PECM - Issue 17 2015 by MH Media Global

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PECM

Global Success Through Innovation

Process Engineering Control & Manufacturing Issue 17 ÂŁ3.95

practical advice & solutions on the technical and management challenges faced by engineers and managers in the process engineering & manufacturing industries.

Control & Automation

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Advanced Engineering Show

Drives, Gears & Motors 60

Health & Safety 77

Process 100 Technologies

Software & Systems 110

Fluid Handling

Machining & Machinery 86

Storage, Handling & Equipment 116

industry news & events || boilers & maintenance || fluid handling || manufacturing || software & systems || water & effluent treatment

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PECM

Global Success Through Innovation

Process Engineering Control & Manufacturing

Issue 17 Contents Editor:

Editors Choice

Elizabeth Hutton Tel: 01227 392575 Email: elizabeth@pecm.co.uk

Advanced Engineering Show

News & Events

Assistant Editor:

Air, Gas & Odour Control

Justine Sanders Tel: 01227 392575 Email: justine@pecm.co.uk

Boilers & Maintenance

Cables

Sales Director:

Cleaning

Benjamin Dubois Tel: 01227 392529 Email: benjamin@pecm.co.uk

Connectors & Fittings

Control & Automation

Sales Manager:

Drives, Gears & Motors

Sophie Plowman Tel: 01227 392517 Email: sophie@pecm.co.uk

Electrical & Electronics

Fluid Handling

Digital Manager:

Health & Safety

Jamie Bullock Tel: 01227 392571 Email: jamie@pecm.co.uk

Hydraulics & Pneumatics

Lubricants

Publishing Director:

Machining & Machinery

Martin Holmes Tel: 01843 830249 Email: martin@pecm.co.uk

Measurement & Monitoring

Process Technologies

100

Product News

104

Sensors & Systems

106

Software & Systems

110

All web addresses are inter-active, simply click the web address of your choice to view the company website. There is also a useful tool bar where you can search for a specific product, or simply view the index on page 3 and then type in the page number of the section that you wish to view. Please mention Process Engineering Control & Manufacturing when responding to items in this issue.

Storage, Handling & Equipment

116

Switches

119

Tools

120

Every effort is made to ensure the accuracy and reliability of material published in Process Engineering, Control & Manufacturing however, the publishers accept no responsibility for the claims or opinions made by the contributors, manufacturers or advertisers. No part of the publication may be reproduced or transmitted in any form or by any means, mechanical, electronic (including printing), recording or stored in any information retrieval system without the prior written consent of the publisher.

Training & Recruitment

122

Valves & Flow Control

126

Waste Management

129

Water & Effluent Treatment

129

M H Media Global Ltd. St Augustineâ&#x20AC;&#x2122;s Business Centre, 125 Canterbury Road, Westgate On Sea, Kent, CT8 8NL Tel: 01843 830249 Fax: 08721 152240 www.pecm.co.uk

Issue 17 PECM

Eco Obsolete Technology Tips H

ere, Jonathan Wilkins,

Through programmes such as the

Directive and ESOS have penalties and

marketing director of

European Union's Ecodesign Directive,

sanctions, the Irish Energy Auditing

industrial spares supplier

the Energy Savings Opportunity Scheme

Scheme doesn't. This puts the emphasis on

European Automation,

(ESOS) in the UK and the Energy Auditing

Irish companies driving their own energy

talks about the alternative: Eco Obsolete

Scheme (EAS) in Ireland, companies are

efficiency policies.

Technology (EOT), and the important role

becoming more interested in energy

it's playing in keeping industry energy

efficiency. If you'd like to read more about

Let's say in your company's energy audit,

efficient.

these programmes, you can download

an electric motor is found to be highly

the European Automation special energy

inefficient and not compliant with energy

Cutting industry's carbon footprint is

efficiency report at - www.euautomation.

regulations. You could get rid of the

incredibly important and it's a common

com/en/automated/special-reports.

motor completely and risk overhauling

goal we're all pulling towards. However, nobody wants to be forced into a drastic

other parts of the system so as to ensure Compliance

change like a costly system upgrade, when

compatibility. This is the all or nothing approach to compliance. Or you could seek

they could instead make smaller revisions

As you're reading this, there's a good

to significantly improve efficiency.

chance an appointed lead assessor is

a simpler, quicker and cheaper option.

carrying out a company's initial energy

By sourcing a compatible variable speed

This is where Eco Obsolete Technology

audit in time for the ESOS December

drive (VSD) and retrofitting it to the motor,

comes in. EOT refers to automation parts

2015 deadline. The stages after this

you reduce the energy usage and comply

and components that comply with current

involve identifying areas of large energy

with energy efficiency regulations. Two

standards of energy efficiency, despite no

consumption - whether buildings,

energy efficiency birds with one EOT stone.

longer being produced by their original

industrial processes or transport - and

equipment manufacturer (OEM).

evaluating energy saving opportunities.

But it's not just mandatory energy efficiency schemes that EOT is helping

In the UK alone, industry is responsible

For large UK companies, compliance with

companies meet. Businesses complying

for 25 per cent of total CO2 emissions.

ESOS is mandatory, just as the Ecodesign

to the more proactive ISO 50001 standard

You might think this a large figure, but

Directive is for countries in the European

can also reap the benefits of obsolete

the sector is slowly becoming greener.

Union. However, whereas the Ecodesign

technology.

Reduced downtime For those of you that love a good paradox, you need look no further than automation in industry. Concepts like the Internet of Things (IoT) and Industry 4.0 are driving innovation in automated technologies - so much so that parts sometimes become obsolete after just a few years. Yet industrial manufacturing systems can also often live to see 40. If manufacturing facilities were upgraded every time new parts came out, they would be bankrupt before components were even unpacked from the boxes. Similarly, those relying on dated systems run the risk of falling behind in terms of production speed and ease. The key is a happy combination of the two: progress rather than change. By using EOT instead of implementing costly upgrades every time, factories can avoid the downtime that would be incurred when setting up a new system, while also reducing their carbon footprint and looking after the pennies. For industries in which upgrades are often too convoluted to be worthwhile due to procedures and regulations - like pharmaceutical manufacturing, nuclear and medical - EOT is crucial for keeping everyday operations efficient and

Savings

More importantly, by using EOT, companies can reduce their impact on

When it all comes down to it, being

the environment sooner rather than later.

energy efficient is about both looking

EOT negates the need for board level

at the bigger picture and the here and

discussions into efficiency upgrades,

now. Utilising EOT within an automated

that often only result in one of the most

system can save money by providing an

disliked of business idioms - "let's put a pin

alternative to expensive new technology

in it”. Roughly translated as, “come back to

and reducing energy bills.

me when the situation is critical”.

Sourcing a part, especially if you work with

EOT is giving industries the chance to

an industrial automation spares supplier,

make energy efficiency improvements

can mean products are with you within 48

now because they embody progression,

hours, drastically reducing downtime and

not drastic change.

the associated costs.

affordable.

For further information contact: Jonathan Wilkins, European Automation Unit 3, Parker Court, Staffordshire Technology Park, Stafford, ST18 0WP Telephone: +44 (0) 845 521 3088 Website: www.euautomation.com E-mail: jonathan.wilkins@euautomation.com Twitter: www.twitter.com/euautomation LinkedIn: www.linkd.in/EUAuto Facebook: on.fb.me/EuroAuto

"Everybody loves progress, but nobody likes change" is the kind of phrase you might find in a fortune cookie, but it also largely represents feelings towards energy efficiency in industry right now. While businesses want to reduce their impact on the environment, there are also strong feelings opposed to implementing brand new energy efficient automation systems, when the current equipment still works.” Jonathan Wilkins, marketing director of industrial spares supplier European Automation

Editors Choice

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Y-type strainers • Basket strainers • Duplex strainers • T-type strainers • Radial fin cartridge filters (to 1 micron) Filter separators and demister pads • Quick release closures Materials available include: Carbon Steel & LTCS • Stainless Steel 304/316 • Duplex and Super Duplex Stainless Steel 6Mo • Monel • Aluminium Bronze • Cunifer • Hastelloy • Incoloy 625 & 825 • Titanium • Norsok MDS

Based in the UK, Barton Firtop manufacture and stock hold an extensive range of ASME/CE Marked Y-type, Basket and Duplex strainers.

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UK Flowtechnik Discover more at www.ukflowtechnik.com 6

PECM Issue 17

Specialist suppliers to Large Industry

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DIGITAL DMS BASED LOAD CELLS OPEN THE DOOR TO NEW MARKETS With the manufacturing industry demanding technology that is both accurate and affordable, Bernd KnĂśll, Product Manager, HBM GmbH, looks at how new digital DMS based load cells can open the door of opportunity to machine manufacturers.

s continuous growth, high competitive pressure and large production quantities in the manufacturing industry look set to continue, particularly within expanding markets such as China, India and East Asia, the entire processing chain, including manufacturers of packaging machines and checkweighers, is placed under greater performance pressure than ever before. Confronted with the demand for ever increasing precision and higher speeds for packaging â&#x20AC;&#x201C; often with expectations of reduced costs at the same time â&#x20AC;&#x201C; machine manufacturers are faced with a challenge.

PECM Issue 17

The core of weighing and packaging processes One of the most crucial components for constructing powerful packaging machines is the load cell. Up until recently, manufacturers of checkweighers have had to rely on load cells which were based on the principle of electromagnetic force compensation (EFC), although this has been at a relatively high component cost. But there is an alternative which has been in development for some years but is now readily available: digital load cell based strain gauge (SG) technology, which offers up to 60% cost savings in

comparison to load cells based on EFC. But does this new age of digital load cell technology compromise on the speed and accuracy of EFC sensors traditionally found in packaging machines? And is the arrival of digital load cells the right answer for machinery manufacturers to develop products for new markets? The hard facts Precision and speed are the two determining criteria for load cells, ultimately because both factors save cost; precision because it makes for improved safety margins, and speed because faster weighing means greater

BERND KNOLL Product Manager, HBM GmbH

output. Featuring an accuracy class C4 per OIML R60 and a maximum scale division Y of 25,000, digital load cells, such as the FIT7A load cell from HBM, offer total precision and allow overfill to be kept to a minimum. In addition, as dynamic movements and vibrations require sophisticated digital signal processing and calculation methods to determine the correct weight in a very short time, SG-load cells now make it possible to achieve more than 180 weighing processes per minutes, resulting in faster and ultimately, more productive packaging processes.

A load cell is only able to make full use of its strength and specification in combination with the final design of the machine,

Extremely robust in comparison to traditional load cells, digital load cells are also less likely to be damaged and can be easily replaced. Featuring a smooth stainless steel surface, digital load cells can be cleaned quickly and easily, which makes for short down times and correspondingly higher availability.

Dealing with malfunctions In order to achieve a productive weighing and packaging process, a smooth running production line is a necessity. The digital diagnostic channel can be used to analyse results during operation, predicting any potential errors or malfunctions and for this reason, digital solutions, with their wide range of possibilities, are in greater demand than ever before. Interaction: Installation into existing designs A load cell is only able to make full use of its strength and specification in combination with the final design of the machine. Ideally the component and the machine should meld together, therefore it is important for the sensor elements to be integrated into the machine design as seamlessly and compact as possible, and this is where digital load cells come into their own. Easily integrated into existing machines and weighers, digital load cells are the ideal choice when it comes to renovations Optimum communication: software embedding In the context of the Industrial Internet or Industry 4.0, communication and software are also becoming ever more important for dynamic weighing. The PanelX software for configuring FIT7A load cells from HBM, for example, has an intuitive user interface, optionally available with touch

control to adjust all parameters for measurement. In addition, PanelX can also be used to adjust load cells, select the bus address and baud rate, and enter the limit values with hysteresis and for graphical analysis and for realisation of measurement results. Conclusion A look at todayâ&#x20AC;&#x2122;s market shows that the advanced development of strain gauge based load cells makes them an excellent alternative to load cells based on electromagnetic force compensation. Precise, durable and reliable, they deal masterfully with malfunctions and can be easily integrated seamlessly into most machine designs.

Precise, durable and reliable, they deal masterfully with malfunctions and can be easily integrated seamlessly into most machine designs. As machine manufacturers are confronted with the demand for greater precision and higher speed, particularly in the food market, we can see how, whilst this may be a challenge for machine manufacturers, it is in fact an opportunity to get a firm footing in other growth markets, if they have the right response to the demand. The new generation of SGbased load cells, such as the FIT7A from HBM, offer huge gains in precision and speed for processing measurement data and are particularly well suited for dynamic weighing processes. For further information on the FIT7A digital load cell, contact HBM on +44 (0) 20 8515 6000 or via email: info@ uk.hbm.co.uk or visit the HBM website at www.hbm. com/en/menu/seminars/ seminar-calendar/ Founded in Germany in 1950, HBM is today the technology and market leader in the field of test and measurement. HBMâ&#x20AC;&#x2122;s product range comprises solutions for the entire measurement chain, from virtual to physical testing. The company has production facilities in Germany, USA and China and is represented in over 80 countries worldwide. Issue 17 PECM

Temperature Measurement Solutions Providing Increased Efficiency e.g. for Hardening Processes The ISR 6-TI Advanced infrared thermometer by LumaSense combines accurate (2-color) pyrometry and thermal imaging in one non-contact temperature measurement system. his hybrid pyrometer solution by LumaSense Technologies is a major breakthrough combining an infrared thermometer with thermal imaging capabilities to open new sensing opportunities for heat-dependent manufacturers and various industrial applications.

Particularly in the steel and metal processing industry, the use of non-contact temperature measurement has become essential for monitoring and controlling production processes. One example is induction hardening and tempering, where a particular spot of the workpiece (such as precision parts made of steel or cast steel) is heated up and subsequently quenched rapidly. For such contactless heating methods, usually only a special area on the surface of the workpiece is selectively heated. This method of selectively heating and quenching a workpiece is critical in achieving the desired hardness of the material. If the temperature is too low, it will lead to insufficient surface hardness. However, if the temperature is too high, it may damage the workpiece so it becomes unusable. For measurement tasks with high reproducibility (as required in hardening processes), LumaSense offers IMPAC Series 6 Advanced pyrometers, which are available in different wavelength ranges and cover temperatures from 50 °C to 3000 °C, depending on model and application.

PECM Issue 17

IMPAC ISR 6-TI Advanced It is a novel solution to combine accurate twocolor pyrometer measurement (from 700 °C to 1800°C) with thermal imaging display capability.

As the latest special in this Series and in order to detect and monitor the temperature distribution on the workpiece, the IMPAC ISR 6-TI Advanced comes into play. It is a novel solution to combine accurate two-color pyrometer measurement (from 700 °C to 1800°C) with thermal imaging display capability. This allows a specific indication of the temperature distribution of a dedicated region on the objects surface. The ROI functionality contained in the supplied InfraWin software enables the definition and evaluation of specific “regions of interest”. When combined with an optional I/O module, it is e.g. possible to trigger external (switching-) contacts based on the temperature data of one or more ROI’s. More information: www.lumasenseinc.com

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JIANGHAI: ELECTROLYTIC FILM & SUPER CAPACITORS

NIC PERFORMANCE PASSIVE COMPONENTS

DUMMIES GUIDE TO Eco FutureLab FZE Technologies Using both light and heat of solar radiation to produce electricity Eco Futurelab FZE - The Nano Lens Chroma Solar Intensifier (NLCSI) echnicians at Eco FutureLab FZE have developed a technology to simultaneously use the light and heat of the sun to generate electricity in a way that could make solar power production more than twice as eﬃcient as existing methods and potentially cheap enough to compete with oil.

Unlike photovoltaic technology currently used in solar panels - which becomes less efficient as the temperature rises the new process excels at higher temperatures. Called “Eco Futurelab FZE - The Nano Lens Chroma Solar Intensifier (NLCSI) “Or NLCSI, the process is able to surpass the efficiency of existing photovoltaic conversion technologies. Unlike photovoltaic technology currently used in solar panels -- which becomes less efficient as the temperature rises -- the new process excels at higher temperatures. “This is really a Innovative breakthrough, a new energy conversion process, not just a new material or a slightly different tweak,” said Ahmet Kianin, CTO and president of Eco FutureLab FZE, who led the research group. “It is actually something fundamentally different about how you can harvest energy.” The materials needed to build a device to make the process work are much better priced and readily available; meaning the power that comes from it will be affordable. Most photovoltaic cells, such as those used in rooftop solar panels, use the semiconducting material silicon to convert the energy from photons of light to electricity. But the cells can only use a 42%

Until now, no one had come up with a way to combine thermal and solar cell conversion technologies.

portion of the light spectrum, with the rest 53% Ir + 5% UV just generating heat and not utilised. This heat from unused sunlight and inefficiencies in the cells themselves account for a loss of more than 50 percent of the initial solar energy reaching the cell. NLCSI harvests this wasted energy to make a much more efficient system. The problem has been that high temperatures rapidly decrease the efficiency of conventional Solar Systems, Yet the higher the temperatures go, the better the NLCSI performs. Until now, no one had come up with a way to combine thermal and solar cell conversion technologies. Ahmet Kianin developed NLCSI by Applying his experiences in Photonics technology and looking at other applications in Military technologies, he could by coating a piece of semiconducting material with a thin layer of a new mixture, it would make the material to use both combined light and heat to generate electricity. 24/7 NLCSI is capable of producing energy Day and Night, giving added Value to the customer’s installations. “What we’ve developed is a new physical process that is not based on standard photovoltaic mechanisms, but can give

you a photovoltaic-like response at very high temperatures,” Ahmet Kianin said. “In fact, it works better at higher temperatures, the higher the temperature the better.” While most silicon solar cells have been rendered inert by the time the temperature reaches 100 degrees Celsius, the Eco FutureLab FZE device doesn’t hit peak efficiency until it is well over 200 degrees C. “The light comes in and hits our NLCSI device, first we take advantage of both the incident light and the heat that it produces, and then we transfer the heat to our thermal conversion systems, for use in Air Conditioning system or further electricity Generation” Amet Kianin said. “So the NLCSI process has two really big benefits in energy production over normal technology.” Contact details Eco FutureLab FZE London - UK London W11 1LJ Tel.+447813992353 Fax.+447092101460 Dubai - UAE PO Box. 123758 Dubai-UAE Tel. +971567912014 Fax.+447092101460 email. ecofuturelab@gmail.com

Editors Choice MSPS part of consortium to design new Cell Therapy Catapult Manufacturing Centre Supporting growth of UK cell therapy industry Morgan Sindall Professional Services (MSPS), the multidisciplinary design and engineering ﬁrm, is providing mechanical and engineering, civil and structural and CDM services to design the Cell Therapy Catapult’s new £55 million large-scale ‘Good Manufacturing Practice’ (GMP) manufacturing centre. MSPS worked with a consortium of companies to complete the RIBA Stage 3 design: 3PM to provide project management; The Fairhursts Design Group as project architects; and Gardiner & Theobald as cost managers.

Make your checkweighers fit for speed and precision

The large-scale GMP manufacturing centre, due to open in 2017, will be used by companies for the manufacture of late-phase clinical trial material and initial commercial supply of advanced therapeutic medicinal products including cell and gene therapies. Simon Steed, associate director, building services of MSPS, says that the consortium team was chosen for its combined expertise in designing a Class B environment facility: “The design will allow for further growth and business eﬃciency.”

Email: Clare.K.White@morgansindall.com www.professionalservices.morgansindall.com

SuperCORR A protects and lubricates Contacts on the new Charge/Sync Cable from Lifedge SuperCORR lubricant and protective coating widely used by the military, electronics and aerospace industries for critical applications is used to protect contacts on the new Lifedge lightning connector to USB cable to offer the protection needed in extreme conditions. SuperCORR deposits a dry protective film with excellent corrosion protection and lubricant properties plus the added advantage of a hydrophobic surface rejecting water that ensures the easiest and best connection for the very close spaced connectors. Lifedge is the world’s first 100% waterproof, rugged Lightning to USB cable for charging and mobile connections whatever the weather or conditions. Developed for use in all outdoor activities including sailing, hiking, military, naval, surveying or other challenging uses. With an ultra-durable outer coating that will never fray and double-moulded, super-tough plugs, charging, downloading and data transfer is improved even in the most extreme and difficult conditions.

Tel 0208 281 6370

www.envirotech-europe.com

High End Chain Lube Spray

Fit for speed Top speed in measurement signal conditioning with up to 180 weighings per minute, FIT7A is guaranteeing speed and efficiency in your machines.

Fit for precision Donghua Limited has launched a new Chain Lube Spray to combat 80% of chain wear which is a result of poor lubrication. Whilst Donghua chain already comes pre-treated to improve wear-life, their new Chain Lube enhances the performance of their chain even further. Designed for regular use or in between routine maintenance schedules, the Chain Lube Spray provides a simple but eﬀective way to actively replace or top-up the lubrication that is inevitably lost during daily operation.

Top values when it comes to precision, with standard deviations of only 0.1 g for 10 kg and the new accuracy class C4. So your machines can guarantee safety and precision with minimum reject rates.

Participating stockists of Donghua chain are running a ‘3 for 2’ promotional campaign until 31/12/15.

Fit for competition

To locate your nearest stockist visit: www.donghua.co.uk/locate-a-dealer

With up to 60% cost advantage over other load cells based on electromagnetic force compensation, the FIT7A is competitively priced.

Flotronic Pump’s new ‘E’ Series’ achieves the EHEDG seal of approval Having already secured 3-A Sanitary Standards, Inc (3-A SSI) approval for its ‘H’ series pump, Flotronic Pumps Limited have now achieved the European Hygienic Engineering & Design Group (EHEDG) accreditation for their new ‘E’ Series pump. Flotronic’s ‘E’ Series pump has been speciﬁcally designed for the Food and Beverage industry and other processes where product contamination must be avoided. The pump’s features include Flotronic’s established and unique ‘ONE-NUT’ pump design which allows swift diaphragm access without disconnecting process pipework. The internal surfaces of the ‘E’ Series pump can be eﬀectively ‘cleaned in place’ or, alternatively, easy dismantling can be carried out for cleaning and inspection.

Tel: 01444 881871

Your machines can stay competitive and help you open up new, previously unobtained market segments.

More information: www.hbm.com/automation-fit7a

HBM United Kingdom Ltd info@uk.hbm.com www.hbm.com

www.ﬂotronicpumps.co.uk Issue 17 PECM

Editors Choice ThyssenKrupp puts its reputation on the line A two year £4.0m investment programme is entering a critical phase at Vetchberry Steels, the coil processing division of ThyssenKrupp Materials (UK) Ltd., a subsidiary of ThyssenKrupp AG. Having completed the ground work, the custom built components for the new ﬂagship 1850 mm wide coil slitting line are currently undergoing installation in Birmingham (UK) by Heinrich Georg GmbH Maschinenfabrik, a 3rd generation, family owned German company at the forefront of developing technically leading production solutions capable of delivering world class results. Under the close supervision of Adrian Palmer, Operations Manager, who has lived and breathed the project from its inception, it is expected to be the most eﬃcient slitting line in the UK for stainless steel and aluminium coil production. “It took 11 full size trucks just to ship in the components from factories in Germany and the UK, which gives you some idea of the scale of the equipment. Installation is, of necessity, a painstaking business, and I can’t wait to see it up and running in full production.“ For more information contact Vetchberry Steels on 0121 322 2345 or visit www. vetchberrysteels.co.uk.

Energy savings in the can for Brammer and Ball Expertise in pump management and maintenance from Brammer, the UK’s leading distributor of industrial maintenance, repair and overhaul (MRO) products and services, has delivered £30,000 in energy savings for Ball Packaging Europe, a leading manufacturer of beverage cans. The Brammer team, led by Del Tiwana who specialises in beverage and packaging manufacturing processes, found that the 10 pumps within the can cleaners were at least 20 years old, providing an opportunity to upgrade to more modern, energy-eﬃcient models. With a run time of 8,400 hours per annum, based on the pumps running 24/7 for 50 weeks of the year, Brammer identiﬁed potential energy savings of more than 450,000 KWHh/yr. For further information on Brammer’s MRO products and value-added services, visit www.brammeruk.com

Global Logistics Leader specifies hydraulic dock levellers from Stertil Specialist loading bay equipment and industrial door manufacturer Stertil Dock & Door Products has installed a series of 11 hydraulic dock levellers for a worldwide logistics company. As a top ten global provider of supply chain solutions, the logistics company operates a UK network of strategically located ambient and temperature controlled warehousing facilities. The company’s Amber Park warehouse in South Normanton, Derbyshire was recently upgraded and 11 outdated levellers were replaced with an installation of Stertil XP 2521 hydraulic dock levellers. Up to 80 rigid lorries and articulated vehicles with trailers are loaded and unloaded in a typical working day at the Amber Park site. These operations are undertaken safely and swiftly by the 6000kg capacity XP 2521 dock levellers which feature an ingenious telescopic extending lip. Simple, precise positioning of this lip onto the rear of a vehicle’s deck enables loading by pallet truck right up to the rear doors thereby ensuring maximum use of available space.

