy
3,8x
Wind
0,5x
Biomass
0,4x
Geothermal Energy
1,0x
Tidal Power
0,05x
Hydrogen Power
0,15x
Less is more – power efficiency
The largest power plant does not produce any energy;
it is designed to save energy by intelligent and efficient
usage. On the road from power production to the enduser there are often losses of up to 90% measured against
energy input. There are losses within the power-plants,
losses of transmission and distribution, and losses in power
conversion, for example:
• A bulb converts only 3 % of electric energy into visible
light
• Only 13 % of gasoline energy reaches a car’s wheels.
• 80 % of heating and climating losses in buildings could
be avoided by efficient thermal insulation.
The reduction of losses is multiplied as the energy travels
back to power plants. If losses cause a reduction of energy
from say 100 produced units to 10 units output, an increase
of efficiency from 1 unit on the output side will save 10 units
on the input side. Therefore energy efficiency is the most
promising power source of the future.
The Evolution of Technology
For more than 150 years the increasing availability of energy
has improved access to resources and the production and
supply of food. It has enabled unprecedented mobility,
information availability, communication, and the usage
of sophisticated technical devices. New technologies
evolve whenever existing applications turn out to be
too costly to resolve new problems. Old technologies
will either be optimised or gradually substituted by their
successors, unless the problem itself is altered or changed
by new perspectives and solutions. It is obvious that
an environmental and socio-economic driven change
in energy-technology lies ahead. It is also obvious that
essential technologies already exist or are in development,
ready to compete to provide useful and practical solutions.
Even now there are numerous inventions and innovations,
such as new technologies to produce and save energy or
efficient production solutions to preserve natural resources.
New materials, components and drives are steadily
reducing the energy demands of industry and transport.
New concepts of mobility will evolve to a essential criteria.
The final goal should be, as Traditional Chinese Medicine
advises, to keep the flow of energy alive – with every breath
we take.
bn:
billions 1 billion =
1,000,000,000 =
1x109
barrel:
1 barrel = 159 litres
or 42 US Gallons
CO2:
Carbon Dioxide
PJ:
Petajoule
1,000,000,000,000,000 J
~ 278,000,000 kWh,
unit of energy
MW:
Megawatt = 1,000,000
Watt
Mtoe:
million tons (of) oil
equivalent, unit of
energy. 1 Mtoe =
11,630,000,000 kWh
Km:
Kilometre, 1 Km ~ 0.62
Miles
kWh:
kilowatt-hour = 1,000
Wh, unit of energy
Dr. Oskar Villani, SDI-Research
World
EU 25
D
A fraction of the area of the Sahara could cover the
world’s energy demands Source: TREC
at work | no. 1/09
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18
| Reliability Report 2
A German
masterpiece
Imagine a 82 m long, rock-eating submarine with four floors, as
tall as a high rise building with 20 floors lying on its side.
This monster is heavier than a dozen 747 jumbo jets and creeps
forward through the earth behind a more than 9 m tall ­rotating
cutting face. Sounds a little outlandish to you? Product of a
­hyperactive imagination? If you thought that, you were wrong.
This is not Hollywood, this is the Discovery Channel.
Engineering Know-How from
Germany for the whole world
at work | no. 1/09
Every mm counts – even when 9t of
steel are waiting at the hook
82 m of pure power – ready for action
This threaded fitting has to resist up
to 350 bar oil pressure
Reliability Report 2
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20
| Reliability Report 2
The main drive of a tunnel boring machine is an assembly of no less than four large gear units that are bonded and bolted together.
Flange faces are coated with Loctite® 586 using a roller, which increases friction 2 to 2.5 times.
Forget Star Wars, forget Star Trek, forget the Matrix.
Reliability
at work
Customer:
Herrenknecht,
Germany
Task:
Securing flanges on
the main drive with a
2 to 2.5 times higher
friction coefficient
within it.
Products:
Loctite® 7070
Loctite® 586
Loctite® 243
Insane pieces of engineering
If you are the kind of person that doesn‘t like the sciencefiction, because you are interested in reality, Allmannsweier
in Baden-Württemberg is the place for you.
Allmannsweier in Baden-Württemberg is one of the more
pleasant regions of Germany, famous for its good food and
the friendly locals. It‘s also the home of Herrenknecht, the
world‘s leading manufacturer of tunnel boring machines.
And it‘s those machines which dwarf the imagination of
your average Hollywood screen writer. It’s not surprising
that the company and its charismatic founder, Dr Martin
Herrenknecht has attracted a lot of attention from the
global media lately.
“An insane piece of engineering” is how the American
Discovery Channel describes the Herrenknecht machine
that drilled a 5.4 and a 3.9 kilometer tunnel in Kuala Lumpur
in 2006.