Boulting Group expands integrated team Boulting Group, due to expansion and growth of the business in its North West heartland, has opened new offices adjacent to the Firecrest Court head office in Warrington. Encompassing civil, mechanical and Electrical and Instrumentation projects, the 50-man operational technology team is now based in 4,000 sq. ft. of offices. New teams are being created within the business, to consist of senior and project managers, QS teams, project, commissioning and software engineers, health and safety personnel and technical support. New, dedicated test bays are being installed for hardware and software testing, covering projects such as instrumentation, control panel construction, software development, networks, SCADA and electrical installations.

Tel: 01925 446000

www.boulting.co.uk

Large Capacity Turning – No Problem for Watford Based Firm Watford-based Gate Machinery International Ltd (www.gatemachinery. com) has added a range of large capacity, heavy duty lathes to its wide range of machinery and equipment. With a number of these machines already supplied to customers in the Oil, Gas and Petrochemical sectors both in the UK and overseas, there is also a great deal of interest being generated from customers in other sectors such as aerospace, marine and renewable energy. The new range is divided into three main categories; ‘Large Capacity – Heavy Duty’ ‘ExtraLarge capacity – Oil Country’ and Gate –Eclipse ‘Heavy Duty CNC Lathes’. Machines and guarding can be tailored to meet the diﬀering demands of industry.

www.gatemachinery.com

Tinytag Data Loggers: Robust Environmental Monitoring Solutions Tinytag Data Loggers record environmental conditions including temperature, relative humidity, CO2, single and three phase power usage. Tinytags range from compact units for indoor use to rugged, waterproof devices for industrial and outdoor applications. Accompanying probes are available for measuring extremes of temperature, for comparing ambient and process temperatures, and for monitoring awkward to reach areas such as pipework. Stand-alone Tinytags record data downloaded to a PC for analysis. A Radio System is available for premises with multiple monitoring points: data is gathered automatically and sent via a receiver for direct viewing on a PC, across a LAN, or remotely across the internet.

Email: info@tinytag.info

www.tinytag.info

Industrial marketing specialists gear up for future outsourcing growth The Product Marketing Company, a specialist B2B outsourced marketing business for the engineering and manufacturing sectors, have rebranded and launched a new website following a succession of new business wins. Hertfordshire based TPMC has grown year on year following its inception in 2008 due to the expertise of its experienced team who have a worked in industrial sectors for almost three decades. Working closely with clients at board level, the senior directors are able to identify core competences and opportunities for established engineering and manufacturing organisation’s and implement a comprehensive, tailored marketing plan

Stertil UK Limited www.stertil.co.uk

PECM Issue 17

TPMC provide an entire team of professionals for strategic planning, marketing communications, media relations and digital services oﬀering customers a ‘bolton’ marketing department for the annual equivalent cost of a senior marketer. For more information please visit www.theproductmarketingcompany.co.uk or for an informal discussion telephone 01462 432303

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ge and

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Video inspection, position indicator, home function and locator with the WĂśhler VIS 350 Video inspection in a case: With the new WĂśhler VIS 350 camera system, you not only have everything you need to inspect

PAN&TILT COLOR CAMERA HEAD

VIDEO FUNCTION

WIDE RANGE OF APPLICATIONS

waste water pipes, flue gas and ventilation lines as well as industrial systems â&#x20AC;&#x201C; you can also precisely locate the damage and

UNIQUELY CLEAR VIEW NEW UNIQUELY CLEAR VIEW NEW

POSITION & ANGLE DISPLAY

accurately document the results of the inspection.

Video inspection, position indicator, home function and locator with the WĂśhler VIS 350

Video inspection, position indicator, home function andhome locator function with the WĂśhler VIS 350 Video inspection, position indicator,

Video inspection in a case: With the new WĂśhler VIS 350 camera system, you not only have everything you need to inspect

waste water pipes, flue gas and ventilation lines as well as industrial systems â&#x20AC;&#x201C; you can also precisely locate the damage and

Second 24â&#x20AC;? King Crimper commissioned Âˇ Waste water lines of Ă&#x2DC;PAN&TILT 70 mm and larger POSITION & VIDEO ANGLE DISPLAY

COLOR CAMERA HEAD

Âˇ House connections up to Ă&#x2DC; 200 mm FUNCTIONROBUST

PHOTO FUNCTION

Âˇ Flue gas systems of Ă&#x2DC; 60 mm and larger HOUSING Ventilation lines of ventilation systems WIDE RANGEÂˇOF APPLICATIONS TECHNICAL DATA False ceilings, hollow spaces, shafts Analyze damageÂˇ and inspect:

WĂśhler VIS 350 camera system, you not only have everything you need to inspect and locator with thenewWĂśhler VIS 350

accurately document thein results of the With inspection. Video inspection a case: the

INTEGRATED LOCATOR TRANSMITTER

POWERFUL RECHARGEABLE BATTERY UP TO 4h MOBILITY

TECHNICAL DATA

Analyze damage and inspect:

ROBUST HOUSING

PHOTO FUNCTION

Monitor Dimensions housing..............176 x 114 x 32 mm POWERFUL INTEGRATED LOCATOR TFT-Display ..........................7" /RECHARGEABLE 16:9 format BATTERY TRANSMITTER UP TO 4hPAN&TILT MOBILITY Video-Out.............................FBAS signal POSITION & COLOR CAMERA HEAD Weight .................................400 g ANGLE DISPLAY

VIDEO FUNCTION

Power Supply .......................Space for 2 rechargeable batteries, each 12 V or via power pack Battery operating time...........Max. 2 rechargeable batteries, each 120 mins. = 4 h (battery status in display)

Monitor Dimensions housing..............176 x 114 x 32 mm

Pan&tilt camera head TFT-Display ..........................7" format Ă&#x2DC; 40 mm color crimping RANGE OF/ 16:9Finnpower APPLICATIONS waste water pipes, flue gas and ventilation lines as well as industrial systems â&#x20AC;&#x201C; you can also precisely locateÂˇ House the damage and Dynamics - the UKWIDE Hydrapower distributor for and FUNCTIONALITY connections up to Ă&#x2DC; 200 mm Type ....................................1/3â&#x20AC;&#x153; COLOR CMOS

Âˇ Waste water lines of Ă&#x2DC; 70 mm and larger

a case: With the new WĂśhler VIS 350 camera system, you not only have everything you need to inspect waste water pipes, flue gas and ventilation lines as well as industrial systems â&#x20AC;&#x201C; you can also precisely locate the damage and accurately document the results of the inspection.

Video-Out.............................FBAS signal

cutting machinery - are pleased to announce the sale and commissioning of a second Crimper toÂˇ Waste W.E. Couplings of Chorley. This makes remain 24â&#x20AC;? hiddenKing from your view Battery operating time...........Max. rechargeable batteries, each 120 mins. =4h water lines 2of Ă&#x2DC; 70 mm and larger Viewing angle ......................115Â° Âˇ False ceilings, hollow spaces, shafts (battery status in display) them the first company in the have both machines (1200 Light source ........................12 white LEDs ton & Âˇ Store video footage and photos on world a 2 GB SDto card (WĂśhler Âˇ House up to Ă&#x2DC; 200 mm Pan&tilt Ă&#x2DC;connections 40 mm color camera head Degree of protection .............Waterproof to IP 67 VIS 350) FUNCTIONALITY 2000 tons) on one site. Type ....................................1/3â&#x20AC;&#x153; COLOR CMOS ..........................Ă&#x2DC; 40 mm x 60 mm Dimensions

Weight .................................400 g Pixels ...................................768 x 576 (PAL), 656 x 492 (NTSC) Âˇ Optics pan maximum moveÂˇ Flue gas systems of Ă&#x2DC; 60 mm360Â° and and largertilt 180Â° â&#x20AC;&#x201C; facilitate Analyze damage and inspect:

Light sensitivity ....................0.5 Lux radius systems and ensure even the smallest damage does not Âˇ Ventilation lines ment of ventilation Power Supply .......................Space forLens 2 rechargeable batteries, each 12=V or power pack ....................................f 2.3viamm, F= 2.5

Pixelsgas ...................................768 xof 576 (PAL), 656temperature x mm 492 (NTSC) systems Ă&#x2DC; 60 and larger Âˇ Optics pan 360Â° and tilt 180Â° â&#x20AC;&#x201C; facilitate maximumtransmitter move- Âˇ Flue Âˇ Camera head with integrated harmonizes locaOperating ..........0...40 Â°C, RH 95 % MAX Light sensitivity ....................0.5 Lux ment radius andtion ensure even theby smallest damage doesLocator not Storage temperature .............-20...50 Â°C, RH 95 % MAX detection the WĂśhler L 200 Lens ....................................f = 2.3ventilation mm, F = 2.5 Âˇ Ventilation lines of systems remain hidden from your view

W.E. Couplings can offer Viewing angle ......................115Â° Âˇ Digital position and angle displayed on Push rod a crimping diameter ofof the camera head Light source ........................12 white LEDs Length .................................20 False ceilings, hollow spaces, shaftsm of protection .............Waterproof to IP 67 Diameter ..............................6.5 mm up to Âˇ650mm and cancamera head to aDegree Dimensions ..........................Ă&#x2DC; 40 mm x 60 mm Home function aligns the straight position Âˇ Camera head with integrated transmitter harmonizes locaOperating temperature ..........0...40 Â°C,Plastic RH 95 %case MAX crimp diameter ortheby display parallel to ground above Storage temperature .............-20...50 Â°C, RH 95 % MAX tion detectionby byâ&#x20AC;&#x201C; the WĂśhler L 200 Locator FUNCTIONALITY Dimensions ..........................51 x 43 x 17 cm (L x W x H) Âˇ Digital positionÂˇ and angle of theassuring camera headcamera displayed on 60 Push Brightly illuminating color head, mmrodin length Weight .................................8.2 kg pressure, thus Lengthbends .................................20 m Âˇ Optics pan 360Â° and tilt 180Â° â&#x20AC;&#x201C; facilitate maximum movethe monitor and 40 mm in diameter, easily negotiates tight Diameter ..............................6.5 mm Distance Measurement total accuracy of the Âˇ Home functionÂˇ aligns the camera head to a straight position ment radius even smallest does not WĂśhler VIS 350 / VISthe 300 ......Electronic meterdamage counter Electronic meter counter with a resolution of 0.04 m dis-and ensure Plastic case â&#x20AC;&#x201C; fi display parallel to the ground above nished played crimp which on the monitor Dimensionshidden ..........................51 x 43 xMemory 17 cm (L x(WĂśhler W x H) VIS 350) remain from your view Âˇ Brightly illuminating color camera head, 60 mm in length Weight .................................8.2 kg Recording ............................2 GB SD card (2.5 h recording capacity) is essential for product Bright TFT color monitor (tiltable supplies and 40 mm in Âˇdiameter, easily negotiates tight bendsand removable) Âˇ Store video footageInterface and ..............................Mini photos on a USB 2 GB port SD card (WĂśhler Distance Measurement razor sharp images VIS 350 / VIS 300 ......Electronic meter counter safety. Âˇ Electronic meter counter with a resolution of 0.04 m disVISWĂśhler 350) Locator transmitter Âˇ Store video footage and photos on a 2 GB SD card (WĂśhler Âˇ the monitor VIS 350)

Battery operating time: 2 x 120 min. with 2 Memory rechargeable played on the Âˇmonitor (WĂśhler VIS 350)

Transmission frequency ........8.9 kHz

Excepted from this: Opening of the housing, inappropriate handling; For further information please see our guarantee guidlines

Video inspection accurately document the results of the inspection.in

harmonizes locaTo ensure total tion detection by theDisplay WĂśhler L 200 Locator .................................Graphic visualization of transmitted position satisfaction of product Locator transmitter Âˇ Battery operating time: 2 x 120 min. with 2 rechargeable Transmission frequency ........8.9 kHz Output impedance batteries Âˇ Digital position and Headphones angle .........................32 of the camera Peter(optional) Hart M.D. requested Ohm head displayed on Locator receiver Power supply........................3.7 V Li-Ion rechargeable battery Âˇ Fully equippedLOCATOR mobile solution in a robust plastic case theDisplay monitor .................................Graphic visualization of transmitted position (OPTIONAL) the most advanced Operating temperature ..........0...40 Â°C Output impedance Storage temperature .............-10 Â°C...40 Â°C Âˇ Transmitter integrated in camera head makes it possible to Headphones .........................32 Ohm Âˇ Home function aligns the camera head to a straight position crimping control system Weight .................................605 g Power supply........................3.7 V Li-Ion rechargeable battery precisely locate the camera head LOCATOR (OPTIONAL) ..........................32 x 14 x 7 cm (L xdata W x H) Operating temperature ..........0...40 â&#x20AC;&#x201C; display parallel toÂ°CDimensions thefor ground above in the world, plus total connectivity of data transfer online quality Âˇ Facilitates targeted damaged Storage temperature .............-10 Â°C...40 Â°C Âˇ Transmitter integrated in camera headrepairs makes ittopossible to pipelines Weight .................................605 g Brightly illuminating color camera head, mm in length precisely locate the camera head monitoring. This has been achieved by providing Finnpower UC 60 Control Âˇ Telescopic holder makes it possible toÂˇlocate damage unDimensions ..........................32 x 14 x 7 cm (L x W x H) Âˇ Facilitates targeted to pipelines der repairs floors or damaged in ceilings with Option 3 connectivity control.and 40 mm in diameter, easily negotiates tight bends 1)

Recording ............................2 GB SDintegrated card (2.5 h recording capacity) (optional) head with transmitter Âˇ Bright TFT colorbatteries monitor (tiltable and removable) supplies Âˇ Camera Interface ..............................Mini USBLocator port receiver razor sharp images Âˇ Fully equipped mobile solution in a robust plastic case

Âˇ Telescopic holder makes it possible to locate damage un-ensures it is possible to Âˇ Chalk holder with lithographic chalk Âˇ Electronic meter der floors or in ceilings

counter with a resolution of 0.04 m dis-

Peter said this additional large investment of a second King Crimper and mark located damage immediately PRODUCT FEATURES Âˇ Chalk holder with lithographic chalk ensures it is possible to played on the monitor Âˇ Long-lasting battery has opened up LI-ION new rechargeable world market for his products and thanked both mark located damage immediately PRODUCT FEATURES Chimneys, vents and waste water pipes Âˇ Bright TFT color monitor (tiltable and removable) supplies Âˇ Long-lasting LI-ION rechargeable battery Hydrapower Dynamics and Finnpower for providingChimneys, machinery and control 350 razor sharp images WĂśhler VISvents and waste water pipes 300 systemsDOCUMENTATION that satisfy these products exacting requirements. WĂśhler VIS 300 350 Features Âˇ Battery operating time: 2 x 120 min. with 2 rechargeable

DOCUMENTATION Simply record and store photos and videos on a 2 GB SD Features

Within 24 hrs of the machine being commissioned order was received and tiltable color batteries (optional) Pan-an card (WĂśhler VIS 350) for documentation andPanarchiving purand tiltable color camera head Ă&#x2DC; 40 mm for 3 xVIS14â&#x20AC;? ...documentation 10 mtr and 16archiving bar OIL assemblies. card (WĂśhler 350) for pur- ÂˇHose cameraequipped head Ă&#x2DC; 40 mm Fully mobile solution in a robust plastic case Simply record and store photos and videos on a 2 GB SD

poses for you and your customers.

HOME-FUNCTION HOME-FUNCTION TheThe Home VIS350) 350) Homebutton button(WĂśhler (WĂśhler VIS realigns the to its itsinitial initial realigns thecamera camera head head to position. position.

ROBUST HOUSING

POSITION & ANGLE DISPLAY

ILLUMINATION INTEGRATED LOCATOR BRIGHTBRIGHT ILLUMINATION INTEGRATED LOCATOR to the excellent lighting TRANSMITTER Thanks Thanks to the excellent lighting TRANSMITTER of the color camera The camera is equipped of the color camera head, the head, the The camera headhead is equipped with a with a system system supplies supplies razor sharp images transmitter as standard â&#x20AC;&#x201C; thatâ&#x20AC;&#x201C;means razor sharp images transmitter as standard that means camera camera theeven darkest ofcorners the thethe camera head can easily be locathecorners darkest of the camera head can easily be loca- of even of under inspection. tedted by by the the newnew WĂśhler L 200LLocator. under inspection. WĂśhler 200 Locator.section section

PAN&TILT COLOR CAMERA HEAD

Âˇ Waste water lines of Ă&#x2DC; 70 mm and larger Âˇ House connections up to Ă&#x2DC; 200 mm Âˇ Flue gas systems of Ă&#x2DC; 60 mm and larger Âˇ Ventilation lines of ventilation systems Âˇ False ceilings, hollow spaces, shafts

Digital distance measurement

W.E. hold in stock Water hose up toFoto-24â&#x20AC;? bore, Oil hose to 18â&#x20AC;? bore, the & video record Menu Menu Value of the stock is continually increasing to a target of ÂŁ1,000.000.00 + Foto- & video record

LOCATOR (OPTIONAL) Video adjustments Video adjustments

Mr Hart would like to thank Mr Frank Kerwanintegrated and Mr Noel Chambers anditall Transmitter Transmitter Âˇ Transmitter in camera head makes possible to Position indicator others involved in delivery and commissioning as Position theindicator logistics precisely locate the camera head - transport Home-function Home-function from Finland to meet a timed 50 ton mobile (Specialist crane hire) all Âˇ Facilitates targeted repairs to damaged pipelines completed in Military style precision with no hitches or time lost.

Monit Dimen TFT-D VideoWeigh

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POWERFUL RECHARGEABLE BATTERY UP TO 4h MOBILITY

Tel: 881414 â&#x20AC;˘ Email: sales@vst.org.uk â&#x20AC;˘ www.vst.org.uk WIDE 01935 RANGE OF APPLICATIONS TECHNICAL DATA Analyze damage and inspect:

Digital distance measurement

TECH

Excepted from this: Opening of the housing, inappropriate handling; For further information please see our guarantee guidlines

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Monitor Dimensions housing..............176 x 114 x 32 mm TFT-Display ..........................7" / 16:9 format Video-Out.............................FBAS signal Weight .................................400 g Power Supply .......................Space for 2 rechargeable batteries, each 12 V or via power pack Battery operating time...........Max. 2 rechargeable batteries, each 120 mins. = 4 h (battery status in display)

Tel: +44 (0)1257 Âˇ Chalk holder 475101 with lithographic chalk ensures it is possible to mark located damage immediately Email sales@we-couplings.com Âˇ Long-lasting LI-ION rechargeable battery

DOCUMENTATION

PROD

WĂśhle

PECM

Issue Simply record and store photos17 and videos on a 2 GB SD card (WĂśhler VIS 350) for documentation and archiving pur-

Featu

Pan- a camer

Barnshaws Polska Rolls Out New Tram Design ollowing the recent opening of Barnshaws' Polish facility, the company has been quick to secure substantial orders for rolled steel products and the extended customer list is growing rapidly. One of the latest projects involved creating the skeleton frame for a new Polish tram design and manufacturing the components to meet the tight build schedule.

Modern, aerodynamic designs require a strong, yet lightweight design and this usually means using rolled hollow section steel which can be formed into precise shapes to form the basic shape and structure of the tram. In one of the most recent orders, the tram manufacturer was contracted to deliver 12 new, low floor trams and the task of manufacturing the curved framework was awarded to Barnshaws Polska.

PECM Issue 17

Each vehicle required a total of 60 rolled sections which consisted of three different sections and four different radii, which produced a complete contract for 720 rolled sections. Although the largest section was only 100 mm x 50 mm with a 5mm thickness, this project was about precision bending that could be repeated hundreds of times to ensure accurate assembly.

Barnshaws' new Polish facility offers bending services for IPE European section beams and profiles section sizes up to 533mm, steel tube bending up to 508mm, plate rolling up to 3m wide at 20mm thick and 1.5m wide at 40mm thick. In addition, an aluminium bending capacity is also available on site, bringing further versatility to the new manufacturing centre.

Sales Director Maciej Walkowicz comments, "Our new facility is ideally positioned to deliver projects such as this for manufacturers across Europe. Understanding the needs of our customers enables us to supply their exact requirements and if necessary coordinate with tight production schedules. Using innovative metal bending technology we are well placed to provide high quality and cost effective products."

www.barnshaws.com

Transient Emissions Challenges T

he drive for improved fuel economy has spawned development of a new generation of turbocharged GDI engines. Simultaneously, emissions legislation requires ever lower emissions levels and since 2014 includes a Particle Number constraint which will tighten further in 2017.

Two common scenarios arise in which there is a significant and disadvantageous effect on emissions.

Initial emissions calibration of engines and their aftertreatment systems is undertaken at various representative steady state points, but it is in investigating transients during drive cycles where the use of fast-response emissions analyzers becomes crucial. Recent studies at Cambustion tested a 2.0-litre turbocharged GDI engine on a variety of drive cycles. Data from a WLTC Class 3 (intended for the European and Japanese markets) are discussed here. Although the vehicle is unlikely to have been developed for this cycle (it is Euro 6 compliant), identification of features of interest can show changes that could be used to ensure compliance. The longer cycle duration (WLTC is 1798s, NEDC is 1198s) means that the cold start is less significant for the total cycle emissions- the aftertreatment is working for a greater proportion of the cycle. Attention to the transient operation which dominates the rest of the cycle is therefore of increased importance, reinforced by the higher loads and more aggressive accelerations. Cambustion fast-response analyzers for HC, NOx, CO&CO2 and particle number / size were used. Several features of interest were identified by the fast analyzers, the most significant one being the effects of blow-through on NOx and Particle Number.

Effects of Blow-through on Tailpipe NO Emissions on a 2.0L Euro 6 Turbocharged GDI Engine Blow-through causes the exhaust gas presented to the aftertreatment to become overall lean, even though combustion in the cylinder was close to stoichiometry. This produces low PN (since the combustion lambda remains well controlled) but can lead to NOx breakthrough at the tailpipe.

The phenomenon of blow-through (over-scavenging) has been observed in other boosted GDI engines. During valve overlap, and when significant boost pressure exists, intake air may pass straight through the exhaust valve. True combustion lambda and measured exhaust (aftertreatment) lambda diverge. The level of blow-through depends on many factors, including boost pressure, engine speed and valve timing (which is usually variable depending on load).

emissions legislation requires ever lower emissions levels and since 2014 includes a Particle Number constraint which will tighten further in 2017.

Effects of Blow-through on Tailpipe PN Emissions on a 2.0L Euro 6 Turbocharged GDI Engine Alternatively short-duration spikes of PN can appear during hard accelerations and gear changes, despite a warm engine. The exhaust lambda does not indicate particularly rich conditions, but the fast CO analyzer identifies that combustion lambda was rich. The difference between combustion lambda and exhaust lambda is explained by blow-through. The use of fast analyzers to identify such problems and to help assess calibration improvements is likely to be indispensable as more transient drive cycles are adopted for legislative purposes. www.cambustion.com Issue 17 PECM

Advanced Engineering UK 2015

New Innovators Showcased At Advanced Engineering UK Thanks To Magna International, With KTN Support dvanced Engineering UK, the leading event for the high performance engineering sectors, has announced that global Tier 1 automotive supplier, Magna International will be increasing its involvement at this year’s show.

At the event, which takes place at Birmingham’s NEC on 4 & 5 November 2015, Magna International, supported by the Knowledge Transfer Network, will host and sponsor the Enabling Innovation Poster Zone - a major area at the show - where the ideas and concepts from the UK’s up and coming innovators are showcased. Magna will also run 1-2-1 meetings with interested innovators, deliver a keynote in the show’s conference programme and take an expanded exhibition stand. The Enabling Innovation Poster Zone will provide a unique opportunity for

PECM Issue 17

early stage innovators to showcase breakthrough ideas, products and processes to the UK’s largest advanced engineering audience. The ‘poster’ submissions will come from incubator level organisations, university students, research-based companies and start-ups. The Zone will give the 13,000 visitors attending Advanced Engineering UK the chance to uncover potential technologies, partners and untapped capability. Magna’s R & D team additionally will invite potential innovation partners for 1-2-1 meetings. The sessions will offer innovators the opportunity to discuss new concepts and products, with opportunity for direct investment, collaborative programmes and potential licensing agreements with Magna’s R&D decision makers. Magna is very active in the UK technology community; interfacing with venture capital firms to locate opportunities, actively working with universities on new

technologies, collaborating with multiple start-ups leading to a recent joint venture agreement. Ian R. Simmons, Vice President of Business development and R&D at Magna International, explains the deepening connection:

“Successful commercialization of innovation is one of Magna’s key targets. The Advanced Engineering Show in the UK is helping Magna to demonstrate that we are open for business to suppliers, universities and start up’s that have new or innovative technology. Future collaboration and partnerships will be key to Magna meeting the demands for the next wave of technologies for our global customers.” Magna International is one of the largest automotive suppliers in the world, with 319 manufacturing operations and 85 product development, engineering and sales centres in 29 countries. Katie Crocombe, Advanced Engineering UK Event Director, explains why the company’s involvement is so important:

“Automotive is one of the critical engineering sectors served by the show; to have a global company that supports every major car manufacturer in the world, so deeply integrated with the show demonstrates the importance of the UK as a global automotive manufacturing powerhouse, and of the event itself as one of its major catalysts.

“This November’s Advanced Engineering UK is all about providing opportunities to commercialise innovation, as well as networking up and down the engineering supply chain; our ambition is to provide the perfect opportunity for new concepts to be shared, and OEM engineers and innovators to meet. The Enabling Innovation Zone, Magna’s programme of meetings plus its stand will create so many opportunities for this to happen.”

PECM Issue 17

Advanced Engineering UK 2015 integrates multiple show exhibit zones with the UK’s largest free-to-attend engineering conference programme. The show spans key sectors including aerospace; automotive; motorsport; marine, civil engineering, and more. It also includes over 750 exhibitors and more than 170 speakers, delivering sessions from 6 purpose built auditoriums at the show. Advanced Engineering UK features four

‘shows within a show’ – Automotive Engineering Show, Aero Engineering Show, Composites Engineering Show and Performance Metals Engineering. For further information about Advanced Engineering UK 2015, or submitting a poster please visit www.advancedengineeringuk.com or contact one of the Easyfairs team on +44 (0)20 8843 8800.

Join us where the UK Advanced Engineering sectors come together

4 -5 Nov, NEC, Birmingham, UK

NEW for 2015

The UKâ&#x20AC;&#x2122;s largest annual advanced engineering gathering Pre-register for your FREE entry badge

www.advancedengineeringuk.com

Advanced Engineering UK brings together the engineering supply chain with engineering & decision makers from OEMs and top tier organisations spanning: Aerospace; Automotive; Motorsport; Marine, Civil Engineering, and moreâ&#x20AC;Ś

Advanced Engineering Show Productivity Pioneers Forcam Take Centre Stage at NEC Advanced Engineering Show November 4-5 – Stand H62 CNC - Spezialmaschinen

With UK productivity some 30 per cent behind the USA, Germany and France many manufacturers will be keen to engage Forcam at the NEC. The company typically achieve productivity gains of around 20 percent in the first year following the installation of their manufacturing execution systems. Increases as high as 33 per cent have been recorded, so pay-back is rapid, with all users achieving further continuous improvement. UK Managing Director Andrew Steele explained, “World-wide there are over 60,000 machine tools and manufacturing processes interlinked using Forcam Force factory shop-floor management software. This streams accurate production instructions to machine operators, gathers information from the operators and machine systems, with instantaneous analysis and reporting so supervisors and managers have an accurate real time picture of production status. Any problems are immediately apparent and can then be resolved quickly.”

Andrew will be making a presentation in Forum 5 on November 5, at 12.15pm. He concluded, “We are looking forward to showing how our experience working with the likes of Daimler, Audi, BorgWarner, GKN Aerospace and many others can be deployed to increase production efficiency in UK factories.”

www.maka.com

Composites versatile and durable

– like a

MAKA

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Tel. 01606 833 837 Email: andrew.steele@forcam.com www.forcam.com

Composite Panels (Glass and Carbon) Patterns (Epoxy based and Aluminium) Honeycombs and Foams Thermoplastics

Applications For the Automotive, Aerospace, Marine, racing, sports and leisure industries, and more ...

Green light for a tenth gas-to-grid plant in the United Kingdom The internationally active Agraferm Technologies AG continues to expand its leading market position in England. In addition to their exceptionally reliable technology and high energy yield, their swift planning and realisation of plants have contributed greatly to the German company’s success on the island. The Metheringham Project involves building the tenth biomethane plant in England. Methwold and Crowland are biogas plants which operate using a flexible substrate mix. In addition to gas production, they will also produce electricity using CHP technology. Near Lincoln, in Metheringham, a new gas-to-grid biomethane plant is being built. The plant will consist of just one digestor and post digestor yielding 400 Nm3/h biomethane and 500 kWel. For the plant builder Agraferm, it will be one of its smaller plants. “Plants in this performance class normally require three to four tanks but thanks to our high-load fermentation, Agraferm plants require substantially less tank volume,” explains Chief Technology Officer at Agraferm, Heinrich Schulze Herking. Particularly with large gas-to-grid plants, however, the operators appreciate the advantage of a small environmental footprint, which is why Agraferm is now constructing its tenth biomethane plant in the UK.

MAKA 5-axis machining centres are innovative high-end solutions. Process optimisation, precision, quality and reliability stand for Productivity and Flexibility.

MAKA Machinery UK Ltd

www.MAKA.com

C5 Horton Park, Hortonwood 7, Telford TF1 7GX Tel: 01952 607700 Email: iy@makauk.com

PECM Issue 17

Individualised concepts win British operators over The second project recently entrusted to Agraferm is at Decoy Farm in Crowland adjacent to the compost facility which is run by Material Change Ltd. The digestor and post digestor are loaded directly with a combination of energy crops and refuse. This downstream CHP plant produces 2.8 MWel. The construction and operation of the AD Plant at Decoy is being managed by an affiliate of Material Change. The third project is also based on an individually drafted concept with a flexible substrate mix. Future Biogas Ltd. has entrusted Agraferm with another biogas plant in Methwold. Of the 50,000 tons of the raw material that will be used at the plant, more than half will come from pig dung rather than from energy crops. This is made possible by upstream milling, two digestors and one post digestor. The Methwold plant will produce biomethane at a rate of 400 Nm3/h as well as power the 500 kW CHP plant. With these three new plants, which will all be completed in 2015, the Agraferm Group presence will increase to 20 biogas plants in the UK providing a raw biogas volume of approximately 200 million cubic metres every year. www.agraferm.com

FLEXIBLE SOLUTIONS FOR ANY ATMOSPHERE A

meriflex, Inc.® provides flexible solutions from conceptual design, prototypes to mainstream production and operates on a simple philosophy based on Integrity, Service, and Quality. Our commitment to this philosophy is put into practice on a daily basis in the manufacture of our precision bellows, flanges, and other quality products. With the latest in technologies we supply a wide range of industries ranging from Semi Conductor, Medical, Oil/Gas, Food and Beverage and Automotive. Our bellows and expansion joints are designed to absorb and reduce

vibration and relieve structural stress from working under pressure, extreme temperatures, and other variables. We specialize in thinwall bellows. We also offer the highest quality metal braided flex hose in the industry. Our braided hose is designed for high pressure applications. It provides the protection needed for the inner convoluted hose to withstand high pressure and for vacuum or partial pressure applications requiring protection from hazards. Our stainless steel braided hose can be found on NASA’s Curiosity Mars Rover, on still-in-development commercial spacecraft, and in countless other applications.

Also produced is a full line of bellows assemblies to complement our metal bellows. We manufacture bolt-style and clamp-style bellows assemblies, flanges, valve assemblies, and expansion joints. Every bellows assembly we make is ultrasonically cleaned prior to welding, and helium leak tested after to ensure weld integrity and defect-free construction.

2390 Railroad Street, Corona, CA 92880 Tel: (951)737-5557 www.ameriﬂex.net

Issue 17 PECM

Advanced Engineering Show

THE IDEAS CATALOGUE. • 30,000 30 000 High Quality Qualit Components • Easy Ordering System Online and Offline • CAD Data for Design • Technical Telephone Support • Reliable and FAST Delivery

norelem Sales Team UK Phone: 0121 222 5320 E-Mail: sales@norelem.co.uk Internet: www.norelem.co.uk

PECM Issue 17

Creating Environments

Temperature & Climatic Chambers Test & Evaluation Systems

Tel: 01628 850611 www.unitemp.co.uk

Advanced Engineering Show

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Bouyant auto sector just one of many drivers for growth in UKâ&#x20AC;&#x2122;s largest annual advanced engineering event.

his November 4-5, the UKâ&#x20AC;&#x2122;s advanced engineering communities will come together for their own bonďŹ re night display: in this case the 2015 edition of Advanced Engineering UK, including co locating shows Aero Engineering Show; Composites Engineering Show; Automotive Engineering Show; Performance Metals Engineering, together with one of the most comprehensive free conference programmes in the industry.

sector, Advanced Engineering UK is particularly well positioned to showcase the kind of innovative technology the UK is particularly known for, with an emphasis on its commercialisation possibilities. Typical areas of coverage will include graphene, wearable/ printable electronics, smart materials, additive manufacturing, new approaches to design & manufacturing and much more.

Rapidly shaping up to be the largest Advanced Engineering to date, more than 700 exhibiting supply chain partners will be meeting and doing business with engineering and procurement management from OEMs and top tier supply chain organisations across aerospace, automotive, motorsport, marine, defence and more.

Free to attend presentations from the highest quality speakers Across the show ďŹ&#x201A;oor 6 Open Conference auditoria will host presentations ranging from companies like Boeing, to industry bodies such as Composites UK. Short, sharp deliveries will provide attendees with quickly accessible industry intelligence, applications case studies, and technology updates.

Innovation, innovation, innovation Providing more feature exhibit areas than any other trade event in its

online

Buy and sell CNC machine tools with confidence

Breaking the mould A refreshing approach to buying and selling CNC machine tools and equipment.

uying and selling CNC machine tools and equipment has never been easy, straightforward or always that transparent. From a buyer’s perspective there’s the challenge of locating the right piece of kit; the time it takes to view and negotiate the best price; and finally the hassle and expense of collecting, relocating and installing it. The seller is faced with concerns too; managing the sales process, setting the right market value, calculating selling fees and, of course, getting paid once the item has sold. CNC Online is breaking the mould. As CNC specialists, with over 30 years’ experience, they are providing an online marketplace that unites sellers and buyers from production, manufacturing and engineering sectors, enabling them to sell and buy with confidence through industry knowledge, advice and support. It’s a bold but fresh approach. Managing Director Paul Lee comments; “Using our site gives both buyer and seller the confidence in the asset’s realistic value and provides a competitive and hassle-free trading place for CNC machinery and equipment. For sellers, it’s a successful sale of used or new machinery and for buyers, the confidence to purchase an item which will provide a productive and positive return on investment. We believe it’s the perfect solution for releasing capital from underutilised machinery, upgrading and trading machinery cost effectively and

satisfying both seller and buyer in a transparent and equitable way.” “Three key areas make us different; first is that we are experienced CNC specialists who have developed a dedicated marketplace to sell or buy new or pre-owned CNC machinery and equipment; second is our complete transparency and commitment to both seller and buyer; and third is the advice, guidance and support our dedicated team can provide to help both seller and buyer gain mutual benefit from a successful and hassle-free trading experience.”

Benefiting from the latest online technology and an easy to use awardwinning website, with options to ‘list your lot(s)’ independently or through an assisted or fully managed listing service, and the peace of mind that the CNC Online’s collect, deliver, install service (Assurance+) brings, both seller and buyer are in a win-win situation. Could this be the future of selling and buying CNC machine tools and equipment? The team at CNC Online certainly believe so.

“We were looking for a YCM Mill at a good price and found it on CNC Online. We’re really happy with the price we paid and the quality of the machine, as well as the service we received from the team, so much so that we recommended them to another engineering company.” Nick Beynon, Rhino Engineering (UK) Ltd

CNC Online www.cnconline.co.uk info@cnconline.co.uk +44 (0)333 202 0850

News & Events York EMC Services Celebrates 20 Years in Business Since its launch in 1995 York EMC Services (YES) has built an excellent reputation in the Regulatory Compliance industry for technical expertise and unrivalled customer support to engineers across a range of industries. Today YES operates from 4 sites near Leeds and Bristol, York and a brand new state of the art laboratory in Grangemouth. Specialising in EMC, Electrical Safety, Radio, Telecoms and EMF, we are the trusted provider of Consultancy, Product Testing, Certification, Training and Test Equipment for some of the leading brands and companies in the UK, Europe and worldwide.

www.yorkemc.co.uk

HBM Welcomes its latest addition to the DMP Family

AUMA completes Thames Water refurbishment in record time

HBM – a market leader in the field of test and measurement – is pleased to announce the arrival of the DMP41 digital measuring amplifier, for installation in control cabinets, which is the latest offering from its prestigious DMP range.

AUMA UK has completed a major actuator refurbishment programme at Thames Water’s Ashford Common advanced water treatment works. The upgrade project involved refurbishing 130 electric actuators and installing 30 new units over a nine week period, whilst keeping the site fully operational.

Enclosed in 19-inch housing, the DMP41 is suitable for calibration and adjustment of strain gauge based force, torque and pressure transducers, as well as load cells and flow sensors that are calibrated using load cells. Featuring an accuracy class of 0.005, the DMP41 guarantees maximum precision, even in the toughest of conditions, such as industrial environments with high EMC requirements.

Commenting on the achievement, AUMA UK Managing Director Paul Hopkins said:

For further information, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at http://www.hbm.com/en/

Considerable savings for Flowplant thanks to Invend™ Flowplant’s operators required a system that provided them with a clear understanding of where stock is and how it can be retrieved. Following research into an internal solution, Flowplant contacted Brammer after reading its whitepaper on industrial vending which highlighted the potential savings of between 25 and 40 per cent on consumables. Brammer’s Invend™ allowed Flowplant to benefit from an industrial vending machine service without the upfront cost of having to purchase the machine. Brammer installed the Invend™ machine into Flowplant’s factory, giving site managers a complete oversight of what is being used, by who and how often.

“The ability to renovate a 22 year old actuator is testament to the modular design and high quality construction of the AUMA product. The simple single plug and socket arrangement of the AUMA actuator means minimum downtime during actuator replacement and avoids any possibility of introducing field wiring errors.”

Tel: +44 (0) 1275 871141

www.auma.com

William Hughes boosts component cleaning business with acquisition of AC Services World-leading spring, wire form and assembly specialist, William Hughes Ltd, has purchased AC Services (South West) Ltd of Yeovil, to enhance the component cleaning side of its business. This strategic market move, which will see AC Services’ Managing Director, Albert Curtis, take an integral role in the new business, will be a real boon to manufacturers in sectors such as aerospace, defence, nuclear, oil and gas, medical and electronics that are seeking precision cleaning processes for parts and assemblies. William Hughes is nearing the completion of a new ISO Class 7 cleanroom at its 87,000 ft² headquarters in Stalbridge, Dorset, which will house the cleaning equipment. AC Services has over 30 years’ experience in ultrasonic cleaning, kitting, degreasing and hose cleaning services. The business has established an industry-wide reputation for excellence in the cleaning of parts and assemblies for use in many critical applications, with all processes performed in a high specification cleanroom. The cleaning operation of AC Services will now transfer the short distance east to the Stalbridge site of William Hughes.

For further information, visit www.brammer.co.uk/invend

Email: sales@wmhughes.co.uk

Top technical translation company helps exporters conquer global markets

‘LOCATOR’ – Cellular base station location devices to aid 2G, 3G and 4G wireless modem installation

ALM Translations is now rebranding to reflect its consistent growth in the translation sector, offering companies a streamlined way of finding out about the benefits of translation services. Their new brand is also a reflection of our philosophy and the new website is bold, but professional, inspires trust and is user-friendly. Professional translation doesn’t have to cost the earth either. The latest translation technology can ensure cost savings without compromising on quality.

www.wmhughes.co.uk

LOCATOR, supplied by METMOTEC, is a range of easy to use, battery powered, hand-held units that survey and identify signals from all cellular network base stations available at a local site and measure the signal strength of stations available. The units display the names of network providers. Operation enables identification of a suitable network and discovery of a viable antenna position, thus assisting in the rapid and reliable installation of wireless modems and routers.

ALM Translations is exhibiting at Explore Export at the Vox in Birmingham on 12th November where they will be showing off their brand new image.

The information display can be presented in English, Spanish, French, Italian, Dutch and German. All LOCATOR models have a detachable quad-band stubantenna that can be replaced with the antenna used with a modem for more accurate gauging of performance.

www.almtranslations.com

Email: metmotec@metmotec.com

www.metmotec.com

Issue 17 PECM

Maintenance is virtually eliminated due to the dual-wall, high-density plastic body.

Portable Fans from VAF Air controlling odours and dust in confined work spaces W

Where fumes, smells or dust occur, the VAF Air portable vane axial fans can move contaminated air out of a building or confined space. Effective as a fume exhauster, the VAF Air blowers can also ventilate confined spaces, and increase the flow of fresh air into a building or work space to improve the working environment.

here fumes, smells or dust occur, the VAF Air portable vane axial fans can move contaminated air out of a building or confined space. Effective as a fume exhauster, the VAF Air blowers can also ventilate confined spaces, and increase the flow of fresh air into a building or work space to improve the working environment. The electrically or air driven fans weigh up to 40% less than conventional metal skinned fans of comparable size, and in terms of movement from site to site and indeed on site, this is a huge advantage. Especially when you consider that back problems are still the biggest cause of lost man work days. Maintenance is virtually eliminated due to the dual-wall, high-density plastic body. The polythene casing is resistant to the normal knocks and bangs of everyday use that can stop a sheet metal fan as metal fans often dent which can obstruct the fan blade. The Miniveyor Air units easily withstand blows without denting, giving less downtime and greater productivity. The casing is corrosion free and unlike its metal counterparts will not rust when they are dented, chipped or scratched. They simply last longer and offer greater value for money and because of that come with an industry beating 10 year warranty on the body. The VAF series range has recently been extended with the introduction of the VAF-200C Canister blower. The compact VAF-200C is ideal for confined space ventilation and fume extraction and benefits from a, simple to attach, Duct Canister that neatly clips onto the fan body and houses 7.5 metres of flexible duct. It is great for contractors that have limited storage space in service vehicles and can be carried to the job site with ease. Visit us online at www.vaf-air.com

Boilers & Maintenance

Gas Process Burners Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions. FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple high/low control options Heat Input Range: 9 kW – 880 kW

• • • •

FD-C high turndown oven/ dryer air heating burners.

FD-E low cost high turndown

oven/dryer air heating burners.

FD-C (GA) modulating gas + air process air heating burners.

TX/TRX Series Gas Fired Process Tank Heating Systems High efficiency (80%+) heating of all types of spray and dip process tanks Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space Accurate performance modelling using Lanemark TxCalc design software Heat Input Range: 15 kW (1½") – 730 kW (6")

• • • •

Midco DB Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers. Supplied either as Midco burner heads for OEM system integration or as complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software

• • •

Midco HMA high efficiency,

high turndown, air replacement or “make-up” air heating burners.

TX high efficiency small diameter immersion tube tank heating systems.

Lanemark Combustion Engineering Limited Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com

•

COMBUSTION ENGINEERING

Cables

Issue 17 PECM

Cables

Is HAVS causing you issues? The Vexo Hand-Arm Vibration Meter

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MABAC miniature D38999 connectors from Aerco provide same data performance with 50% savings in size and weight

ow in stock at Aerco is the AB Connector range of MABAC miniature D38999 connectors that provide D38999 Series III performance in a smaller, lighter package making them ideal for aviation and medical equipment, industrial applications and wearable equipment for military personnel. These new connectors make it possible to transmit at least as much data as MIL-DTL38999 Series III connectors with size and weight savings of up to 50%. Available in bayonet, threaded and push-pull versions the MABAC range provides MIL-DTL-38999 Series III capability in shell size 3, the smallest connector available. Easy to wire and handle and with an integrated backshell that accommodates a heat shrink boot and braid retention band, the MABAC series is also compliant with over-moulding. Available in three shells sizes of 3, 5, 7 and retaining the 100% scoop proof and EMI shielding properties of the original D38999 Series III connectors, MABAC connectors have a high grade thermoplastic insert, silicone elastomer grommet and sealing and operating temperature range from 55Â° to 175Â°C. The threaded versions have a triple-start thread and threaded coupling system that provides between 1/2 and 3/4 turn to mate. A ratchet system is provided on shell sizes 5 and 7.

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PECM Issue 17

For more information on Aerco products please visit: www.aerco.co.uk

Implementing a calibration system?

Our calibration and IT expertise helps you face calibration process improvement projects that are typically complex and consume a lot of time and resources. Only 20% to 30% of a calibration system upgrade is tools and technology, the rest is business culture and process. Therefore, the success of a new calibration system depends especially on the implementation of the system and the ability to define and adopt a new calibration process. We are the experts in both technology and implementation, so you can focus on the opportunities, while we support and guide you in the evolution of your calibration system and successful implementation of the calibration process change. Learn more at: beamex.com/CalibrationProcessImprovements

www.beamex.com info@beamex.com

Why Going Above And Beyond Is The Only Way To Improve Energy Efficiency

he Energy Savings

implicate production data, as a view of

Opportunity Scheme (ESOS)

energy data alone won't provide the

was first introduced to

information that is necessary for efficient

the UK in 2014 as a way

energy management. Here Martyn

of implementing the European Energy

Williams, managing director of COPA-DATA

Efficiency Directive. One year later,

UK, discusses the importance of acting on

the first official project deadline is fast

your energy audit recommendations.

approaching. Whilst getting your first energy audit signed off may be all you're

ESOS introduces a programme of regular

thinking about right now, it's important to

energy audits for 'large enterprises'. This

remember that the audit alone won't save

means they employ at least 250 people

you money.

or have an annual turnover in excess of ÂŁ38,937,777 (or â&#x201A;Ź50 million).

It is taking the initiative to implement more efficient processes and equipment

December 5, 2015 is the official deadline

that can make your facilities more energy

for submitting your first energy audit. The

efficient and save you a considerable

audit considers the energy used by your

amount of money. It is essential to

production line, office facilities and means of transport.

PECM Issue 17

Completing an energy audit If you qualify for ESOS and are yet to work towards your energy audit, you first need to appoint a lead assessor. An assessor will carry out and oversee your energy audits and overall ESOS assessment. A lead assessor can be one of your employees, but he or she must be a member of an approved professional body such as the Association of Energy Engineers or The Energy Managers Association. Alternatively, professional bodies are able to outsource assessors to businesses who are in need of one. After completion you should submit your ESOS notification of compliance to the Environment Agency. This needs to happen before December 5, 2015 and should be repeated every four years. You also need to keep a record of your compliance with ESOS in the form of an evidence pack. There is no set format for this, so your assessor can tailor it to suit your business.

Energy data management systems

What next?

Anyone from the CEO to the machine operator

One way of making sure your ESOS

should be able to

You may have avoided a hefty fine by completing your

energy pack is up to date is to use an

access the data that

energy audit, but the possibilities to save money don’t

Energy Data Management System (EDMS).

an EDMS collects at

end there. If you want to go beyond compliance, you can

To truly make significant reductions

any time, and as the

implement ISO 50001. The standard is applicable regardless

in energy consumption, companies

company grows this

of the size of the company and industry it operates in.

should implement an EDMS that allows

becomes even more

the use of relevant measurement data

important.

across the array of your processes and

The International Standard Organisation (ISO) estimated ISO 50001 could influence up to 60 per cent of the world’s energy

sites. A good EDMS should be able to

Another important

use. The core principle of ISO 50001 is its ‘Plan-Do-Check-Act’

collect and process data from the entire

feature is flexibility

(PDCA) continual improvement framework.

equipment infrastructure of a production

when it comes to the

line. This means it should be compatible

reporting function of

with all the major communication

an EDMS. The ability to

The standard requires companies to develop a policy for more efficient energy use and fix targets and objectives to meet the policy. This includes the

protocols, covering all the important

generate reports based

standards, right up to individual drivers

on both historical data and

used in a specific application. Users

real time data according to the

can then request targeted queries from

user’s needs is crucial. Displaying

any sensor, meter, measuring device

information such as energy

or machinery. Additionally, due to its

performance indicators, trend curves,

hardware independence and impressive

alarms, cost distribution or load duration

connectivity, integrating a good EDMS

curves in a clear way carries a lot of weight.

implementation of all types of technology from energy efficient light bulbs to smart meters and sensors.

into existing infrastructures should occur smoothly, without any disruption.

If you're treating the Energy Savings Opportunity Scheme as a requirement,

Secondly, an EDMS must be scalable.

don't expect to save money or improve

As the company grows, the system

your energy efficiency. ESOS should be a

should allow the seamless integration

continuous process similar to that used in

of new devices or machines. It should

the ISO 50001 standard. This will guarantee

also facilitate the simple creation of

better energy efficiency in the workplace

new reports, data visualisation and

and will put your mind at ease when it

straightforward addition of new users.

comes to your company’s carbon footprint. Issue 17 PECM

Cleaning

PECM Issue 17

Connectors & Fittings

Thousands of swivel options... Our custom design service makes possibilities unlimited. Super SwivelsÂŽ provides superior products for a large wide range of hydraulic applications. Designing and manufacturing heavyduty, leak free, live swivels at a competitive price with outstanding performance. These swivels are engineered for simplified connections, allowing direct connections to hose lines doing away with adapters. For nearly 30 years Super Swivels has engineered the best heavyduty and compact live swivel designs allowing manufactures to create the most efficient and smallest products possible. Superior design and reliability features allows for the most efficient aftermarket modifications and repairs.