The defining project of Herrenknecht‘s career and one of
the greatest public works of any kind is the Gotthard Base
Tunnel. The tunnel, which has been under construction
since 2002, will run from the village of Erstfeld, in central
Switzerland, to Bodio, in the southeast, a distance of more
than 57 kilometers. When completed, in 2017, it will be
the longest traffic tunnel in the world; it is also one of the
most geologically challenging, The Gotthard crosses nine
geological zones. It cuts through granite and quartz, along
fault lines and beneath a sugar like layer of dolomitic marble
– a challenge to anything going through it.
No rock too hard, not mountain too high:
Loctite® and Herrenknecht
Herrenknecht has been growing ever since its foundation
in the 70s. It now employs around 3000 people worldwide
and sales reach 1 billion Euro for the first time in 2008.
This impressive success story is partly due to the fact that
Herrenknecht took advantage of the opportunities offered
by the globalisation. China is one of the countries which
Herrenknecht focused on early and in 2008 they were able
to celebrate the delivery of the 100th machine to the powerhouse of the world economy.
at work | no. 1/09
Wherever one of the machines operate, Malaysia, China,
Switzerland or Brazil, Henkel‘s Loctite® products always
play an important role during the construction of those
insane pieces of engineering. Loctite® threadlocker 243 is
used to lock all the screws in the machine, which has to
withstand enormous pressure while it eats its way through
the rock.
Another application which makes good use of the
reliability that Loctite® stands for, is the machine’s rotating
cutting head. The cutting head's power unit relies on a
variable number of single engines. The superstructural
part's flange ring and main bearing as well as transmission
case and main bearing are cemented repeatedly in a
laminary fashion, using Loctite® 586. This process allows to
transmit more than twice the turning moment that would be
possible otherwise. The cementing with Loctite® enhances
the reliability and allows the power unit to withstand the
forces that can come to bear on it underneath the earth.
Loctite® Sales Engineers are also involved in the planning
process of the machines, liaising with the various
Herrenknecht departments in order to meet the customer’s
construction needs as early as possible. Henkel and
Loctite® are ideal partner for Herrenknecht’s tunnel-boring
machines, which never quite know what kind of rock they
will have to taste next. Loctite’s Rapid Response Process
(see Product Development Article), allows to respond to
new requirements in a matter of weeks.
The next stop for the tunnel
boring machines is Paris,
where the new tunnel for the
Metro 12 has to be drilled.
Completed main drive ­waiting
for the assembly into the
­machine.
Reliability Report 2
Interview
You're using Loctite® products for a wide variety
of applications in the manufacturing process of
your equipment. What Loctite® products do you
use in the manufacture of tunnel boring machines?
Mr. Lais: In our department we mainly use Loctite® 586
for bonding flanges and 577 for thread sealing, 243 for
threadlocking and Loctite® 7070 as a cleaner.
Where do you use Loctite® adhesives on your
machines? Mr. Lais: We use Loctite® mainly on the
cutting wheel drive. We apply product 586, to increase
friction.
Christian Draeger, Traffic Tunnelling Sales
Department, Herrenknecht AG
|
21
Wolfram Lais, Head of Subassembly,
Herrenknecht AG
How does such a tunnel boring machine get from this
production facility to its final destination ?
Mr. Draeger: The tunnel boring machine is fully assembled
right here in the factory. But, to move the machine to the
construction site, it must be disassembled again.
That's why the machine is completely modular in design,
and modules are assembled with bolts. We will disassemble
these bolted joints to get accurate structures which we
can transport to the construction site. Once they have
arrived at the construction site, these structures are then
re-assembled, tightened with bolts or welded.
In general, what parts of a machine are most severely
stressed during operation of the equipment? Mr.
Draeger: The cutting wheel and the main drive are
subjected to very high loads. Just imagine that the cutting
wheel is moving through the ground, encountering a variety
of soil types and loading conditions. There may be hard
rock or loose rock. In the case of hard rock it's mainly the
pressure and the force to be transmitted by the
cutting wheel when it's carving away the rock.
With loose rock, it's mainly the torques, the
rotating or twisting forces that act there and
cause very high stresses.
at work | no. 1/09
22
| Handy Hints
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at work | no. 1/09
Outlook
Come along and visit the “kings of earth”.
Discover the plant of TEREX in Scotland.
Get insights into the production of 100 ton rigid trucks.
... coming soon
Discover reliability in the most extreme racing conditions.
Learn more about the Porsche Mobil 1 Supercup and Loctite's
technology partnership with the fastest one make cup in the world.
at work | no. 1/09
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23
Imprint
Publisher
Henkel AG & Co. KGaA
Adhesive Technologies
Henkelstraße 67
40191 Düsseldorf
Germany
www.henkel.com
Editorial Department
Marketing Department EMEA:
Christian Scholze
Andreas Engl
Beate Schneider
Isabelle Feix
Erik Edelmann
Frank Fischer
Contact
Andreas Engl (Project lead)
Phone: +49-211-797-6758
Andreas.Engl@henkel.com
Creation
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