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Issue 17 PECM

New Busbar System Rittal Ri4Power 185mm for Safe and Quick Switchgear Protecting people who work with electrical switchgear is clearly of paramount importance. Their guaranteed safety can often only be achieved through the use of tested and standardised products and equipment. But switchgear components must also be tailored to individual needs and be simple and quick to make and assemble. Rittal addresses all these considerations within its busbar system “Ri4Power 185mm” and its new (Version 6.3) of the Rittal Power Engineering software.

nergy distribution in industrial plants and buildings often depends on the subsequent use of the power supply, which means distribution is typically individually configured within different outlet circuits although users can still expand or convert their energy supplies at a later date if required. It goes without saying that energy distribution must always be safe and comply with the statutory requirements, all of which is integral to the new “Ri4Power 185mm” busbar system. This clever modular system consists of standardised and tested products

which all meet the requirements of IEC 61 439 for low-voltage switchgear assemblies with design verification.

Its smart design is a notable strong point. It is easy to assemble with a modular configuration and ideally adapted to the Rittal TS 8 bayed enclosure. Its smart design is a notable strong point. It is easy to assemble with a modular configuration and ideally

adapted to the Rittal TS 8 bayed enclosure. In addition, the contact hazard protection of the busbar system, which protects the user from touching electrically live parts, is mounted before the switching and protective devices are attached. This uses standardised products, meaning individual and laborious preparation of cover plates is no longer necessary – helping to save both the installer and user both time and money. Configuring moulded-case circuitbreakers with adaptors or NH fusedswitch disconnectors is simple; the devices are used in the frame of the cover and they contact the busbars through the cover. Subsequent retrofitting or extension is also possible

Enclosures from the smallest to the largest. ENCLOSURES

POWER DISTRIBUTION

CLIMATE CONTROL

without having to adjust the contact hazard protection later on. To help support both planning and configuration, Rittal Power Engineering has been extended to include another program module for the â&#x20AC;&#x153;Ri4Power 185mmâ&#x20AC;? within its

IT INFRASTRUCTURE

latest version (6.3). The enclosure panels are selected according to user requirements and fitted out as required. The parts lists and drawings are automatically generated in the background, allowing a clear picture of the final construction as early as at the quotation phase. After the configuration

phase is complete, the necessary design verification can be automatically generated for each switchgear unit. Further information about Rittal can be found at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter@rittal_ltd.

SOFTWARE & SERVICES www.rittal.co.uk

Control & Automation

Maximum Safety Minimum Cost In order to achieve the maximum safety performance level PLe, a category 3 or 4 architecture must be used.

hat this means for a servo system is that a second method for measuring speed is required, this is usually achieved by fitting an additional separate encoder or resolver to the axis increasing the costs and complicity to the system and set up process. Due to its onboard safety card the PMC Protego DS from Pilz is able to measure the motor current to determine its speed, this, combined with the feedback signal provided by any servo motor constitutes a category 4 architecture. This means that using the PMC Protego DS drive and any servo motor it is possible to achieve PLe without any additional equipment.

The PMC Protego DS also has the following Safe Motion Functions included as standard: Safe Torque off, Safe Stop 1, Safe Stop 2, Safe Operating Stop, Safe Limited Speed, Safe Speed Range, Safe Direction, Safe Limited Increment, with Safe Braking functions and Safe Limited Position available as additional options. With free configuration software the PMC Protego DS is straight forward to configure for motion tasks and safety features alike. Contact Ross Fenion from Pilz Automation to discuss your application further on r.fenion@pilz.co.uk

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PECM Issue 17

Pilz launch new PUWER Assessment service

Pilz Automation Technology has launched a new PUWER (Provision and Use of Work Equipment Regulations) Assessment service that aims to provide customers with an efficient yet detailed assessment of their machinery to PUWER. PUWER covers virtually all work equipment from something as basic as a hand tool to a complex production line. Jamie Walton CMSE® from Pilz Automation Technology explains, “The primary objective of PUWER is to make the work environment safe for everyone using or coming in contact with work equipment and machinery including employees, employers, suppliers, contractors and anyone else.” Pilz can inspect your machinery against PUWER and provide a comprehensive report for each item of work equipment. For any non conformance highlighted Pilz will conduct a risk evaluation as specified in the standard EN ISO 12100:2010. Our PUWER assessors can even come and present the findings and discuss any questions you may have.

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With free configuration software the PMC Protego DS is straight forward to configure for motion tasks and safety features alike.

For more information or for a quotation, visit www.pilzpuwer.co.uk, email puwer@pilz.co.uk or call 01536 460766.

Guarding without G uard ding w ithouut barriers barriiers ... PSENsgate PSENopt PS SENo opt - 2Flexible Fl-exible advanced advanced d llight ightt curtai curtains ins

The Integrated System for Safety Gate Monitoring Greater Flexibility & Integration • Large selection of control elements - key-operated push buttons, key switches, illuminated pushbuttons, section stop, emergency stop and escape release • Can be used in conjunction with PNOZmulti, PSENcode and PSENslock • Suitable for all 45mm proﬁles for universal use

Minimal Engineering & Simple Installation • Reduced installation and wiring thanks to a turnkey system with integrated control elements and optional emergency stop • One product rather than multiple single components • Simple assembly for right and left-hinged gates

Maximum Safety & Energy Efficiency • One switch per safety gate for personal and plant protection up to PL e • Reduced current consumption (gate locked max. 2 W) Pilz Automation Technology Corby NN18 8TJ 01536 460766 sales@pilz.co.uk www.pilz.co.uk

Scan the QR code to find out more about the PSENsgate 2

PHOENIX CONTACT’S new relay technology makes this compact design possible

Powerful new safety relays are just 6mm wide T

he new PSR Mini relays from Phoenix Contact are the world’s slimmest safety relays with the power of a large safety relay. With their compact 6-mm width, they ensure high safety thanks to positively driven contacts. Phoenix Contact’s new relay technology makes this compact design possible. The design is based on a slim but powerful basic relay characterized by minimal space requirements, low energy consumption, and high system availability. The safety relays can switch loads up to 6 amperes, are compatible with many signal transducers, and can be used in many different applications thanks to extensive approvals.

This makes the new products especially suitable for mechanical engineering and process industry applications. These slim modules require up to 70 percent less space. As only a single enabling contact is needed, applications can be built with new and improved cost-effectiveness. Safety relays can also be used to build distributed systems in potentially explosive areas. The terminal carriers also enable the use of system cabling solutions for a fast and correct start-up and field connection. The complete PSR Mini range of safety relays consists of 6-mm and 12-mm models.

Phoenix Contact Ltd Halesﬁeld 13, Telford, Shropshire TF7 4PG Tel: 0845 881 2222 • Fax: 0845 881 2211 www.phoenixcontact.co.uk • info@phoenixcontact.co.uk

PECM Issue 17

Nobody manufactures 6 mm safety relays. Until now.

Full SIL3 performance in potentially explosive areas

Relay Technology Designed by PHOENIX CONTACT

PSRmini relays are the most narrow SIL-certified coupling relays in the world. At widths of just 6 mm and 12 mm, they provide maximum functional safety through force-guided contacts. The highly-compact design means space savings of up to 70 %. This is possible thanks to the newly developed relay technology from Phoenix Contact. The safe coupling relays enable simple diagnostics directly at the device or controller and can be installed in Ex Zone 2. For additional information call 0845 881 2222 www.phoenixcontact.co.uk/safety

ION 04-15.001.L1

ÂŠ PHOENIX CONTACT 2015

Convenient Shopping Experience

Shopping for Automation technology Online Shopping in the field of automation technology on the Internet is also on the rise. Among the growing number of providers, Automation24 takes a special position. The purely online-shop combines the user-friendliness of established B2C-platforms along with a comprehensive range of technical support services and very attractive discount prices. By Stefan von der Bey, Managing Director of Automation24 he number of mobile devices is growing steadily. And those who have come to appreciate the benefits of the Internet as a consumer, do not want to miss out on them as a commercial purchaser. Thus, online-shopping is establishing itself increasingly in the automation sector as an alternative procurement avenue for buyers. There are currently very few appropriate providers. Automation24 has taken on a pioneering role in this regard. The first purely online shop for automation technology geared specifically to the user practices of the consumer sector. In addition, the website offers a comprehensive technical advisory service. Products are dispensed safely and effectively without a field sales team, because the portfolio is focused on brand name products which require little explanation. The cost advantage that this sleek business model brings with it is therefore passed directly to the customer.

Quickly Searched, Quickly Found Automation24 sought advice from

renowned experts specifically from the B2C sector in building their website. The result is a modern shop-design, which makes simple, intuitive navigation possible. Through the clear product categorization the desired product group is found quickly. To make things even easier you can explore via the highly visible search function at the top of the page. In both cases, the user arrives at a filter option, with which they can investigate the product group according to areas of application, manufacturers, prices and technical specifications. A special service available is the Product Comparison: Related Searches can be provided with a check mark with respect to, for example, their commonalities and differences. In this way it is made clear which product is most likely the required one. Extensive Information Available When the desired product is located via the filter function, the customer is then provided with extensive information. In addition to manuals and data sheets, the approvals/conformities and CAD data can be downloaded directly

Automation24 A detailed search function with feature filters facilitates the product search

PECM Issue 17

from each product page. Additionally, references are made to the suitable accessories for the respective product.

Even the product pictures are advanced quality. Even the product pictures are advanced quality. There are high-quality zoom images from different angles which truly convey a realistic impression for each product. For example, even the connections can be seen clearly. With many items a 360Â°-3D display is added. Thus, on every monitor the selected product is displayed close enough to touch, and can be freely rotated with a mouse click or viewed from any angle. In this way, the best possible product experience is ensured without the interested party requiring the product to actually be in their hand. They only need a pair of 3D glasses that can be requested free of charge on the website. Chat and Hotline for Questions If questions remain despite the diverse range of information available, these can be clarified with our knowledgeable service staff. For this we find the chat bar near the bottom right of the page. By clicking on it, a window opens in which the user can enter a question. They are then in direct written communication with a competent partner. More complex questions may be resolved with the help of the free telephone hotline, which is open Monday to Friday 8.00 to 16.00 oâ&#x20AC;&#x2122;clock. If by attempting to use these options at a time that no staff should be immediately available, the user can leave their information in the chat window, or by using the contact form on the website. The call-back is initiated as soon as possible.

customer is also in terms of technical support on the safe side. At the same time benefiting from favourable prices that start from “item quantity #1”, without surcharge for small quantities and an average of 30 percent below RRP. Payment can be made by invoice as usual. Likewise, a payment via PayPal or credit card is possible. Delivery is normally made within 48 hours, and as a result of the compact product portfolio, high availability is always ensured. So there are good arguments to secure online shopping as an alternative procurement channel for consideration.

Automation24 In the onlineshop, automation professionals will find a wide range of technical support data and services such as live chat and a real-time product availability displayed

Complete Package - from Sensor to the Control Cabinet The complete range of automation technology includes over 2,200 brand name products in the fields of position sensors, process sensors, control systems, HMI, drive technology, power supplies, control and signalling devices, industrial luminaires, industrial Ethernet, regulation technology, industrial controls, enclosures as well as connection and protection technology. “We are constantly working on optimizing our online

shop and our services,” explains Stefan von der Bey. “In addition to the expansion of our existing product ranges, we will extend our range to include industrial networking solutions with products such as AS-Interface. Variable frequency drives, as well as pneumatics are also being planned.” Online Shopping as a Worthwhile Alternative An online store like Automation24 therefore provides not only a convenient shopping experience. The

Automation24 Phone: 00800 24 2011 24 (free of charge) info@automation24.co.uk www.automation24.co.uk FREE UK Shipping (from GBP 20 NET) Delivering daily across the UK! Issue 17 PECM

Lean Manufacturing has become one of those catch phrases that everyone understands and can immediately see the logic of, but evidence of consistently good results is hard to find.

‘Lean’ in Action within Food and Drink Manufacturing hilst the drive for eﬃciency improvements, within engineering sectors has been relentless there is still a long way to go within the UK food and drink manufacturing sector, yet this is one of the most vulnerable of all manufacturing sectors. This is broadly due to the intense competition between UK supermarkets, jostling for market share, whilst simultaneously demanding higher quality, total compliance, special oﬀers, shorter batch runs and willing to accept few, if any, price increases from their ownlabel manufacturer/suppliers.

Contrast this with the fact that those same suppliers face ongoing demands for higher raw material and energy costs together with increased labour costs, and it is easy to see that any manufacturers, not fully committed to continuous improvement, are likely to struggle in the years ahead within such competitive environments. Lean Manufacturing has become one of those catch phrases that everyone understands and can immediately see the logic of, but evidence of consistently good results is hard to ﬁnd. One reason for this is that, whilst the joint pressures of static sales prices and rising conversion costs are

PECM Issue 17

here now, some companies seem to imagine that continuous improvement or ‘Lean’ is something they can put off until next month/year/the year after. So many are too busy firefighting in order to get through today, to give appropriate thought to continuous improvement. Yet, most can see that, through continuous improvement, much of the need for firefighting will be systematically reduced. Most companies have already carried out their Value Stream Map to determine where they are adding value, where they are adding cost and perhaps have ideas about where they could reduce costs and add value, but this process needs to be constantly reviewed to ensure that gains made are sustained, whilst further improvements are made. In this regard, everything should be questioned, again and again, in pursuit of optimisation on the Lean journey. In addition, all mistakes and non-conformances that tie up so much time and cost in firefighting should be fully investigated so as to effectively eliminate the same problems recurring in future. So why do so many fires break out in the first place?

Our own experience, over nearly four decades, tells us that all factory floor conversion problems (why things don’t always turn out as intended) have their roots in just three things: • Loss of awareness (brief lapses of concentration) • Breaking the Rules (taking short cuts which actually turn out to be anything but) • Errors of Judgement (taking an educated guess instead of asking, or referencing SOPs) Any one of these might cause a problem but a combination could spell disaster, resulting in costly rework, scrap or batch rejection and loss of confidence. So, if these issues are the biggest enemies of Lean, how can they be avoided? So much of Food and Drink manufacturing control is still paper based and it’s easy to see how this has evolved. Paper is cheap and can be deployed anywhere within the supply chain, promptly and easily. Reliance upon paper recording however is fraught with limitations. Firstly it imposes little or no operational discipline and consequently little confidence that recorded tests were

actually carried out at all, were carried out at the recorded times or that the recorded results were the actual results seen/measured. Secondly, even in a moderately sized manufacturing operation 100s or even 1000s of sheets of paper, containing many thousands of test results, can be created every week so, even if the recorded data can be completely relied upon, it is just too time consuming to analyse and prioritise into improvement actions. Where such analysis and prioritisation is attempted, the analysis is available too late to be

Critics might argue that electronic recording of tests can take as long as paper recording, but this is to miss the point. The improvements in operational discipline alone are incomparable with paper recording, but the importance of automatic analysis of test results, prioritisation and distribution to those who can make best use of the information, cannot be overstated. One specialist malt whisky bottler started this journey with us 6 years ago, when their net annual profit was

of value within a fast moving factory operation. Key to resolving many of these problems is to move away from paper recording, to automate testing and production line set up wherever possible (minimising operator error) and arrange off-line testing through operator friendly devices such as touch screen industrial computers, computer tablets, etc. Computerisation just to minimise paper, however, is not nearly enough. The selected computerisation must

£2 million. By the end of 2014 this annual nett profit had risen to £14 million on the same turnover, and they are not finished yet. This is just one example of the true power of electronic, real time information to a company committed to the lasting benefits of lean manufacturing. It would be unfair to give the impression that such radical improvements can be achieved simply through the installation of even the best factory floor computer system. They can’t. Getting the team on board

address the key issues in order to maintain and even heighten cross functional awareness, enforce high levels of operational discipline and accountability and make necessary actions clear and concise to minimise errors of judgement. Making operational issues and improvement opportunities Headline News in real time, across the company Intranet and on large factory screens, ensures that the whole operational team are simultaneously informed about current production status.

from the outset through communication of objectives, training, coaching and sharing in the successes achieved is absolutely crucial to successful outcomes. Great automated systems alone cannot achieve and sustain “Lean” objectives, the people are the essential ingredient that makes the difference between success and failure all the way from the top floor to the shop floor. Roy Green, Harford Control Ltd, August 2015 Issue 17 PECM

On-Line Vision as an Integrated Part of Factory Floor Information Management at Dairy Crest

achine Vision has come a long way during the last couple of decades and its use within food and drink manufacturing industries is now becoming commonplace. One such application which went especially well for the Harford team, because it was the only valid option to solve a complex set of problems, was the installation of vision on the spread packing lines at Dairy Crest in Kirkby, Liverpool. The following account from Mark Lanfear, Technical Manager at Dairy Crest, Kirkby, highlights some of the benefits of sustaining the highest quality standards through machine vision and integrated information management. Case Study: Harford’s Integrated Vision System Helps Dairy Crest Sustain the Highest Standards “Our Harford Control vision system offers us Quality Assurance on packaging and allows operators to focus on other areas of production knowing it is under control. As suppliers to multiple supermarkets it is not unusual for us to have several promotions in process at various times, for many different outlets, which are often running competing promotions. Because of this we often run similar

PECM Issue 17

packaging from stores through production for different supermarkets. Any mistakes in this could damage our customer relationships and even cost us future sales. We also have strict legal requirements on packaging which were amended in 2015 due to FIR Regs. This was pushed through our production comfortably and safely, knowing we had a vision system to ensure we could phase out the old packaging appropriately, minimising waste and downtime by using the vision system to drive change and minimise exposure to risk. However, our Harford vision system doesn’t just ensure legal and commercial parameters are met, but forms an integrated part of our factory floor information management system which, in addition to the security provided by its on-line vision modules, also sets up our date coders, minimises paper recording, analyses line performance such as OEE and materials utilisation whilst maintaining compliance with Average Quantity Law. We rely on the vision system heavily for our packed product quality. Introducing a lid to tub has complications with fit, packaging quality, date print and clean packaging (no spread on tubs). Our Harford Vision System allows us to pick up on

Our Harford Control vision system offers us Quality Assurance on packaging and allows operators to focus on other areas of production knowing it is under control.

these defects, clear the line, check for future faults, archive the images for Team Leaders to view, be satisfied with how any issues have been handled on the line and also helps to determine root cause to facilitate continuous improvement. All this shows our due diligence in supporting our customers’

We rely on the vision system heavily for our packed product quality. needs and helps ensure we meet these high quality demands, for Leading Brands, every time. We also use the system as a training aid, printing off some failed images to check that operators know what to look for when they are running the line and also the appropriate corrective actions to take in all circumstances, thereby highlighting our overriding commitment to quality, whilst continuously improving our operators’ knowledge surrounding our high standards.” For further information contact Harford Control on +44(0)1225 764461 or sales@harfordcontrol.com

GUARANTEED PERFORMANCE IMPROVEMENT through a SINGLE INTEGRATED SOLUTION The Harford END to END Manufacturing Execution Solution Automated line efficiency & OEE Automated coding & labelling verification to meet retailersâ&#x20AC;&#x2122; codes of practice On-Line Vision for Component Matching, OCR and other options Optimised Average Quantity Law Real time paperless quality Integrated production performance improvement Roving quality audits, H&S checks,engineer line attendance, HACCP

Tel: +44(0)1225 764461 Email: sales@harfordcontrol.com www.harfordcontrol.com

Automated Short Interval Control on factory monitors

If you missed us at PPMA, call us today for your FREE site audit

Lipp GmbH

Offers Uk Water Utilities New Totex Compliant Tank Solutions ipp GmbH has developed cost effective tank refurbishment solutions that extend the operating life of old bolted section, concrete and steel tanks. The new liner installation effectively extends the operating life of the tank without needing the capital expense and downtime requirements of demolition and re-build, while also reducing ongoing operational costs.

As the impact and consequences of the new Totex economic model - an aggregated examination of both capital and operational expenditure - to the UK Water Utility are becoming more fully understood, it is recognised that new approaches will be required to meet the newly combined Capital and Operational expenditure considerations. Martin Grant, the Lipp UK Marketing Manager said, “We recognise that the new changes in the UK Water Utility market require new solutions. We have developed and installed cost effective tank lining solutions for the German market over a number of years. The Lipp spiral tank system has proven highly effective for increasing the operational life and capacity of older tanks, without the need for time consuming and expensive demolition and rebuild.” The refurbishment liner is constructed on site and the new liner or extension piece is lifted in by mobile crane and subsequently secured and sealed in place. The liners can be constructed from a variety of steel and stainless steel composites to suit different storage media requirements. This means tanks can also be upgraded and extended to increase storage. During assembly work, the respective container can be retrofitted with extensive accessories, such as container

PECM Issue 17

roof, floor, pumping and stirring, stairs, platforms, etc. Openings or penetrations of any size and shape pose no problems. The approach that Lipp has taken is further corroborated by a new report from Frost & Sullivan, which states that water utilities have identified the TOTEX mechanism as a means to help in the decision making process of rehabilitation projects; saying that European water utilities are faced with the challenge of aging infrastructure in need of urgent rehabilitation. The tank rehabilitation solution offered by Lipp provides a strong long-term economic solution. Lipp’s tanks have been in operation in Germany since 1972, with many tanks giving continuous service for 40 years or more. This 40 year timeframe is one that is being considered by the Water Utilities as the new operational benchmark for TOTEX calculations – a consideration that is new to the UK market. Martin Grant, also commented, “Given the extensive experience that Lipp have in the European Water Utility market, we are confident that many of the water market solutions we offer, such as the tank refurbishment system, will provide proven, cost effective, solutions for the UK Water Utilities as well.” Lipp supplies tank solutions for the anaerobic digestion, waste water, potable water & industrial processing industries. Providing anaerobic digestion tanks, gas accumulator tanks, storage tanks, pressure vessels & silos employing the Lipp System (engineered in Germany) with its unique dualseam tank technology. Lipp in Germany has over 40 years of development & innovations, and over 50,000 tanks installed worldwide.

www.lipp-uk.com

Control & Automation

Most Advanced Autotuning Tool Available in a Commercial Motion Controller EasyTune™ is the most advanced autotuning tool available in a commercial motion controller. Entirely data-driven, the algorithm largely mimics the process followed by an experienced controls engineer. Many existing tuning techniques rely on basic model-fitting or “rules-of-thumb” that ignore machine resonances or nonlinear behavior, but EasyTune™ directly measures and compensates for those effects. It assumes no prior knowledge of the system properties, and begins with a system identification operation. It continues with the development of a baseline stabilizing controller followed by progressively more sophisticated compensation via loop-shaping procedures. The final controller has the highest bandwidth practical for that particular stage system. EasyTune™ was extensively tested and refined on hundreds of different motion systems, including on systems with different bearing styles, drive technologies, and mechanical configurations. It requires no input from the user, completes in a few minutes, and provides measured verification of the servo performance when complete. EasyTune™ is a standard feature

of Aerotech’s A3200, Ensemble, and Soloist motion controls. For further information, please contact Steve McLane at 412-967-6854 (direct), or via e-mail at smclane@aerotech.com.

Issue 17 PECM

New TC Model t 500 - 2000kg/hr t Touch control screen t Full modulation feature 50-100% firing t Natural Gas, Light Oil, LPG and Bio Fuel t Automatic facility option t PM5 Facility option t Pressure range up to 32 barG t >98% Efficiency * t Remote compatible with Profibus/ CANbus etc. t Steam in 3 minutes t Compact construction t Lightweight t Suitable for mezzanine floors t Factory tested prior to dispatch to site t NOx Gas reduction option t Dual fuel option

SC Range t 80 - 2000kg/hr t Natural Gas, Light Oil, LPG and Bio Fuel t Automatic facility option t PM5 Facility option t Pressure range up to 32 barG t >98% Efficiency * t Steam in 3 minutes t Compact construction t Lightweight t Suitable for mezzanine floors t Factory tested prior to dispatch to site t NOx Gas reduction option

Electrical Range t Compact t 8 - 160kg/hr Steam output t Modulating ouput t Skid mountable t Steam in 3 minutes t Automatic facility option

CERTUSS (UK) Limited Unit 45 Gravelly Industrial Park Tyburn Road Birmingham B24 8TG

Tel: 0121 327 5362 Fax: 0121 328 2934 sales@certuss.co.uk www.certuss.co.uk

Duty Standby with CVE Package Plant

CVE Package Plant t compact t Pre-pied, Pre-Wired t Skid mounted t Fully factory tested t Lightweight t Easily maintained

Containerised Plant t Easily relocated t Self contained plant room t Full lighting and heating t Fast site connection

Laser Perforation Revolutionising Intelligent Packaging aser microperforation is revolutionising the food packaging industry, driving forward the advancement of intelligent packaging solutions. From extending the shelf life of fresh produce, to making it possible to microwave a pre-prepared roast dinner in minutes, these microscopic holes are quite miraculous. Here, Steve Hughes, managing director of REO UK, takes a look at how laser microperforation is evolving food packaging and why maintaining accuracy is vital to success.

When it comes to designing food packaging there is more to take into account than the point of sale (POS) appeal. Consumers are becoming increasingly savvy and they want more value for their money than produce that is going off before it’s even made it from car boot to refrigerator. In addition, calls to put an end to food waste are becoming a common sight in international headlines, and packaging that extends the life of produce will go a long way to answer this call. Waste not, want not According to the United Nations Environment Programme (UNEP), around one third of food produced globally for human consumption each year is wasted. That’s about 1.3 billion tonnes. In the United States alone, 30 per cent of all food is thrown away every year. Well designed intelligent packaging can not only help consumers in choosing the right amount of food for their needs, it will also keep it in the best possible condition for longer. This has led to a wave of research and development that has contributed to the increasing use of laser perforation technology in a variety of applications. Breathability In 2013, The Co-operative group of supermarkets in the United Kingdom started using computer-guided laser-cut modified moisture packaging (MMP) for its packaged tomatoes. The small hole perforation technology extended the shelf life of the fruit (yes, tomatoes are a fruit!) by two days. This is because the precise holes in the packaging allowed the tomatoes to continue to respire, i.e. draw oxygen in and release carbon dioxide. Without the right balance of perforation, the packaged tomatoes would either become too dry or would decay and develop mould.

PECM Issue 17

ASDA addressed the same problem with its Extra Special Cornish Crystal Potatoes by working with Ultimate Packaging to develop packaging that employs laser perforation patterns to optimise gas transmission through the film. As a result, ASDA reported a 92 per cent year on year reduction in customer complaints. Revolutionising dinner time The accuracy of laser microperforation is also driving evolution in the preparation of fast-cook oven and microwave meals. For example, Dutch food manufacturer Qizini has been exploring revolutionary variable heat steaming methods in its packaging. While the low density polyethylene (LDPE) material of the film lid plays a role in the effectiveness of this particular packaging, it’s the minute and exact perforations over the two individual compartments that are the key to success. The ready meals are packaged with vegetables in one compartment and meat in another and the distribution of three sets of microperforations, combined with small LDPE pressure sensitive labels, allows for both to cook properly in the same amount of time. As laser perforation is so precise, the intensity of steam and pressure in each compartment can be controlled so that the protein compartment is cooked thoroughly in the same amount of time it takes for the vegetables to be cooked. Accuracy Perforation in food packaging isn’t something that’s necessarily considered new, but for a long time it has been a one size fits all solution. However, laser perforation means that now things can be optimised for individual requirements with great ease. Such is the appeal of bespoke perforation solutions that food packaging companies are investing heavily in laser perforation technology. For instance, in 2014 Clondalkin Flexible Packaging invested £400,000 on new machinery, including a laser perforator to enhance the quality of perforations in its pre-cut lids that are

regularly used on multipack products such as yoghurts. When spending heavily on new equipment, to benefit from its accuracy levels, it’s important to ensure you’re set up to keep those levels as high as possible. Despite the use of new generation laser technology, many applications are still using conventional power supplies that are not suited for the high frequency, highly capacitive load placed on the power supply. This causes power quality problems including voltage fluctuations, unwanted tripping and dips in output voltage, which leads to a drop in laser power resulting in poor process performance. The aim of the game is to consistently achieve very small, well defined, uniformly spaced holes. Disruptions to power quality will have a detrimental effect on this goal. That’s why we've designed the REOTRON SMP to specifically overcome these problems by creating special control algorithms for use with capacitive loads. This means that you can maintain voltage and current along with a high level of accuracy. By overcoming power quality issues anyone using laser perforation is sure to continue to benefit from the capacity for faster product throughput and low reject rate. So if you are looking to get the most out of the revolutionary nature of this laser technology, it’s important to make sure you have the right infrastructure to support the accuracy it is so renowned for. www.reo.co.uk

PLC HMI ALL IN ONE

"Unitronics offers the most cost-effective answers" Rick Gallimore, Innovative Automation and Controls, Inc.

In the picture – Packaging Machine controlled by Unitronics V1210™ and SAMBA 4.3™. Bimetec BV, Netherlands.

3.5"

4.3"

Unitronics is a pioneer in the manufacture and design of PLCs with integrated HMI and on-board I/Os - rugged PLC product lines that meet a diverse range of requirements. You program your entire application in a single, intuitive software environment, and benefit from premier technical support, both provided at no extra cost.

SAMBA - Unbeatable price - performance ratio CANbus (Optional)

Microcontroller with onboard I/Os 3.5", 4.3" or 7" integrated color-touch HMI Serial, Ethernet and Modbus communications Software & Support included at no extra cost!

On-Board I/Os Digital and analog RS232/RS485 programming port in 3.5” model (USB in 4.3” model) Ethernet (Optional)

Epsom 2 Keys Business Village. Keys Park Road, Hednesford, Staffordshire, WS12 2HA Tel: +44(0) 1543 271899 sales@alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.uk

Sulzer provides industry leading solutions including specialist coatings that can resist corrosion and fouling as well as precision engineering for improved performance in pumps and compressors

Sulzer Bringing Latest Pump Designs And Coating Technology To Turbomachinery & Pump Symposia 2015 his year's Turbomachinery and Pump Symposia, held in Houston, Texas, will see Sulzer showing the benefits of investing in the latest technology to deliver long term performance and reliability. Industry experts from the company will also be involved with the discussion groups where both visitors and exhibitors can learn more about a wide range of current issues.

will see this innovative solution applied to a compressor rotor assembly in the form of Sulzer's HICoat® A24 Coating. This metallic-ceramic-polymer coating has been specifically formulated to provide extended service and prevent loss of efficiency.

The symposia, which run from September 14th – 17th at the George R. Brown Convention Center, represent an excellent opportunity for all those involved with rotating equipment to meet with industry leaders and discuss both current and future issues. Sulzer brings its worldwide engineering experience to share with visitors to the symposia on Booth No. 1609.

Pumps Equipment has developed a single stage, radially split pump that offers the broadest performance range in the industry. Designed for heavy-duty applications in refineries, petro-chemical plants, gas processing and offshore oil production, the overhung, horizontal, centerline mounted pump is ideal for highhead applications. In addition, the low flow variant of the pump uses a unique low-flow impeller diffuser design that provides gap-free coverage for improved performance.

Sulzer provides industry leading solutions including specialist coatings that can resist corrosion and fouling, delivering improved performance in pumps and compressors. On this year's booth, visitors

Ron Adams, Global Portfolio Manager – Petroleum for Sulzer, is a member of the Pump Advisory Committee and will take part in Discussion Group 01: Monitoring Vibration and Other Critical Machine

PECM Issue 17

Conditions on Tuesday 15th as well as Discussion Group P11/Panel Session: Subsea Pumps and Drivers on Wednesday 16th. In addition, Bob Davis, Advanced Engineering Manager at Sulzer, will be involved in Discussion Group P08: Vertical Pump Problems and Solutions on Tuesday 15th. TPS continues to provide outstanding value for both exhibitors and visitors because it is organized and managed by recognized leaders within the oil & gas, petrochemical and power generation communities. As such it presents an ideal opportunity for face-to-face meetings with experts in their fields, as well as attending a large number of discussion groups led by industry experts. Sulzer welcomes everyone interested in improving the performance of their rotating equipment or looking for a professional, independent service and maintenance provider to visit the team at Booth No. 1609.

Web: www.sulzer.com Email: jennifer.cardillo@sulzer.com

PLC HMI ALL IN ONE

"Rapid programming and a terrific feature set. Unitronics delivered more capability for less money." Matthew Cronin, MSI Tec, Inc. Natural gas engine well pumps

5.7"

Flat Panel

Classic Panel

Vision570™ – advanced PLC with an integrated HMI Supports up to 1000 I/Os Options for high-speed, temperature and weight measurement Variety of communication options Software & Support included at no extra cost! Optional - 5.7” with a flat panel

SNAP I/O Module S ((optional ) D Digital, analog aand temperature

SD card

USB programming port

CANbus RS232/RS485 Ethernet I/O Expansion port

Epsom 2 Keys Business Village. Keys Park Road, Hednesford, Staffordshire, WS12 2HA Tel: +44(0) 1543 271899 sales@alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.uk

Creating strong connections stablished in 1988, ATP specialises in developing and manufacturing client-speciﬁc adhesive products. Renowned for their range of superior quality products, the company develops and produces solvent free, pressure sensitive and heat activated adhesive tapes and ﬁlms up to 2,250mm in width.

With an established, worldwide distribution network and modern manufacturing capability, ATP supplies to a variety of industry segments including automotive, transportation, foam, graphic, electronics, plastics, speciality labels, medical and building and construction. “ATP always strives to exceed customer expectations by developing customer aligned solutions which offer technical advantages competitively and quickly,” commented Segment Manager, Richard Simpson. “ATP is a very customer focussed organisation. Because we formulate and prepare all our own adhesives, we have the ability to customise solutions for our customers and can produce bespoke products which satisfy their exact requirements.” The company have developed a new innovative range of low emission adhesive tapes and films which are capable of bonding a wide variety of materials used in the production of automobile components including foamed plastics, nonwoven acoustic insulation, seals and gaskets, anti-rattle felts, electronic components and sensors, decorative trims, door panels, headliners and textile components. The target of the new development was to fulfil the widest spectrum of bonding performance whilst realising the lowest possible adhesive emissions according to VDA275, VDA 277 and VDA278. These new adhesive tapes can be supplied in rolls from 10mm up to 2,250mm or as die cut pieces, the products offer customers a wide choice of adhesive without compromising bonding performance. “We work privately with our

The target of the new development was to fulfil the widest spectrum of bonding performance whilst realising the lowest possible adhesive emissions 56

PECM Issue 17

customers to formulate solutions that are unique to them. To ensure the upmost quality of our products, the quality status and level of appropriateness are evaluated on an ongoing basis. Our continuous quality control procedures guarantee the best possible product for our customers,” explained Richard. During June 2015, ATP Adhesive Systems commissioned and opened a new factory. The overall investment of ca. 20 million euro for the site includes the construction of a production and warehousing facility with a 12,000m² floor area together with an 860m² office complex. The central focus point of the new factory is a new 70m long, state-of-the-art coating line with clean-air manufacturing will enable ATP to produce self-adhesive films to extremely tight tolerances and with exceptionally high quality optical appearance. “Our production processes are also optimised to have the lowest possible environmental impact.” The company recently achieved accreditation to ISO50001 which is an energy management system that helps the company identify and realise energy savings throughout the business. “Responsible energy resource management, plus an increasing use of renewable energy, results in a reduction of greenhouse gas emissions, which helps protect and preserve of our world for future generations,” concluded Richard. “We are extremely pleased to have gained this accreditation as well as opening our new production facility. Not only will the new factory be an asset to the company and our customers, it will also create up to 50 jobs for highly trained staff. “In regards to the future, we aim to continue expanding the company and are constantly working on improving our existing products and introducing new systems to help our customers keep up to date with the latest technology. This includes solvent free adhesive tapes with high levels of cohesion and a range of fire resistant tapes. The new production capability also affords us the opportunity to produce very thin adhesive films up to 1,800mm in width, critical in a number of electronic applications.” ATP attends many trade shows throughout the year and will be appearing at the Advanced Engineering show in Birmingham on the 4-5 November 2015 and Batimat in Paris, France on the 2-6 November 2015. Contact T +44 (0)1706 219815/+41 438881515 info@atp-ag.com www.atp-ag.com/en

ATP Adhesives Team

PLC HMI ALL IN ONE

"For a first-time user, I had a great experience. I look forward to incorporating Unitronics on future jobs." Jeremy Charles Keene, Controls Manager at General Broach Company

In the picture – Packaging Machine controlled by Unitronics V1210™ and SAMBA 4.3™. Bimetec BV, Netherlands.

12.1"

Vision1210™ Advanced PLC with an integrated HMI USB programming port

SD card

CANbus

Supports up to 1000 I/Os

SNAP I/O Module (optional ) Digital, analog and temperature

RS232/RS485 Ethernet

Options for high-speed, temperature and weight measurement Variety of communication options Software & Support included at no extra cost!

I/O Expansion port

Epsom 2 Keys Business Village. Keys Park Road, Hednesford, Staffordshire, WS12 2HA Tel: +44(0) 1543 271899 sales@alldrivesandcontrols.co.uk www.alldrivesandcontrols.co.uk

Control & Automation

Your dedicated specialist for factory automation. For the last 60 years the world’s No. 1 in factory automation has been at the forefront of innovation, continually pushing back the boundaries of automation to increase productivity and drive down costs across a whole range of industries. Boasting 99.9% reliability, a customer-centric approach, world-class service and infinite solutions for industrial robots, CNC systems and purpose-built machines for wire cut EDM, electric injection moulding and milling and drilling, we’re there to help you make the most of your automation. All you need is yellow.

www.fanuc.eu

Being a small company Wilks needed to be certain that any machinery investment would yield a return relatively quickly Scott Berry – Joint Managing Director: Wilks is a 25 strong, family run, manufacturing company specialising in the supply of PVC profiles globally to the Marine and Shop fitting industries. With a senior tool maker due for retirement later this year it seemed the ideal time to investigate ways in which we might improve our tool making process compared to our traditional use of turret milling machines.

anuc had come highly recommended to us and following a meeting with Andy Spence to discuss our requirement we immediately felt that we had found a long term partner for our tool room rather than simply making a oneoff machinery purchase. Being a small company we needed to be certain that any machinery investment would yield a return relatively quickly and would not create a bottleneck in tooling schedules whilst new skills were developed. Our minimal CNC and CAD experience was of initial concern to us but with the Fanuc’s reassurance, demonstrations and ultimately a training course at their UK Headquarters we felt enthused and confident in both our own ability to deliver as well as having purchased the right machine to work with. Immediately following our training the Robocut was put to work. A die that would

PECM Issue 17

have previously taken 40 hours to produce was programmed and set in 2 hours and cut within a further 16 hours. A time saving of over 50%. Even more impressive was that the tooling ran first time when trialled on our extrusion line and without need of tuning. The saved man hours can be spent on other areas such as R&D, product trials, tuning of tooling or the design of new dies. We are now working

more efficiently and experience can only see things improve further still. Surprisingly the step-up has been very simple too… we only wish we had followed this path years ago. The dies we make are now accurate within microns and the speed of manufacture has been cut by approximately 50%. Now we have our Fanuc Robocut there is no looking back.

Issue 17 PECM

Drives, Gears & Motors

ROTEX® SH with T-PUR®

Reduce Your Downtime

ROTEX ROT RO OTEX O OT TEX E X® G GS S& S SY SYN YN Y NTE TEX T EX E X®-NC -N SYNTEX

It’s a known problem with electric motors; bearings fail prematurely due to misalignment and vibration, causing downtime and increased maintenance costs. Choose quality to reduce these failures by half…… Insist on a KTR coupling. Any pump to any motor, we’ve got a coupling to suit the job and our split hub ROTEX® and BoWex® designs offer one of the quickest maintenance turnarounds in the industry!

www.ktr.com

New development: Active fixed caliper brake T

he brake specialists of KTR have developed an active fixed caliper brake whose pads can easily be replaced in assembled condition. On request the system can be designed with an automatic air gap regulation. The new series of the KTR-STOP® line generates clamping forces up to 203 kN and can be used in the low temperature range up to -40 °C. KTR is going to present the brake system at the HUSUM Wind (hall 5, booth C04) for the first time. The active fixed caliper brake of the KTR-STOP® line is hydraulically driven and can be used both as an operating and as a stop brake. Its friction pads are available in “organic” or “powder metal” material and can easily be replaced in assembled condition. For this the side screws are loosened, the pad holders are removed and the pads are pulled out to the sides. On request the brakes can be designed with an automatic air gap regulation (CAG system “Constant Air Gap”). It

PECM Issue 17

regulates the distance between pads and brake disk and thus keeps the reaction time of the brake constant. At present the new series is available in the sizes KTR-STOP® S-D and KTRSTOP® M-D. With a weight of 68 or 76 kg the compactly designed highperformance brakes generate

maximum clamping forces of 141 or 203 kN. The series is completely made from steel and can be used in the low temperature range of up to -40 °C. Tel: +49(0)5971 798-0 Email: uksales@ktr.com www.ktr.com

Drives, Gears & Motors

Arcusaflex - not just a coupling, it’s probably the best coupling in the world. The Arcusaflex Coupling protects your drive train by damping vibration

Unit 4 Bankside Business Park Coronation Street Stockport SK5 7PG T: Office + 00 44 161 714 4191

PLEASE VISIT WWW.REICH-UK.COM FOR MORE DETAILS

Tru Temp Black Oxide Provides Blackened Parts Break In Lubricity For Gear Technology Applications Eden Prairie, Minnesota: Gear component manufacturers asked for an in-house metal finishing process to provide break-in lubricity, robust corrosion protection and galling resistance on critical components. Birchwood Technologies’ TRU TEMP® low temp black oxide process meets all those requirements while creating a non-dimensional finish, maintaining the same material hardness and load-bearing properties. The TRU TEMP blackening line operates at 200 degrees and forms a satin black magnetite finish that protects critical surfaces in storage, shipment and startup, resists galling and aids in break-in. The process takes just 30 minutes. The TRU TEMP finish is Mil Spec and RoHS compliant, and withstands up to 120 hours of neutral salt spray or several hundred hours of humidity, verified by independent testing. The finish is a 0.5 microns thick (20 millionths) crystalline structure that allows it to effectively hold a rust inhibitor and serves as a sacrificial barrier to provide break-in lubricity and galling resistance. Critical parts are protected for storage or overseas shipment. Gear component manufacturers are turning to the TRU TEMP® low temperature black oxide process as the preferred finish because of its many benefits. The process can be installed in any plant setting, without endangering personnel or surrounding equipment. The operating solutions contain no EPA regulated chemicals; process rinse waters are normally sent to the sewer as non-hazardous discharge. Most process lines do not require waste treatment equipment. TRU TEMP process lines are available in any size to fit part size and production volume. Please see the website for details on 100 gallon and 40 gallon systems. Want more information? See at: www.birchwoodtechnologies.com Email: info@birchwoodtechnologies.com

Issue 17 PECM

Vacuum Clamping Of Orthopaedic Insoles Before Forming the Poland but soon the market will spread to neighbour countries. Mariusz Strzecha is sure that this innovative technology will be adoptedby many others throughout the world. In Poland, KOORDYNACJA works with orthopaedic specialists who make their own diagnosis, take measurements, and send data for the insole to be produced by KOORDYNACJA. Before the insole is milled, the most suitable foam material must be selected. KOORDYNACJA uses a variety of materials comprising layers of different hardness, allowing a perfect match to the patient’s

he KOORDYNACJA company

convinced that at some point in their

in Radom, Poland, has

lives, most people experience back or

made a name for itself with

joint problems caused by misaligned or

innovative ideas in podiatric

asymmetrical feet or different leg lengths.

orthopaedics. In addition to a podiatric clinic, KOORDYNACJA also develops and markets orthopaedic devices. The latest development is a CNC milling centre, which reads patients’ data and automatically manufactures orthopaedic insoles from foam material with the required dimensions and density.

These problems could be avoided by compensating for foot and leg discrepancies using custom-made orthopaedic insoles. Mariusz Strzecha uses a number of diagnostic devices in his clinic: patients’ feet are 2D scanned, photographed, casts are made in foam, and pressure points are identified by the

During the milling process, the foam

patient walking on a pressure platform

material is clamped securely to the

or treadmill fitted with pressure sensors.

machining table by vacuum. Mariusz

The alignment of knees and hips are also

Strzecha, the proprietor of Koordynacja

measured, and finally a 3D scan of feet is

and developer of the milling centre,

conducted.

chose a Busch Seco rotary vane vacuum pump for the vacuum supply. Numerous trials with other vacuum generators were conducted, but only the Seco system met all the requirements for series production. KOORDYNACJA was founded in 2010, and initially specialised in podiatric orthopaedics for athletes. Mariusz Strzecha

Information gathered from these examinations is entered using a special software package developed by the company. The software calculates the perfect shape of

requirements to be made. A block of the chosen foam material is placed on the machining table of the milling centre, and is clamped securely using vacuum applied through channels in the table by a Busch Seco rotary vane vacuum pump. The vacuum pump must apply sufficient force to prevent the material from moving. For Mariusz Strzecha it was important to find a vacuum pump with adequate performance reserves that operated quietly, reliably and without oil. After a number of experiments with other vacuum generators, he found that the Busch Seco rotary vane vacuum pump provided the perfect solution. Seco rotary vane vacuum pumps work without operating fluids, which means they use no oil and maintenance tasks such as oil and filter replacement are not required. The compact dimensions of the vacuum system allow it to be installed in the housing of the milling centre. The Seco vacuum pump runs very quietly, and is inaudible above the noise of milling

the insole required, and passes the data to the CNC milling centre.

operations.

attending his clinic benefit from the latest

The CNC milling centre “CNC Foot Insole”

to air to some extent, so a certain amount

diagnostic equipment. Mariusz Strzecha is

was developed in 2014, and is sold across

of leakage is experienced during the

used the experience acquired in this field to develop new diagnostic devices, which he now manufactures and markets with the help of his employees. The patients

PECM Issue 17

Vacuum pump output was an important issue for Mariusz Strzecha: all the layers of foam used for the insoles are permeable

milling process. The Seco vacuum pump

gold medal (rehabilitation product

has a pumping speed of 5 m3/h, providing

of the year) at Rehmed-Plus,

sufficient reserves to evacuate through the

rehabilitation exhibition in April

foam material without loss of vacuum level

2015. Both awards recognised

and subsequent reduction in clamping

the innovative character of the

force. The high throughput also reduces

new milling centre “CNC Foot

the time taken to conduct the clamping

Insole”.

operation. KOORDYNACJA’s achievements in orthopaedic insole manufacture have been recognised by two awards: one in 2014 by the PTOiPr (Polish Society Orthopaedic Technology and Prosthetics) at the Rehabilitation Trade Fair in Lódź, and a

www.buschvacuum.com

Seco rotary vane vacuum pumps work without operating fluids, which means they use no oil and maintenance tasks such as oil and filter replacement are not required. The compact dimensions of the vacuum system allow it to be installed in the housing of the milling centre. The Seco vacuum pump runs very quietly, and is inaudible above the noise of milling operations.

Electrical & Electronics

New innovations in Stainless Steel Enclosures providing high protection for harsh environments

innovative enclosure solutions for industrial & electronic applications

www.eta-enclosures.co.uk ‘STRONGHOLD’ – New fixed optical probes for continuous meter reading

Selecting electrically conductive compounds made easy

METMOTEC announces its ‘STRONGHOLD’ probes that create a permanent connection between meter optical ports to modems or energy management systems. The probes eliminate the complex task of accessing a meter’s electrical communication port. It also enables reading of meters without an electrical communications port.

Chomerics Europe, a division of Parker Hanniﬁn, has updated its selector guide of class-leading electrically conductive compounds. The guide, which can be downloaded from http://bit.ly/1icKOgA, includes the company’s CHO-SHIELD conductive coatings, CHO-BOND and TECKNIT sealants, gap ﬁllers and adhesives, as well as CHO-LUBE conductive grease.

Mechanically ﬁxed meter probe

I&C electricity meters feature an optical port with a ferromagnetic disc traditionally used for reading by hand-held computer via probes of low magnetic attachment. STRONGHOLD’s secure attachment is achieved by magnets with over twenty times the attraction force speciﬁed in the IEC 62056-21 standard (also known as ‘1107’ and ‘FLAG’).

Using the new guide, engineers and speciﬁers have at-a-glance access to all of the products’ typical properties, including speciﬁc gravity, min/max temperature use, shelf life, VOC and many more. To make selection even easier, a handy list of typical applications and useful comments are included against each product.

Another version of the probe is oﬀered with a mechanical mechanism for latching to and from the optical port. The probes are high quality, competitively priced and available with connectors for modems and RS485 and other networks.

Comprehensive ordering information is also included, covering pack size/ weight, part numbers and whether there is a primer requirement. Primer ordering information is featured on the same page.

Email: metmotec@metmotec.com

www.chomerics.com

www.metmotec.com

RCT Industrial AC Current Transducers • Easy to install, thin, clip-around AC current transducers • Rated current from 100A to 50kA • Single-phase or 3-phase models available • Suitable for a wide range of industrial applications, including: monitoring, logging and protection systems

RCT1A

- True RMS AC current measurement

- Genuine current transformer (CT) replacement 0-1A output

- Instantaneous voltage output: 0.333V or 5Vac

- Standard 4-20mA output

- Accurate, <0.5° phase error at 50Hz

- Accurate and wide bandwidth (0.6Hz to 1MHz)

- Use with SCADA & PLC systems and data-loggers

- Safe operation

RCTrms RCTi

Global manufacturer & distributor of fasteners and components

- Use with meters, data-loggers and acquisition systems

- Use with meters taking standard CT inputs

Full service provider offering end to end support from engineering & design through to specification, manufacture, quality control & logistics. Please contact us to discuss your application

sales@trfastenings.com | www.trfastenings.com

PECM Issue 17

Power Electronic Measurements

Tel: +44 (0)115 946 9657

www.pemuk.com

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Electrical & Electronics

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Fibox continue to maximise their exposure M

aintaining their commitment in providing their customers with the widest range of innovative electrical enclosures coupled with the highest standard of process and technical support, Fibox the Finnish manufacturer of high quality enclosures for the protection of electrical and electronic components and systems, have announced that they will once again be exhibiting at Northern Manufacturing on 30 September-01 October in Manchester. Steve Gallon, MD of Fibox in the UK announced â&#x20AC;&#x153;All of the shows that we have recently attended have matched our expectations of visitor levels and visitor quality. Having exhibited previously at both the Northern and Southern Manufacturing shows; repeating the exercise at these trusted, established events which successfully bring the specifiers and product developers together, was again a nobrainer!â&#x20AC;? Speaking specifically about their successes, he continued, â&#x20AC;&#x153;These regional Trade & Technical exhibitions have, this year, become an important part of our marketing activities, due mainly to the extremely favourable response we have received to our ARCA range, together with the positive feedback we have received to our products and our customising services in general. â&#x20AC;&#x153;At the Northern Manufacturing Show, Fibox

PECM Issue 17

will be introducing a major new design feature that can be easily embedded into the ARCA range.â&#x20AC;? Developed for use with the ARCA range of enclosures, the versatile design of these highly demanded glass reinforced polycarbonate cabinets, now feature windows and swing handles as optional extras, making them even more suitable for a wider range of applications. Introduced specifically for use in control and monitoring applications, the ARCA is the ideal choice for use by industrial, electrical and electronic OEMâ&#x20AC;&#x2122;s and their Design or Development Engineers whose products must operate in harsh and demanding environments, yet may require regular and easy access. While boasting a host of innovative and user friendly features and benefits, this newly expanded range will offer control system builders and installers an even more attractive, robust and corrosion resistant enclosure option, whilst maintaining its aesthetically pleasing appearance. Also on stand, (D 45) Fibox will present visitors with examples of the ARCA range where they have been specified for use by manufactures whose products are marketed outside the boundaries of the traditional electrical products market.

A growing list of these unconventional applications, range from enclosures that house ANPR monitoring stations in exclusive London car parks and cabinets that control batch feeding in the agricultural industry to totally non-electrical applications like a Substation Life saving kits; housings fire extinguishers on the decks of ships, and purpose built cabinets designed allow quick access as well as secure storage for vital life saving Automatic External Defibrillators (AEDâ&#x20AC;&#x2122;s) www.ďŹ box.co.uk

Electrical & Electronics

ODU AMC® HIGH-DENSITY

SMALLER – LIGHTER – FASTER ODU AMC High-Density is a robust miniature connector series that fulfills all the demands of the modern military equipment. The compact and lightweight connector solutions offer an excellent transmission performance, easy handling and high reliability.

Innovation in a compact package

Break-Away for maximum safety 2 up to 40 contacts Watertight – protection class IP 68 USB 2.0 + USB 3.0 data transfer > 5,000 mating cycles durability

ODU-UK Ltd. Phone: +44 1509 266433 sales@odu-uk.co.uk www.odu-uk.co.uk

14 mm fig. 1:1

One week, £65,000 saving with our Sinergy e-TRacKER The client – a manufacturer of heating products – installed a Sinergy e-TRacKER sub-metering unit to get an in-depth view of its energy usage over one week. When the stats were examined the company discovered its electricity meters were making incorrect readings. The matter was taken up with the power supplier and a refund of £65,000 issued along with an assurance that future bills would be correct. The e-TRacKER, which took about 30 minutes to install between the Mains supply cable and the Main Distribution Board, was removed after one week and the statistics examined. The client, with the aid of the e-TRacKER, identified that its electricity meters were reading incorrectly. They questioned the billing data with their supplier and received a refund of £65,000.The Sinergy e-TRacKER is a portable kWh meter allowing users to monitor incoming power supply, specific circuits/equipment etc to show the pattern of demand over an hour, day, week or month. The unit utilises non-invasive clipon transducer (CT) clamps that are quick to install and do not require power being turned off. They are magnetic-backed so attach easily to switch boards making them perfect for temporary monitoring. e-TRacKER measures current from 10Amps to 2500Amps. The system offers 16 days of battery life or runs off mains supply. Other features include pulse input, optional voltage connections, CT amps range indicator and EV-Trac electrostatic phase identifier. Sinergy Meters Unit 1, Union Road Estate Union Road, Macclesfield SK11 7BN E: sales@sinergymeters.com T: 01625 611808

PECM Issue 17

Please see our new website www.sinergymeters.com

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ECS Engineering Services has been awarded the contract to replace seven screw pumps between two Severn Trent Water sewage treatment plants

ECS To Install New Archimedes Screw Pumps For Severn Trent Water CS Engineering Services has been awarded the contract to replace seven screw pumps as part of a larger contract for NMC Nomenca. Split between two Severn Trent Water sewage treatment plants, the project installations are due to start in October and will run concurrently to ensure a timely completion.

With over 25 years' experience in delivering projects such as this and an exclusive partnership with Landustrie, a leading manufacturer of Archimedes screw pumps, ECS is able to provide a complete design, build and install package. In-house engineering expertise and site engineering skills provide the necessary support to complete a cost effective installation. The first project will involve the complete replacement of four screw pumps, gearboxes and motors at the Warmsworth sewage treatment plant. Here two primary pumps and two humus pumps have now reached the end of their serviceable lives after nearly 45 years' service and

are in need of replacement. Originally manufactured by Landustrie, the screws are 14 meters long and 900 mm in diameter. The second project involves three complete screw pump installations at Melton Mowbray treatment works, which again are no longer serviceable due to their extended service life. These slightly smaller screw pumps measure 8 meters in length and 800 mm in diameter and will be replaced one at a time to ensure continued operation of the works. Dave Bennion, Project Manager for ECS, comments: "Our partnership with Landustrie means that we can get started on the design and manufacture of the new screws immediately. At the same time we will develop the installation plan and ensure that we complete both projects on time. It is also essential that we coordinate the work carefully with Seven Trent Water to ensure that we deliver the new screw pumps without affecting the operation of the treatment works."

About ECS Engineering Services ECS Engineering Services has over 20 years experience in delivering high quality, reliable and cost effective engineering solutions, specialising in bespoke design and construction of water, energy and environmental processing and management projects. In partnership with Landustrie Archimedes screw pumps and Waterfront Fluid Controls, ECS has the expertise and capacity to design and install a wide range of water control engineering projects. With in-house fabrication services, which have CE Marking approval to EXC3, well equipped and highly skilled engineers can also complete structural steelwork, bespoke fabrication work and access metalwork to the highest standard. With a complete range of site services available, ECS offers a full turnkey project managed service for mechanical and electrical installations including managing civils contractors and supplying pipework, control and automation work to ensure that every installation is installed and commissioned to the highest standard. Existing clients include the majority of the UK Water Utility companies, Government Agencies and Internal Drainage Boards. www.ecsengineeringservices.com

Issue 17 PECM

Andrews Chillers Hire Ensures Critical Storage Guidelines Maintained W hen a major pharmaceutical centralised distribution centre was struggling to maintain critical warehouse storage temperatures below 25oC, the fast response of an engineering team from Andrews Chiller Hire supplied and quickly installed a 500kW fluid air chiller working in harmony with a twin-stacked pair of 150kW Andrews air handling units. Working alongside the existing warehouse services, this temporary system ensured that an ambient temperature below 25oC was achieved throughout the storage facility, preventing degradation of the stored medicine as well as protecting reputations. The MHRA (Medicines and Healthcare Produces Regulatory Agency) has previously reported that temperature rises above desired parameters are the number one critical deficiency in pharmaceutical warehouses. MHRA statistics

PECM Issue 17

show that temperature increases above 25°C have been the single biggest issue for those responsible for the storage of pharmaceutical products.

Uncontrolled temperature fluctuations are serious because non-compliance with the manufacturer’s storage recommendations and the MHRA’s guidelines on general storage can lead to expensive product recalls, may prompt the destruction of affected products and potentially cause a health risk to patients. Extremes in temperature can affect product quality. New warehouse developments nowadays are built to better standards with improved insulation and are more airtight, better thermal qualities ensure buildings are warm in winter. A major concern is caused by the vagaries of the British weather – cool one minute and roasting the next. Air-conditioning top up Generally warehouse in-house air-conditioning is designed

to cope with the norm in ambient temperatures; it would be too costly to incorporate a permanent system able to handle the short-term higher external summertime temperatures being experienced over the past decade. This is where the flexibility of a chiller hire organisation is extremely cost-effective. As specialist in the chiller hire business Andrews now operates with an established network of 25 depots in the UK and engineering teams able to discuss individual requirements and propose a cost-effective solution to their problem. Part of the Andrews Sykes Group, the chiller division holds an impressive range of modern air-cooled fluid chillers with capacities from 6kW to more than 750kW and single air-handlers capable of delivering up to 600kW and provides 365 days, 24/7 dedicated support. This level of customer commitment has enabled Andrews Chiller Hire to respond and deliver many time critical temporary solutions, prevent business losses due to faulty or underperforming in-house air conditioning plant. Andrews Chillers response in less than 4 hours and their fast action presented a solution to the pharmaceutical warehouse air-conditioning issues and meant temperature control was maintained in good order and in line with official compliance figures. Issues relating to poor

Andrews Chillers Air chiller being delivered

temperature control can cost distributors in a number of ways if not tackled; they can lead to a loss of confidence in the distributor by manufacturers, the MHRA and pharmacists. At this pharmaceutical warehouse Andrews Chillers supplied a 500kW fluid air chiller and four 150kW air-handling units. Each of the air handing units is able to cool an area of 3,624m3 (127,000ft3), for this applications the units were arranged in pairs, and stacked to reduce required floor area. The air handling units are designed to connect to existing chilled water circuits or to an Andrews’ water chiller as was the solution for this medicine distribution centre. The four air handling units where situated in the warehouse with the 500kW fluid air chiller positioned externally but close to the building to reduce pipe runs, maintaining adequate chilled water passing through flexible hoses to air handler units.

Andrews Chillers twin-stacked pair of 150kW Andrews air handling units

As specialist in the chiller hire business Andrews now operates with an established network of 25 depots in the UK and engineering teams able to discuss individual requirements and propose a cost-effective solution to their problem.

Each Andrews’ chiller is a selfcontained unit complete with heat exchanger, condenser, control system, compressor and circulating pumps and features a rigid and robust, base plates that ensure site stability. the cooling pipework flows directly into the external chillers where the chilling process begins again. This cyclic, closed loop system with air handling situated within the building is the most effective for environmental temperature control.

Chilled water is fed directly into each of the four air handling units and passes directly in front of a large fan which expels the cold air either directly or via trunking back into the warehouse. Warm air extracted via

Conclusion With global warming seeming to be a reality, temperature control issues are likely to become even more of a problem in warehouses that are not equipped with appropriate, adequate cooling. To ensure compliance of temperature control guidelines Carl Webb, Sales Director of Andrews Specialist Hire

Andrews Chillers The 500kW fluid air chiller is positioned externally but close to the building to reduce pipe runs.

Division suggests establishing a working relationship with an experienced chiller hire company before its services are required. Pre-qualified requirements mean that a solution for maintaining correct temperature control is closer to hand - equipment on-site in just a few hours which could save a reputation and prevent financial losses. Choosing the right hire company can certainly pay dividends – quicker response to cooling problems, competent engineers, faster delivery – and above all temporary installation of the right chiller and any ancillary equipment.

Andrews Sykes Hire Limited Chiller Division, Unit 54 Gravelly Industrial Park, Tyburn Road Birmingham B24 8TQ Tel: +44 (0)1902 328725 E: shdinternalsales@andrews-sykes.com www.andrews-sykes.com Issue 17 PECM

Capital Safety Unveils Lightest Wearing Harness Ever Invented By using innovative Lifttech weight-

on protection rather than comfort and

distributing technology, capital safety, the

productivity. This led Capital Safety to create

global leader in fall protection equipment

the ExoFit STRATATM, literally taking the

and rescue systems, has created the lightest-

weight of workers’ shoulders.

wearing safety harness yet - the exofit strata. Sandra Paiva, EMEA Product Manager at As part of the DBI-SALA® portfolio, the new

Capital Safety commented: “Safety and

harness incorporates many of the existing

functionality are of limited use if harnesses

features that make the range so successful.

cause the user discomfort. Having real

The new ExoFit STRATATM is designed

industry experience means we understand

to take the weight off workers shoulders

issues workers face day in day out. We have

and redistributes it to where the body is

developed the lightest-wearing harness in the

better suited to carry it: the hips. It features

industry to address the needs of our end user.”

PolarMesh™ padding, which keeps users’ backs cooler with greater air flow alongside a

Capital Safety will present the new product

Revolver™ Vertical Torso Adjuster and Tri-Lock

for the first time at the A+A Work Safety trade

Revolver™ Connectors that provide added

fair in Düsseldorf. The Capital Safety team can

security around the legs.

be found in hall 06/D05.

Capital Safety has partnered with ergonomics

For further information visit:

specialists at North Western Health Science

www.exofitstrata.eu

University in Minnesota to test several key aspects of the ExoFit STRATATM and compared it with alternative full body safety harnesses on the market. Using thermal sensors, load calls and motion capture cameras, a series of rigorous lab tests were performed resulting in an advanced harness solution. During testing, the ExoFit STRATATM demonstrated the least amount of force on shoulders while the wearer is standing stationary, reducing forces on subject’s shoulders by up to 85 per cent compared with other competitive harnesses. With more than 20 years expertise in designing products to ensure the safety of thousands of men and women who work at height, Capital Safety’s latest offering represents the culmination of years of design, research, and manufacturing know-how. Capital Safety has helped shape and define what the modern safety harness looks like and how it performs. Previously the development of safety harnesses has focused

PECM Issue 17

Fluid Handling

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The Master solution to staying safe Master Abrasives has been offering solutions for industry over many years, through its experience and knowledge of abrasives and tools. To complement its product and service range, Master now offers the complete solution for training with its safe use of abrasives (machine and handheld power tools) course as well as awareness of Hand Arm Vibration (HAV) via Toolbox Talks. As a member of the British Abrasives Federation (BAF), Master supports its recent statement that, when used correctly, abrasives have an excellent safety record. Whilst reputable manufacturers follow precise manufacturing standards (EN 12413) to ensure products are fit for purpose, problems are likely to arise when products are used incorrectly or for materials and applications for which they were not intended. Abrasive wheel breakage is the largest risk for incidents, as grinding tools have operating speeds up to 180 mph and can accelerate and decelerate faster than a Formula 1 racing car. Personal injuries resulting from wheel breakages are usually a result of using hand held machines and unfortunately are the single largest reason for a wheel breakage is operator error. For this reason it is a requirement of the Provision and Use of Work Equipment Regulations (PUWER) that all people who use, supervise or manage the use of work equipment have received adequate training. Master offers the solution to ensure this requirement is covered for employers, helping to keep their workforce safe - the safe use of abrasives training course, accredited by the BAF - issuing all who have attended and passed the course with a certificate. This course familiarises abrasive users with simple, basic but vitally important facts about abrasives, the use of them and how, when used correctly, they have an excellent safety record. Please contact us if you would like more information on any of the products or services that Master Abrasives offers.

Email: sales@master-abrasives.co.uk www.master-abrasives.co.uk

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Issue 17 PECM

Explosion Venting with and without TARGO-VENT

n contrast to their consequences, explosions are only discernible to a limited extent by sight alone. They happen within a few milliseconds, yet leave behind considerable damage. Diﬀerent approaches of explosion protection are implemented to limit this damage. Bursting discs are often used in facilities where relief of the explosion in the surrounding area is possible. Bursting discs are relief ﬁttings, which are extremely economical and relatively easy to manage. However, this type of traditional explosion pressure relief presents a big problem for many facility operators – extensive safety areas have to be set up around the relief area to protect people and machines. These areas cannot be used. TARGO-VENT is an opening angle limiter developed

New methods of free explosion pressure relief Intelligent explosion protection does not necessarily have to be expensive or complicated. An innovative technology makes it possible to divert the shock wave and flames of an explosion in a controlled manner. The result being that the required safety area is reduced, and spaces that are freely available are increased. People and machines are protected in the best possible way. especially for bursting discs, which guides the pressure relief speciﬁcally into areas, in which there is no danger for the adjoining infrastructure. It dynamically and progressively cushions the bursting disc situated

TARGO-VENT is assembled on the bursting disc in a space-saving manner.

beneath it, and can therefore also assimilate large kinetic forces resiliently. The damper absorbs the enormous repulsive forces of the explosion energy and guides the flames and shock wave in the desired direction. Depending on what’s required the flames and shock wave are diverted at a defined angle of approx. 30° to approx. 45° upwards or to the side. Facility operators can therefore minimise the safety areas around the vent opening. The utilisable area is increased. A further advantage of TARGO-VENT: the top module is made in all the usual bursting disc sizes, so that retrofitting in existing units can be undertaken without a problem. Conversions or new buildings are protected by TARGO-VENT without the explosion protection concept of the existing facility having to be significantly altered. TARGO-VENT is assembled on the bursting disc in a spacesaving manner. There is no need for expensive baseplates or reinforcements. The system is made from maintenancefree stainless steel materials and, in combination with REMBE® bursting discs and pressure relief panels, is typetested in accordance with the ATEX Directive 94/9/EC (ATEX 114) and authorised in accordance with (FSA 13 ATEX 1637). Email: info@rembe.de www.rembe.de

PECM Issue 17

T +49 2961 7405-0

Made in Germany

Your Specialist for PRESSURE RELIEF and EXPLOSION PROTECTION

New, improved safety sign printers from Brady The new BBP™35 Multicolour Sign & Label Printer and BBP™37 Multicolour and Cut Sign & Label Printer support safety and operations professionals to quickly create a safer, more productive facility with multi-colour and multi-shape signs and labels. The printers offer great colour and cutting capabilities as well as a simple, automatic label setup and intuitive touchscreen to make any sign on demand and on-site.

ncrease productivity & reduce accidents Attention-grabbing safety & lean facility signs can reduce machine downtime, increase productivity and help to meet compliancy, safety and efficiency goals. They instruct employees and contractors on optimal work procedures, warn against dangers and promote safety precautions. The BBP35 and BBP37 printers enable professionals to create highly customisable signage to increase a facility’s safety and

productivity on demand and on-site.

setup, LAN and optional wifi connectivity or standalone use, all at a print speed of 12.7 cm per second.

Print any colour, in any shape For signage to be effective, it needs to grab the attention of employees and contractors on the workfloor. Customised multicolour signage in various shapes is better able to do that. The BBP37 printer is equipped with outstanding colour and cutting capabilities. Both printers also feature ‘drop in’ consumables, automatic label

For signage to be effective, it needs to grab the attention of employees and contractors on the workfloor.

Both BBP35 and BBP37 are compatible with Brady’s wide range of durable label materials, able to resist the toughest industrial contexts. Multi-colour printing and cutting features enable users to create a wide variety of signs with just one label supply. Extra efficiency with Brady Workstation BBP37 works perfectly with Brady Workstation, a downloadable app-platform.

BBP37 works perfectly with Brady Workstation, a downloadable app-platform. Brady Workstation opens up a host of dedicated signage creation apps. Combined with Brady Workstation, the BBP37 printer enables the on-site and on demand creation of any customised lean or safety sign a facility could require. Email Brady at emea_ request@bradycorp.com to receive a BBP35 and BBP37 printer brochure.

PECM Issue 17

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Group HES is excited to announce a new division - HES Automatec Building on many years of accumulated experience in critical and complex fluid power control systems, Group HES has now formally launched a dedicated control division, HES Automatec. Specialising in providing fluid power control solutions. •

Skilled engineers with extensive experience in electrical engineering and enterprise software development.

•

Full turnkey capabilities - The multidisciplinary engineering team comprises fluid power, electrical, instrumentation and control engineers.

•

Official distributors of Danfoss Plus+1, the complete development environment for off highway applications.

•

Technical excellence in National Instruments products for data acquisition and test rigs and Siemens S7 for bespoke industrial machinery applications.

•

Total project management drawing on the support and structure of Group HES and the sister divisions.

Typical market sectors covered: • • • • •

Industrial Automation Fluid Power Mobile Machinery Control Instrumentation Data Acquisition

Call or email the specialists to discuss your next project

t. 01452 733108

e. automatec@grouphes.com

part of

Dowco House | Insworth Technology Park Innsworth Lane | Gloucester | GL3 1DL automatec@grouphes.com

GroupHES GroupHES company/group-hes-ltd

Top 3 Tips For Choosing Your Grease lthough often neglected, we all know that proper greaselubrication of industrial equipment and machinery makes everything run smoother, more efficiently and minimises problems associated with high temperature, friction, wear, rust, corrosion and extreme pressure. Despite the fact that at least 70 per cent of greases are lithium based, newer calcium sulfonate greases offer superior multi-purpose performance. But with a multitude of products on the market, how do you choose between them?

Here, Mark Burnett, VP of the lubricants and fuel additives platform of water, energy and maintenance solutions provider, NCH Europe, gives three key tips for choosing your grease. 1. Make sure your grease can stay put under heavy loads We ask a lot of multipurpose greases nowadays. From ultra clean and dry air conditioned environments and general machinery in industrial plants, to severe outdoor applications where conveyors, pulleys and bucket wheels exert heavy loads on machinery, your grease must perform. When put under these strains, lesser greases will quickly lose their structural integrity and get squeezed out of equipment under heavy loading. Whether it's the bearing on an industrial pump or a bucket pin on an industrial digger, heavy loads can cause grease to leak and squeeze out under the force of gravity and high pressure. To overcome this, NCH Europe developed K NATE, a calcium sulfonate grease with unique properties. Made using a blend of tackifier additives, K NATE contains adhesive polymers that allow K NATE to stick to surrounding metal as well as cohesive polymers that allow it to stick to itself. This formula means the grease can minimise the effects excessive wear and heavy load shock conditions, withstanding a weld load in excess of 800kg on a four ball machine. 2. Make sure your grease can handle extreme heat and friction Most of us know that over 70 per cent of machine wear occurs on cold startup. Before your lubricant has chance to circulate and coat the internal surfaces, metal-to-metal contact causes friction and temperatures can very quickly reach

PECM Issue 17

over 1,000 degrees, welding together core components. Extreme contact temperatures, combined with operating and ambient heat in applications such as steel mills, where equipment such as blast furnaces, electric arc furnaces, casting machines, cranes, transfer cars and mill motors, can cause catastrophic failure. Ultimately, this leads to extended down-time, charred grease and unprotected bearings. When choosing a grease that can perform as you need it to under heat and friction, look for a grease that has a high working temperature and dropping point, along with other extreme pressure agents. For example, K NATE provides effective lubrication from -30 to 200 degrees centigrade continuously and up to a maximum of 230 degrees centigrade intermittently. To top this off, K NATE offers a dropping point – the point at which a grease moves from semi-solid to liquid form – of 288 degrees centigrade. This high dropping point reduces grease consumption, providing protection for longer. Heavy loads, combined with high temperatures and friction lead to extreme pressure (EP). That’s why we developed our grease with EP agents that react to heat, relieving pressure by introducing a thin lubricating film. This film fills in the gaps between asperities (the rough projections present on metallic surfaces at an atomic scale) even on surfaces polished to a mirror surface. This lubricating film allows surfaces to glide over each other, reducing wear and elongating component life. 3. Make sure your grease can handle contamination Water, dust and corrosion are the three biggest killers of industrial equipment and

no matter how much you try to minimise ingress, over time, your grease will come face to face with these problems. If you've ever repaired, serviced or replaced a motor, you'll be familiar with the damage that can be caused by dust and airborne particles. Especially susceptible are applications such as packaging, card and paper processing plants where, despite the best ventilation and ingress protection, dust can infiltrate motor housings over time, clogging air filters and overheating windings. Likewise, dirt and other organic matter can mix with grease to become an abrasive powerful enough to score bearings, cause pitting on gear teeth, and lead to long term microbial growth. Combined with exposure in outdoor environments, or steam and condensation in indoor plants, water washes away grease like there’s no tomorrow, leaving surfaces unprotected. This is another reason why continuous production plants can never be truly shut down, instead being serviced in a phased process. If the plant is shut down entirely, lubrication dissipates, corrosion sets in and equipment seizes up when the system is restarted. To prevent these problems, K NATE is specifically formulated with excellent water resistance that limits water-washout to just 0.5 per cent, where standard grease exhibits over five per cent, along with corrosion inhibitors that form a protective barrier against external and internal contaminants. Even if you don’t neglect the regular maintenance and repair of your industrial machinery and equipment, using a high quality grease will make all the difference. From higher temperature and load endurance to a more sophisticated ability to combat contamination a good grease makes all the difference. So remember, choose a grease that can handle the pressure, handle the heat and handle the contamination. www.ncheurope.com

Lubricants

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your global specialist

Morris Lubricants Passes Worldwide Tests In Style A

A leading oil manufacturer has seen its laboratory testing procedures given the seal of approval by a worldrenowned organisation. Morris Lubricants has received a strong endorsement from the ASTM (American Society for Testing and Materials), an international standards organisation, which ensures their quality assurances practices are comparable with the global elite. The Shrewsbury-based company signed up for the ASTMâ&#x20AC;&#x2122;s engine oil proďŹ ciency testing programme, a statistical quality assurance test which enables laboratories around the world to assess their performance in conducting test methods. Morris Lubricants â&#x20AC;&#x201C; along with other leading laboratories around the world

- received a sample from ASTM to examine. Each laboratory tested the sample and their results were assessed against ASTMâ&#x20AC;&#x2122;s benchmarks. Morris Lubricants undertook tests including base number, density, colour, viscosity, cold crank simulator, open and closed ďŹ&#x201A;ash points and pour point and measured well in all, producing accurate results and leading the way against competitors in a number of categories.

of Morris Lubricants investing around ÂŁ200,000 in new equipment to ensure its products remain at the very highest standard. The company purchased a new automated open ďŹ&#x201A;ash point machine, a top-of-the-range density meter, a new Karl Fischer to measure trace levels of water, a low temperate BrookďŹ eld viscometer and a high temperature high shear simulator.

Quality assurance manager Phil Saunders said the hugely positive results represented another signiďŹ cant step towards the business becoming the ďŹ rst ever lubricants manufacturer to secure the UKAS ISO 17025 accreditation for laboratory quality.

Morris Lubricants has been manufacturing lubricants since 1869. Over 140 years of development has seen the company grow to become one of Europeâ&#x20AC;&#x2122;s leading oil blenders with a reputation for quality and service. The company oďŹ&#x20AC;ers an extensive range of performance lubircants covering a wide variety of application areas.

The ASTM results come on the back

www.morrislubricants.co.uk Issue 17 PECM

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Machining & Machinery

Hyperloop: Transport into the Future Oerlikon Leybold Vacuum, vacuum pioneer based in Cologne, imparts extensive expertise in vacuum technology to one of the most challenging transportation projects of the future. The GermanAmerican visionary Dirk Ahlborn, CEO of Hyperloop Transportation Technologies, has set the goal of making the seemingly utopian idea of Tesla founder Elon Musk become reality: From 2018 onward, people shall travel with aircraft speed through a reduced pressure tube system.

Manufacturer of High Quality

Anti Vibration Products

Before any implementation, however, a multitude of tests and calculations for the vacuum conditions are required, before the Hyperloop track will be built in Quay Valley, California starting in 2016, transporting the inhabitants of this conceptual city. The track will be an eight kilometers long tunnel, to which the vacuum pumping equipment from Oerlikon Leybold Vacuum is connected. For further information, please contact: carl.brockmeyer@oerlikon.com or christina.steigler@oerlikon.com • www.oerlikon.com/leyboldvacuum

FlyMarker® mini: Most likely the lightest, portable marking unit in the world The fourth generation of the mobile dot peen marker called FlyMarker® mini, can be described as a new milestone in the history of the battery operated hand-held marking units. It builds on the strengths of the proven previous models and convinces with its light weight of only 2.7 kg and its compact design as well as also due its unique introduction price.

Email: sales@fibet.co.uk Visit: www.fibet.co.uk | Tel: 01282 878200

Thanks to the less weight and the powerful Lithium-Ion-Battery, this marking unit for durable markings can be carried through the works premises directly to the work piece. This is very helpful when big and unmovable work pieces need to be marked. Nearly all materials can be marked – from plastics, aluminum, stainless steel up to hardened steel. More information on www.ﬂymarker.com

PECM Issue 17

Celebrating 10 years of the

Scrap Shaker

Premitec is celebrating the 10th anniversary of their ﬁrst scrap shaker unit to be installed in the UK. Baxi Boilers of Preston, took delivery of the first UK scrap shaker in November 2005. With a scrap tray clamping beam of 2,500mm, stretching along the back of the press, the ‘setters’ have to replace only the scrap trays for each tool. No spare parts have ever been required even though it has been running 12 hours/day 5 days a week for the past 10 years. As the Press Setter John Waite stated “it’s never missed a beat”. Baxi engineers found that belt conveyors were not reliable and in many cases not shallow enough to lay under the press tools. Being an electro mechanical scrap shaker, the Premitec unit provides a reliable alternative to belt conveyors and air shakers, as belts can tear and air shakers fail due to poor air or lack of robustness.

To request a quotation or to discuss any aspect of integrating a Scrap Shaker into your production process call 0044 (0)845 0066 210 or email info@premitec.co.uk web: www.premitec.co.uk

The Baxi tool setters found that the scrap shaker is easily adaptable to meet their requirements. A selection of trays can be mounted on the unit. Common trays can be used for different tools. The length of the trays present no problem. Scrap Shakers can be found in many other industries, which are ideally suited for this method of transportation such as in casting, foundry, machine tools and the food industry. Many of which have replaced conventional belt conveyors. Premitec UK are happy to celebrate Baxi’s 10th year of trouble free scrap shaking. Success made possible by a simple robust design. If you are looking for a helpful alternative to belts and conveyors or would like more information on the Premitec UK products, please call 0845 0066 210 or email info@premitec.co.uk

Click to View https://vimeo.com/31736395

Issue 17 PECM

The New Temperature & Process Controllers The most powerful PID Controller on the market is now the easiest to use! • High Performance • Extremely Versatile • Full Autotune PID with Fuzzy Logic Adaptive Control • No Jumpers to Set, Fully Menu Conﬁgurable

omega.co.uk/cnpt_series

Your One-Stop Source for Process Measurement and Control > 100,000 products online

IN P IP S H S ERpply E F RE OF & C’s A

> Easy online ordering > Same day shipping on instock items

omega.co.uk 0800-488-488

sales@omega.co.uk Temperature

Pressure

Automation

Flow

DAS

Heaters

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Leaders in temperature measurement

Thermocouple Sensors and Fittings Manufactured by Labfacility thermocouple cables thermocouple connectors PRT sensors temperature instrumentation

Buy on-line

www.labfacility.com info@labfacility.com

Bognor Regis tel: +44 (0)1243 871280 Sheffield tel: +44 (0)1909 569446

The comprehensive selection of mineral insulated thermocouples features 0.5mm sheath diameter versions in addition to 1.0mm, 1.5mm, 3.0mm and 6.0mm.

Thermocouple & Resistance Thermometer Sensors A new, comprehensive brochure from Labfacility features detailed product information and technical guidance on a wide range of temperature sensors and probe assemblies & installation fittings. Thermocouple and Resistance Thermometer Sensors

The Labfacility Collection

Buy online

www.labfacility.com

hermocouple conﬁgurations range from fine wire, high sensitivity types to heavy duty industrial assemblies and include special designs for plastics machinery, surface & air temperature sensing and furnaces. Mineral insulated and fabricated constructions are offered. The comprehensive selection of mineral insulated thermocouples features 0.5mm sheath diameter versions in addition to 1.0mm, 1.5mm, 3.0mm and 6.0mm. The 0.5mm diameter thermocouples combine low thermal mass and fast response to temperature changes with durable construction; they are highly flexible and their use minimizes process intrusion. The range of high accuracy, high quality Type K, handheld thermocouple probes suit various surface and penetration applications.

The brochure includes thermocouple wire colour codes and a short-form catalogue of the entire Labfacility product range.

Probe and tip configurations include high sensitivity surface contact sensors with straight and right angled probes for alternative process access and a rugged, heavy duty penetration probe. Applications include machinery and packaging temperature sensing, frozen product temperature sensing and any requirement for accurate

surface temperature measurement up to 900 oC. The 1.5m coiled cable is terminated in a “moulded on” miniature connector; cable and connector are IEC colour coded. The type K thermocouples comply with IEC584. Platinum Resistance Thermometer conﬁgurations include mineral insulated and fabricated assemblies for scientific and industrial applications, special designs for air and surface temperature sensing and high precision sensors. A wide range of Platinum Resistance thin film and wirewound sensing elements are offered in Pt100 and Pt1000 versions and with a comprehensive choice of tolerance classes. The brochure includes thermocouple wire colour codes and a short-form catalogue of the entire Labfacility product range. Labfacility is an ISO 9001 company; the brochure is available on request via www. labfacility.com Labfacility Ltd Bognor Regis Tel: +44(0)1243 871280 Sheffield Tel: +44(0)1909 569446 info@labfacility.com

Issue 17 PECM

Measurement & Monitoring New Central Weighing Terminal B+L Industrial Measurement announces the release of a new user weighing terminal that works in conjunction with up to 16 filling controllers. Aimed at automated system builders the new terminal reduces costs and complexity by eliminating the need for individual user interfaces and displays at each weighing head. Bag filling in the 1 to 50 kilogram weight range will often utilise multiple filling heads in a linear or rotary configuration. Setting-up these heads and monitoring them usually means control panels with keypads and displays at each of the filling points. The new Central Terminal (CT) from B+L operates remotely via Ethernet meaning each filling head can be set-up and operated from the CT. A 7inch touch screen display enables the CT to show a graphic representation of the filling system. This makes selecting a filling head and adjusting its weight parameters very straightforward.

Email: info@bl-im.de

www.bl-im.de

Highly Accurate Outdoor Measurement EE33-M is the newest addition to the well proven EE33 transmitter series for relative humidity (RH) and temperature (T). The heated RH sensor, the additional heating of the RH sensing probe and a separate T probe ensure highly accurate outdoor measurements even under condensation conditions. A special coating protects the RH sensor against pollution. Together with a radiation shield, EE33-M is ideal for high-end meteorology applications.

Modular and fully configurable Gas Analysers Due to a large growth in our product range, the Rapidox gas analysers have now become modular and fully configurable. A range of single, dual and multigas analysers are available in bench mounted, portable and rack mounted configurations. Customers will now have the ability to tailor their requirements in order to meet their bespoke gas analysis requirements. For further information on Rapidox gas analysers or advice and information on using gas analysis within your process please contact Cambridge Sensotec on: +44 (0)1480 462142 or email sales@cambridge-sensotec.co.uk. Further details can also be found on our website www.cambridge-sensotec.co.uk

Advanced Torque Calibration Service from HBM The new DAkkS (National Accreditation Body for the Federal Republic of Germany) Accredited Torque Calibration machine developed by HBM – a market leader in the field of test and measurement – means HBM is now the only commercial calibration laboratory in Europe able to provide calibration in the high torque range with sufficient delivery times.

A radiation shield is essential for best performance outdoors. The sensing probes of EE33M match modern radiation shields with forced ventilation such as LAM630. EE33-M calculates all RH and T related parameters such as dew point temperature, absolute humidity, and mixing ratio. An optional connection cable allows for easy adjustment and configuration of the transmitter. The optional RS485 interface enables a network of up to

As manufacturers and users of motor test benches tend to only accept calibration certificates from accredited calibration laboratories, this can often take up to 15 months. The new Torque Calibration machine from HBM, which is used by HBM as part of its in-house accredited calibration service, significantly speeds up delivery times, which is a often a competitive factor in project management.

Email: info@epluse.at

For more information, please contact HBM on +44 (0) 208 515 6000 or visit www.hbm.com.

32 transmitters.

www.epluse.com

The ABR Automated Breakthrough Analyzer – characterizing novel materials for gas separation and purification applications

Achieve Zero Error in Manufacturing of Parts, Modules and Kits

Hiden Isochema is delighted to announce the launch of our all-new ABR Automated Breakthrough Analyzer, which complements our existing larger scale breakthrough reactor systems.

Weighing is an inexpensive and easy-to-apply method for in-process and end-of-line quality control. It allows high throughput to support errorfree automated manufacturing. The new white paper Zero Errors for Automated Manufacturing – Efficient Control Method Succeeds outlines how to obtain:

The ABR is designed to meet the needs of researchers wishing to characterize the gas separation performance of novel materials, such as metal-organic frameworks (MOFs), zeolitic imidazolate frameworks (ZIFs) and covalent organic frameworks (COFs), without the time or expense of synthesizing larger quantities of material. Breakthrough curve measurement allows high-throughput screening and testing of adsorbents, for a wide range of separation processes including CO2 capture and storage, the purification and recovery of noble gases, natural gas and biogas upgrading, toxic gas removal and air separation.

• Accuracy and reliability • Easy verification of equipment • Multiple high speed control points It also discusses successful applications of weight based quality control and how to remove defective parts, modules or kits from the manufacturing process. METTELR TOLEDO’s compact and rugged weigh modules optimise in-production quality control and ensure zero error weighing. The weigh modules are easily integrated into machines and instruments and provide fast, accurate and precise results.

For further information on this or any other Hiden Isochema product contact Hiden Isochema at info@hidenisochema.com or visit www.hidenisochema.com

For more information download the zero error white papers: www.mt.com/ind-wp-zero-error

The PK160 Thermal camera is the newest entry level thermal camera from Satir

SONOTEC – Ultrasonic Solutions for Preventive Maintenance

160x120 resolution {19200 pixels ] ANDROID based camera for a price of a typical 80x60 [4800 pixels] Key features as standard • 160x120 resolution • 8meg pixel CCD • Jpg format • Touch screen • Wi-Fi • Built in Analytics & Reporting Software • User data / software can be added Over 20 years’ experience engaged in manufacturing infrared cameras & core , SATIR innovative design is ideal to meet the changing demands of the thermal industry.

Tel: +44 (0) 1332 638101 www.satir-uk.com

PECM Issue 17

Email: enquiry@satir-uk.com

SONOTEC is an internationally operating technology venture, established on the market as a provider of ultrasonic solutions for preventive maintenance. For more than 25 years, we develop, produce and distribute ultrasonic testing devices for leak detection, tightness testing, bearing monitoring, valve inspection and detection of partial discharges. In addition, the technology company manufactures customer-specific ultrasonic transducers and sensors as well as testing equipment and measuring technology solutions for noninvasive fluid monitoring and non-destructive testing. These range from medical technology and the chemical and pharmaceutical industries to engineering and plant construction.

email: sonotec@sonotec.de

www.sonotec.eu

A key to the success of the company has been the constant development of new products to keep abreast of market demand.

Ray-Ran Test Equipment Ltd grows from strength to strength

ay-Ran has always maintained a strong engineering and manufacturing base to its core business activities, with over 40 different products and a strong oneoff project capability. The company can offer a wider portfolio than most other test equipment manufacturers worldwide. A key to the success of the company has been the constant development of new products to keep abreast of market demand. Equipment has been designed for diverse industries from Medical (testing prosthetic joints) to the ever growing recycling industry. Ray-Ran’s product range starts with instruments to test raw materials in pellet, flake or fibre form for Bulk Density and pourability, through to Density testing using Density Balances or Columns and the testing of the MFI or MVR of materials using the 6MPCA Melt Flow Tester. Sample preparation is another area where Ray-Ran excel by manufacturing

a range of equipment to prepare samples from either the raw material or sheet form like the Small Injection Moulding Apparatus which will mould small samples like dumbbells etc from pellets and ﬂakes or the Cutting Presses which will cut samples from sheet material, then for the thicker sheets over 10mm thick or Pipes up to 100mm thick, the CNC Milling machines.

Ray-Ran’s product range starts with instruments to test raw materials in pellet, flake or fibre Then finally Ray-Ran also manufacture a range of machines to test the samples & finished products, such as the Izod or Charpy Impact Tester, Static & Dynamic Friction for films & foils, Tensile Tester for elongation or compression, Softening point &

Heat deﬂection with the HDT/Vicat equipment to name but a few. Ray-Ran has been working on a new generation of Dedicated Microprocessor Systems to enhance the current product range, these include the MFI and Falling Dart Machines, Static & Dynamic Friction Tester, and the Pendulum Impact Tester which have already been released, the 6 Station Advanced HDT/Vicat apparatus is currently undergoing redevelopment and will incorporate the new microprocessor and will be released next year. New features of this microprocessor will include Graphical Display, AlphaNumeric Keypad, Storage of user information, including Types & Testing parameters, Ethernet & RS232 Connectivity. These new products and enhancements will keep Ray-Ran’s name synominous throughout the world for Quality Testing Instruments.

Tel: +44 (0)24 7634 2002 • Email: polytest@ray-ran.com • www.ray-ran.com Issue 17 PECM

Hydraulic, electric or mechanical drive systems Speed Sensors and instruments = RHEINTACHO

or applications, that expose the sensor tip to particularly high pressures, RHEINTACHO has developed special speed sensors with a heavyduty design, either with brass or stainless steel housing. Sensors that have to be used in machines, such as orbital motors, must meet the highest requirements. The high pressure sensors of the FE series from RHEINTACHO are particularly intended for use in hydraulic drives with high pressures of up to 210 bar (tested according to ISO 6605:2002). They comply with protection classes IP6K9K and IP67, operate over a wide frequency range from 0.1 to 20,000 Hz and guarantee high EMC stability.

RHEINTACHO Messtechnik GmbH is a company with longstanding tradition and has been engaged for over 114 years in the field of rotational speed, a crucial control quantity for mechanical processes. Just over 70 employees

www.rheintacho.com

PECM Issue 17

work at the company’s headquarters in Freiburg, Germany. In-house product development, production and assembly departments guarantee quick and innovative solutions to customers’ individual requirements. RHEINTACHO is specialized in developing and manufacturing sensors for the harshest environments. The sensors’ resistance to high pressure, temperature changes, electromagnetic interference, aggressive media, water and steam jets is crucial for their operability and service life. RHEINTACHO offers a wide range of standard products for the most varied applications, with suitable measuring systems and electronics, as well as appropriate housings, designs and connections. In addition to this, the German company also provides custom solutions, quickly and inexpensively. RHEINTACHO UK Ltd (formerly Foundrometers), has belonged to the RHEINTACHO Group since 2000 and is engaged in the customization, manufacture and assembly of mechanical and electrical instruments for measuring and controlling rotational speed. A further specialty is the repair and refurbishing services for nearly any instrument in this field regardless of age or manufacturer. And as far as trading is concerned, all RHEINTACHO Group products are also available through RHEINTACHO UK.

Further products from RHEINTACHO are: • Digital hand-tachometers rotaro and redpoint as well as ATEX certified mechanical hand-tachometers htm that record rotational speeds and run lengths • Portable and stationary stroboscopes with LED or XENON technology that are instruments for the visualization of very fast movements • Speed monitor systems such as the programmable rotas that measures the motion of engines, machines and systems • Electrical indicators that visualize process factors such as rotational speed, velocity, flow, positions and filling levels Typical applications of RHEINTACHO products are: • Mobile hydraulics • Large engines • Wind power • Material handling • Electric drives • Service & Commissioning Our aim is to meet our customers’ every need by consistently producing the best possible rotational speed measurement product at a competitive price. Since this also means providing an excellent all-round service we place great emphasis on optimizing levels of cooperation, reliability and continuity.

RHEINTACHO UK Ltd, a subsidiary of the German company RHEINTACHO Messtechnik GmbH, is specialized in the production of non-electronic measurement and indication instruments, and acts as a sales and service center for the UK and Ireland. In-house product development, production and assembly departments guarantee quick and innovative solutions to customers’ individual requirements. The production range incorporates a wide range of solutions of a high technical quality, principally in the field of rotational speed: sensors, hand-held measuring devices, rotary encoders and switching devices.

As a manufacturer of measuring devices, sensors and accessories for rotational speed recording and monitoring, RHEINTACHO has been offering first-class solutions for a wide range of applications for more than 114 years. Our rich experience in rotational speed measurement is reflected as much in our standard products as in the special solutions we develop for our customers.

Tel: 0113 287 4411 • Fax: 0113 287 4422 • Email: sales@rheintacho.co.uk • www.rheintacho.com

Measurement & Monitoring

Go with the flow

ifm is committed to working closely with its customers to develop products which precisely match their needs

Inline vortex flow meters with user-friendly display

new range of flow meters is now available direct from leading sensor manufacturer ifm electronic Ltd. The SV range of flow meters measure flows is designed primarily for cooling water flow measurement and will also handle deionised water. Critically for cooling applications, the SV also features integrated temperature measurement. In contrast to flaps and floats, a vortex flow meter has no mechanical moving parts to go wrong, so the SV range will provide reliable metering for years to come. A highlight of the SV is also the rotatable display, which can show the flow rate and temperature as well as user-defined location information. The display shows flow or flow and temperature and colour indications

for flow and/or temperature can be set independent of one another. The background lighting is adjustable, and the background colour can be changed from black (factory setting) to white. The two available outputs can be configured in a variety of ways; to provide a simple switched outputs (selectable as PNP or NPN) or frequency outputs indication flow or temperature. The SV is also IO-Linkenabled, providing the user with full control over settings and more process or diagnostic information, with the true measured value available. The SV comes in three sizes for flow ranges up to 20, 40 or 100l/min in ½” or ¾” pipes with a medium temperature between -10 and 90°C. Flow measurement accuracy is ±2% MV + 2 % MEV and temperature measurement: ±1k.

ifm is committed to working closely with its customers to develop products which precisely match their needs, and the company provides expert, readily accessible technical support to help users maximise the benefits they gain from ifm products. For further information, contact Gemma Anderson, ifm electronic Ltd., efector House, Kingsway Business Park, Oldfield Road, Hampton, Middlesex, TW12 2HD. Telephone: 020 8213-0000. Fax: 020 8213-2234. Email: gemma.anderson@ifm.com.

PECM Issue 17

Measurement & Monitoring dĞƐůĂdĞƐƚ ^ǇƐƚĞŵƐ ŝƐ ƚŚĞ KĨĨŝĐŝĂů h< ŝƐƚƌŝďƵƚŽƌ ĨŽƌ ƚŚĞ ŝŶĚĞƌ 'ŵď, ZĂŶŐĞ ŽĨ dĞƐƚ ŚĂŵďĞƌƐ Θ KǀĞŶƐ͍

sŝƐŝƚ ŽƵƌ E t Ͳ ŽŵŵĞƌĐĞ tĞďƐŝƚĞ ĨŽƌ Ăůů zŽƵƌ ŶǀŝƌŽŶŵĞŶƚĂů dĞƐƚ ŚĂŵďĞƌƐ Θ ,ĞĂƚŝŶŐͬ ƌǇŝŶŐ KǀĞŶƐ ƌĞƋƵŝƌĞŵĞŶƚƐ

revolutionary!

dĞƐůĂdĞƐƚ ^ǇƐƚĞŵƐ ĂƌĞ ĂďůĞ ƚŽ ƐƵƉƉůǇ ĂŶ

Multi-circuit metering

DIRIS Digiware The new multi-circuit energy metering system that will revolutionize electrical installations.

DIRIS Digiware The new multi-circuit plug & play energy metering & measurement system www.diris-digiware.com

www.socomec.com

Tel: 01462 440033

E-mail: info.uk@socomec.com

ĞǆƚĞŶƐŝǀĞ ƌĂŶŐĞ ŽĨ dĞŵƉĞƌĂƚƵƌĞ Θ ,ƵŵŝĚŝƚǇ ƚĞƐƚ ĐŚĂŵďĞƌƐ͕ ,ĞĂƚŝŶŐͬ ƌǇŝŶŐ KǀĞŶƐ ĂŶĚ ^ƵƉƉŽƌƚ ^ĞƌǀŝĐĞƐ͘ tĞ ĂƌĞ ĂďůĞ ƚŽ ƐƵƉƉůǇ Ă ďƌŽĂĚ ƌĂŶŐĞ ŽĨ ƐŽůƵƚŝŽŶƐ ĨŽƌ Ăůů ǇŽƵƌ ƚĞŵƉĞƌĂƚƵƌĞ͕ ŚƵŵŝĚŝƚǇ ƌĞƋƵŝƌĞŵĞŶƚƐ ĨŽƌ ǇŽƵƌ ƉƌŽĚƵĐƚ ƚĞƐƚƐ Žƌ ĐŽŶĚŝƚŝŽŶŝŶŐ ŶĞĞĚƐ͘

More versatile, quicker to install, more accurate and more cost effective.

tĞ ƐƵƉƉůǇ ĞƋƵŝƉŵĞŶƚ ǁŝƚŚ ƚĞŵƉĞƌĂƚƵƌĞ ƌĂŶŐĞƐ ŽĨ ͲϭϬǑ ƚŽ нϭϬϬǑ ͖ ͲϰϬǑ ƚŽ нϭϴϬǑ Θ ͲϳϬǑ ƚŽ нϭϴϬǑ ǁŝƚŚ ĂŶ ŽƉƚŝŽŶĂů ŚƵŵŝĚŝƚǇ ƌĂŶŐĞ ŽĨ ϭϬй ƚŽ ϵϴй Z, ĂŶĚ ,ĞĂƚŝŶŐͬ ƌǇŝŶŐ KǀĞŶƐ ƵƉ ƚŽ нϯϬϬΣ ͘ KƵƌ ĞǆƚĞŶƐŝǀĞ ƌĂŶŐĞ ĞŶĂďůĞƐ ƵƐ ƚŽ ŽĨĨĞƌ ƐŽůƵƚŝŽŶƐ ŽǀĞƌ Ă ůĂƌŐĞ ƌĂŶŐĞ ŽĨ ƚĞŵƉĞƌĂƚƵƌĞ ĂŶĚ ŚƵŵŝĚŝƚǇ ĐŽŶĚŝƚŝŽŶƐ͘ dĞů͗ ϬϭϳϳϮ ϲϬϬϳϳϭ͕ ͲŵĂŝů͗ ĂŶĚǇΛƚĞƐůĂƚĞƐƚ͘ĐŽ͘ƵŬ͕ tĞďƐŝƚĞ͗ ǁǁǁ͘ƚĞƐůĂƚĞƐƚ͘ĐŽ͘ƵŬ

The worldwide number 1 supplier of power transmission products

Torque Measurement to 1600Nm ROBA®-DSM

Benefits

Applications

• Robust ‘Industrial’ Design • Economic Torque Measurement • Simple Installation and Set-Up • Bearing Free Compact Design • Direct PC Connection • Vibration and Temperature Resistant

• Test/Measurement Rigs • Production Machinery • In-Process Condition Monitoring • Process Control Equipment • Torque Tool Testing/Setting • Drive Line Testing/Monitoring • Pump/Gearbox Inspection

01535 663900 ® sales@mayr.co.uk www.mayr.co.uk Torque Limiters

Safety Brakes

Shaft Couplings

Issue 17 PECM

Process Technologies

Tel: 0208 339 7370 Fax: 0208 339 7371

Unit 5 Russell House, Molesey Road Walton-on-Thames, Surrey KT12 3PE

Email: sales@blackfast.com Web: www.blackfast.com

Total Process Protection Flameless Venting

Explosion Venting

Bursting Discs

Dust Detection

In these demanding times companies have a lot to deal with to meet financial targets. On top of that EHS departments have to ensure that adherence to the relevant H&S legislation such as ATEX and DSEAR for potentially explosive atmospheres and environmental legislation such as VOC & IPPC for fugitive emissions are dovetailed into safe working practices. Fike are the experts in providing protection against dust/hybrid explosion protection and over-pressure or vacuum conditions. We can work with you to protect your plant and personnel against such incidents and also assist in meeting the relevant EHS requirements of your site. Our Total Process Protection capabilities include: ■ ■ ■

ʻStandardʼ Bursting discs – flange mounted, to prevent against over pressure or vacuum conditions. Customised bursting discs – to suit bespoke mounting requirements.

ValveGuard Bursting discs – to protect PRVʼs and reduce fugitive emissions.

Explosion venting – where the product is not an environmental problem and can be vented into a safe area. ■ Flameless venting – where you have to vent inside a building ■ Active or passive explosion isolation – to prevent propagation. ■ Active explosion suppression – where it is not suitable for flameless, or the product does not want to be released for economic or environmental reasons. ■

■

Since 1986 Mydax has offered process temperature control solutions for OEM and one of a kind custom chiller applications. With the ability to provide extreme temperature stabilities of ±0.05°C for critical applications, even with high cooling power requirements up to 70kW, Mydax is bringing laboratory precision to the industrial market. Mydax also offers the CryoDax series of chiller systems for the most demanding requirements with fluid temperature ranges of -70°C to +150°C with cooling capacities from 2kW up to 15kW @ -50°C available. Please call or visit Mydax online for more information.

Dust detection systems – to validate the protection strategy of non-zoned areas.

Please call 01622 01622 677081 677081or oremail emailsales@fike.co.uk sales.uk@fike.com Please call and our specialists specialists will will provide provide sound sound advice adviceevery every and our step of the way to meet your goals. step of the way to meet your goals. Fike UK, 35 35Earl EarlStreet, Street,Maidstone, Maidstone, Kent, ME14 United Kingdom Fike UK, Kent, ME14 1PF, F1PF, United Kingdom T: +44 W: www.fike.co.uk T: +44(0) (0) 1622 1622677081 677081E:E:sales@fike.co.uk sales.uk@fike.com W: www.fike.co.uk

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Mydax Inc. 12260 Shale Ridge Ln. Auburn, Ca. 95602 USA 00-1-530-888-6662 www.mydax.com

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Process Technologies

Industrial Vacuum – Vuototecnica Guarantee Application success

solutions.

uototecnica are celebrating 40 years as one of the market leaders in manufactured vacuum

UK Director, Jonathan Plumb says: Vacuum is commonly misunderstood not only by end users but also by agents or suppliers. Many suppliers

of vacuum equipment do not fully understand or have the technical knowledge to support the products they supply which often leaves many end users lost to find the correct solution or even someone who can”. Vuototecnica are market leaders in providing Total Vacuum Solutions as they are vacuum engineers rather than just suppliers of equipment. The Vuototecnica range of equipment is probably the largest available from a single manufacturer and therefore ensures the correct equipment is selected for the job at hand. • over 2,500 suction cups, cup holder and fittings. • full range of vacuum control valves and instruments. • comprehensive range of Electric and Pneumatic vacuum pump. • vacuum lifting & pick and place systems.

Techsil launches Momentive’s High Performance Silicone Adhesive Sealant in the UK

Vuototecnica • guarantee a solution. • provide a 5 year materials guarantee on specific equipment. • can offer the most cost effective solution supported by specific operating costs when applied to a vacuum system. To find out more on how Vuototecnica can provide the best solution for your application please visit www.vuototecnica.co.uk sales@vuototecnica.co.uk or call Jonathan on tel 01908 227892

New entry-level model introduced to 14.5cm LCD touchscreen Fluke TiX Expert Series Infrared Cameras

Techsil have just launched SnapSil TN8000 silicone adhesive into the UK market. It is a very versatile, high performance silicone adhesive sealant that is manufactured by Momentive Performance Materials in Japan - one of the world’s leading manufacturer of RTV silicones. SnapSil TN8000 adhesive is a one-component condensation-curing silicone rubber developed for sealing.

With a full 180° articulating lens and 14.5cm touchscreen, the new entry-level Fluke® TiX500 Infrared Camera allows thermographers to easily navigate over, under, and around objects to preview and capture images. The recently-introduced Fluke TiX Expert Series cameras are ideal for predictive maintenance, in R&D, oil and gas, and utility applications, where flexibility and higher resolution are essential, and they enable users to share their data in real time via Fluke Connect™.

It has a thixotropic paste consistency and exhibits excellent corrosion-free adhesion to many substrates such as metals (including copper), plastics, PPO/PPE, ceramics and glass without the use of primers.

The responsive 14.5cm LCD touchscreens of the Fluke TiX Expert Series offer a large viewing area, which enables thermographers to quickly identify issues while still in the field, as well as easily edit images directly on the camera, eliminating time in the office.

Email: technical@techsil.co.uk

www.techsil.co.uk

Specialist Pilot Plant Trials Facility helps manufacturers optimise their Filtration Processes Manufacturers wishing to develop or optimise their separation processes are benefiting from the comprehensive pilot plant testing services of membrane filtration specialists, Axium Process. Pilot plant separation studies help determine at an early stage process feasibility, plant design and an evaluation of likely operating costs. Utilising its comprehensive range of mobile membrane filtration pilot plants, Axiums’ specialist engineers will carry out trials on fresh feed supplied by the customer at its state- of- the-art Swansea based laboratory and testing area or at the customer’s premises. Each customer is supplied with a test protocol prior to the trials and a sample analysis together with a detailed report is provided upon completion. A range of different membranes can be used througout the trials as the company is independent of any membrane manufacturer ensuring that the optimum membrane can be selected for a given application.

Email: info@axiumprocess.com

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www.axiumprocess.com

For more information on all Fluke products, please visit: www.ﬂuke.co.uk

Heraeus Installs First Gas Catalytic Infra-Red Oven in the UK Heraeus Nobleight has installed a gas catalytic infra-red oven at its Neston, Wirral, Applications Centre. This complements the range of electric infra-red systems at Neston, so that customers, and potential customers, will now, for the first time, have the opportunity of trialling their products using various infra-red technologies, to achieve the optimum process to meet their heating, curing or finishing requirements. The new oven is particularly suitable for powder coating and the Neston installation also includes a powder-coating station and an overhead conveyor to simulate real process situations. Other applications include food drying, thermo forming, textiles drying, leather curing and curing coatings on heat-sensitive substrates, such as MDF.

Tel: 0151 353 2710

Email: ian.bartley@heraeus.com

Process Technologies Save energy & save money! Air Dryer Technology is an independent specialist company providing service and after sales support on all types and makes of compressed air/gas dryer, filtration and condensate management systems. The main activity is providing technical support and comprehensive packages for on-site servicing of compressed air/gas treatment equipment and desiccant air drying plant. Air Dryer Technology also provides consultancy and equipment upgrades to increase efficiency and reduce energy costs. Retrofitting a dryer control system provides significant benefits by operating to actual site conditions, rather than original design specification. It will also restore customer confidence in equipment operation and performance. Installing a dewpoint control system to a compressed air desiccant dryer will save energy, considerably reduce operating costs, and provide efficient dewpoint control. Features and benefits include; Controls Compressed Air Monitor Dewpoint Extends Service Time Extend Cycle Time Constant Dryer Knowledge Retrofit Design Record Performance Data Installation Service/Technical Support

Tel: 0161 788 7900

Save Money Reduce risk Maximise desiccant life Reduce switching valve wear Increase conﬁdence No equipment modiﬁcations required Predict dryer failure Peace of mind

www.airdryertechnology.com

:(67,1*+286( Old, Tired, Troublesome Valves?

Call for a free on-site survey!

Leaking shaft seals? Worn out valve? Product discharge problems? We offer a free of charge assessment of any rotary valve or diverter valve to help diagnose the fault. With DMN’s unrivalled knowledge and experience of rotary and diverter valves we are sure to have the solution to keep your process in operation.

O LI LIDS I DS HANDLING H AN ANDL D I COMPONENTS FOR BULK SOLIDS

• • • • • • • •

DMN UK Ltd. T +44 1249 818 400 dmn@dmnuk.com

www.dmnwestinghouse.uk Issue 17 PECM

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Product News Joint Venture between Stahl & OEM NuTech responds to demand for VOC-free powdercoatings for heat sensitive materials Chemical company Stahl has entered into a joint venture with OEM NuTech, a world leader and innovator in powder coatings for heat sensitive materials. Like Stahl, Australian company OEM NuTech has a strong focus on sustainability. With their environmentally friendly powder coatings, the companies expect to make a substantial contribution to the increasing demand for organic and ecofriendly materials for interiors and architectural applications. Stahl will use the partnership to expand its coatings oﬀering, thus strengthening its market position as a coatings specialist.

www.stahl.com

Netherlocks paves way into the future with Ex certification As a manufacturer of traditionally mechanical process safety solutions, Netherlocks is already bridging the gap for some years now between mechanical standalone safety systems and the plant level distributed control systems (DCS). This lead to a growing requirement for integrated electronics in our traditionally mechanical product portfolio (check link 1 and link 2 for examples). Due to this, together with the common use in explosion hazardous environments, Netherlocks has acquired new specialist knowledge in the field of electronics and explosion proof technologies. In this respect, Netherlocks has now reached an important milestone, by receiving the EN ISO/IEC 80079-34: 2011 ATEX/IECEx-certificate from international certification body Kiwa. Starting in February this year various new processes were designed, personnel was trained in Ex regulations and multiple audits were conducted by Kiwa. Finally, on July 14 2015, a final audit found no discrepancies and an official certificate was awarded.

www.netherlocks.com

Elcometer 456 Scanning Probes

Russian Oil Company Reaches across the Globe to Improve Efficiency

Elcometer oﬀer three Ultra/ Scan probes for the Elcometer 456 Coating Thickness Gauge, providing very fast, reliable and accurate measurements. Ultra/Scan probes measure on either ferrous metals (F scale 1 to 1,500 µm and F scale 2 to 5 mm range) or non-ferrous metals (NF) metals. The probes are available as F only or dual FNF options.

When a Russian oil company wanted to improve the company’s oil extraction and processing eﬃciency they reached out across the globe and turned to the Cardiﬀ based Tema Group to call upon their vessel engineering expertise.

Probes have a replaceable cap to prevent wear during scanning. This is crucial to maintaining probe accuracy. They use the Elcometer 456’s patented oﬀset feature, ensuring the thickness of the cap is included in the adjustment process and discounted from the thickness readings.

The skilled Tema Vessel Division provided with three diﬀerent vessel packages to support oil productivity: a water treatment package, a de-oiling hydrocyclone package and a stand-alone sand collection vessel. The experienced team at Tema Group manufactured the vessels to a high quality standard with Duplex S31803, a hybrid stainless steel, which is extremely corrosion resistant, so the vessels are built to ensure a long lifespan on the exposed oil platform.

www.elcometer.com

www.temagroup.co.uk

Terex offers Latchways’ fall protection systems

ESAB Launches Cutmaster® Series of Handheld Plasma Cutters

Terex Material Handling is a registered specifier, supplier and installer of Latchways’ comprehensive range of fall protection and working at height products. The company is offering the safety systems alongside its extensive range of Demag lifting equipment for new crane installations, retrofits and refurbishments. Terex Material Handling will also supply and fit the fall protection systems to the cranes of other original equipment manufacturers.

ESAB Welding & Cutting Products announced the launch of its ESAB Cutmaster® Series of portable air plasma cutting systems, which range in output from 20 to 120 amps and produce a recommended “quality” cut on material from 6 mm to 40 mm. ESAB Cutmaster plasma cutters are among the lightest and most compact in the industry, making them highly portable and easy to store.

Latchways manufactures a comprehensive range of safety equipment, including the innovative ManSafe® fall protection system for working at height. ManSafe® aﬀords operators unfettered movement and continuous, hands free security whilst working at height. The operator’s safety harness is secured to the ManSafe® line via a high integrity lanyard and a ‘transfastener’ mobile anchor point, providing comfort and mobility for the operator.

With ESAB Cutmaster products, the recommended cut capacity equals the system’s true cut capacity. A recommended cut has a smooth cut face with little or no dross and requires little or no rework or grinding, all of which improve productivity and quality. ESAB Cutmaster products provide additional output when needed, oﬀering a maximum cut thickness that ranges from 60 to 150% greater than the recommended cut. As a result, they eliminate the concept of having to “buy up,” or purchase a machine larger than end-users actually need.

www.terex.com

www.esab.co.uk

Straightpoint Launches Running Line Dynamometer

Phytron space engines power the cameras of the DAWN space probe

Force measurement, load monitoring and suspended weighing load cell manufacturer Straightpoint has launched a new product for measuring tension on lines—the Running Line Dynamometer (or TIMH).

The final frontier Space flight of the 21st century has not even left our solar system and already fills the people with wonder, through stunning images and data. Step by step, the extreme environment of space is being conquered in ambitious scientific missions such as DAWN. The space probe DAWN has been on a journey through our solar system since 2007, exploring the asteroid Vesta and the dwarf planet Ceres. The fact that DAWN is still sending high-resolution pictures to Earth even after eight years in space is owed to the developers of the two framing cameras.

The product, part of the tension in motion range, is built with dockside, marine, offshore, towage and salvage applications in mind but it is anticipated that the TIMH will also be used in other industries once it is proven in the field. End users have noted two outstanding features of the dynamometer. First, the product is launched with a Straightpoint hallmark, the ability to deliver to a short lead-time of within just three days. Second, it can be used when there is no anchor or dead end on the line, for example, when there is a requirement to measure a force at a specific point of a longer line.

VSS space precision stepper motors by the company Phytron (diameter 25, 200step) adjust the filter wheels of two onboard cameras and drive the spindle-driven mechanism of the flap that protects the sensitive camera lens from dirt and damage. The Phytron VSS motors, originally optimized for vacuum use, provide the basis for space-qualified VSS space designs. A variety of modifications protect the motor from vibrational loads during rocket launch. Materials and tests are extensively documented.

Tel: + (0)2392 484891

www.phytron.eu

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www.straightpoint.com

Product News

Sieving technology takes a leap forward with Farleygreene’s Sievmaster and Sievgen ranges

arleygreene have updated their already successful SIEVMASTER ‘Slimline’ straight through vibratory check sieve to include new features that have been part of ongoing development by the company. This range of sieves is primarily designed to pass material straight through a mesh screen to remove any contamination from bags, silos, drums etc… and can incorporate an under screen rare earth magnetic separator to remove any ferrous metal. The unit can fit into existing lines due to its low height profile or into a debagging station which can dispense into containers or can connect

to any type of convey line, mechanical, vacuum or pneumatic. Farleygreene’s range of sieving machinery is extremely comprehensive. Their equipment and technologies cover almost every type of sieving and screening process, their new website shows the full range of their portfolio. They also offer the benefit of a tailored bespoke design service, either through adaptation of their standard units, or a machine or system developed for a specific application. You should take the opportunity whilst on the website to view the new SIEVGEN 400-US ultrasonic sieve which is designed for separation of very fine powders such as toner, ceramics; or heavy metal powders used

in the additive manufacture arena. All Farleygreene’s machines come with a 24 month warranty, full support for spares and a rapid response re-meshing service for any type of ring or frame. Sieve units can be trialled in their new test facility in Hampshire or the test can be carried out at your site with their 1 week free trial service. Tel: +44 (0) 1256 474 547 Email: info@farleygreene.com www.farleygreene.com Issue 17 PECM

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Sensors & Systems

Sensor-Technik UK Ltd. Mobile Controllers and Measurement Technologies

A08 Pressure Sensor

Sensor-Technik UK Pressure Sensors

Delivering An Integrated Solution

> Measuring up to 3,000 bar

> Sensor & Measuring Systems

> Versatile, low failure rates

> Controllers & HMIs

> Thin-film, ceramic or silicon available

> Complete Engineering Lifecycle

NGS2 Inclination/Gyrosensor

M01 Pressure Sensor

L03 Pressure Sensor

> Varied media compatibility

> Measuring Range ±180°

> Off-highway vehicles

> Food Industry

> 0-1000 Bar Range

> CANopen Output Signal

> 0-800 Bar Range

> 0-20 bar range

www.sensor-technik.co.uk sales@sensor-technik.co.uk Sensor-Technik UK Unit 21M, Bedford Heights, Bedford, MK41 7PH Tel: 01234 270770 | Fax: 01234 348803

Your Ideas. Realised

Hansford Sensors to showcase solutions for effective vibration monitoring at Maintec 2016 H ansford Sensors, the leading manufacturer and global supplier of industrial accelerometers, will be presenting a selection of its market leading vibration monitoring solutions at Maintec 2016.

its popular low cost HS-420 on-line sensor for monitoring such equipment as fans, pumps and motors, as well as the HS-620 Vibration Monitoring Kit, which enables maintenance technicians to measure bearing condition and levels of velocity, acceleration and displacement.

explains Chris Hansford, Managing Director at Hansford Sensors. “By implementing an eﬀective maintenance strategy that features vibration monitoring, maintenance teams can minimise the downtime of their assets and achieve greater productivity.”

At the show, visitors can see the many vibration monitoring options oﬀered by Hansford Sensors for themselves. This includes: the HS-100 series, which is an AC industrial accelerometer that enables quick and easy measuring of vibrations in rotating machine components; and the Premium HS-170, which delivers improved frequency response and enhanced eﬃciency compared with many other market options. Hansford Sensors will also be showcasing

In addition, visitors will have the opportunity to discuss their own application and condition monitoring needs and the many beneﬁts of vibration monitoring with Hansford Sensors’ experienced on-stand specialists.

Maintec 2016 will be taking place at the NEC in Birmingham on 22-24 March 2016. Visitors to the show will ﬁnd Hansford Sensors at Stand M314.

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“Maintec is one of the most important events in most maintenance technicians’ calendars, which is why we’ll be presenting our leading range of vibration monitoring equipment once again,”

For more information on the extensive range of Hansford Sensors products, please visit: www.hansfordsensors.com.

Sensors & Systems

New Infrared Sensor Lets Engineers Check Temperatures with a Smartphone App

alex Electronics Ltd announces the new PyroNFC, a small, low-cost infrared temperature sensor that lets engineers and machine operators use a smartphone app to check temperature measurements on the production line. The PyroNFC sensor measures the temperature of surfaces in industrial processes without contact, and at just 29 mm in length, it is the smallest sensor that Calex has ever produced. It has a linear voltage output for connection to industrial process instrumentation, and an open drain alarm output that can be used simultaneously. By touching an NFC-enabled smartphone against the back of the sensor, the user can read the measured temperature with the free app. The reading updates continuously while the phone is touching the sensor. With the app, the user can also read or write conďŹ guration parameters including the emissivity setting, which allows an accurate reading on a variety of materials. There is no need to power the sensor to do this: hundreds of sensors can be conďŹ gured in minutes on a benchtop without connecting a single wire or cable. As well as being extremely user-friendly, the PyroNFC is also very low in cost. Machine builders will appreciate this, along with its IP65 sealing, compact size and direct linear output for direct connection to instrumentation. Email: mail@calex.co.uk www.calex.co.uk Issue 17 PECM

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Many years experience of supplying Differential Pressure Transmitters Halstrup Walcher Gmbh have many years experience of supplying Differential Pressure Transmitters for applications where it is necessary to maintain a continuous overpressure; e.g. in hospitals, cleanrooms, and hygienic plants. It can also be necessary to maintain continuous underpressure to prevent bacterial spread in isolation wards. We can offer a range of high precision devices to suit these applications, but for the basic requirements of HVAC our PS27 series unit offers a competitive alternative. This compact unit is available with two-wire technology and an optional display. Four different measurement ranges can be selected by toggling, or by jumpers, and a range of analogue outputs can be selected.

With such a large number of Differential Pressure units out in the field the need for a high precision all in one measurement and calibration device becomes apparent. The KL200 runs on mains supply or battery and is ideal for mobile applications. An internal pump quickly and accurately generates positive or negative differential pressure up to 100kPA. Multilingual with USB interface. Suitable for calibration of blood pressure monitors. Twenty ranges up to 100kPa.

Contact ; OMNI SENSORS AND TRANSMITTERS LTD www.sensorsandtransmitters.com â&#x20AC;˘ Email: sales@sensorsandtransmitters.com â&#x20AC;˘ Tel: 01926 6142633

Differential Pressure Transmitters manufactured by Halstrup Walcher Gmbh The measurement of differential pressure, and its precise regulation, has importance in many areas of air handling process technology. Halstrup Walcher have been providing solutions for applications found in Cleanrooms, Hospitals, Filling Machines, and Hygienic Plants for many years. The high precision “P26” DP Transmitter is available for “top hat” rail or wall mounting , in a wide range of pressures and volume flows. The unit has scaleable ranges, and zero point calibration to prevent drift. The “P26” has a built in valve to provide a high level of overload protection. There is a variant of this unit, the “P29”, which can be used for measurement of natural gas.

The compact and innovative “P34” DP Transmitter is DIN Rail mounting. It has optional analogue temperature input and internal pressure sensor for PT compensated volume flow measurement. It is ideal for panel mounting. The USB interface allows for scaling via PC, and the setting up of the characteristic line form (and many other parameters) can be managed.

The “PUC24” panel is a stainless steel unit for the display of air conditioning data in a cleanroom or other process. There is integrated measurement of DP, humidity, temperature, and pressure. The unit has digital interface, 3 analogue outputs, acoustic alarms, and adjustable switch functions.

Halstrup Walcher offers both standard and customer specific solutions for performing high precision measurements (normally around 0.2% accuracy). With an accredited in-house calibration laboratory and a range of mobile calibration devices (mains and battery powered), we would be pleased to discuss your applications. Contact ; OMNI SENSORS AND TRANSMITTERS LTD www.sensorsandtransmitters.com • Email: sales@sensorsandtransmitters.com • Tel: 01926 6142633

Software & Systems AMG Systems offers free ‘Basics of IP Video Network Design’ whitepaper AMG, the British manufacturer of CCTV transmission solutions and sophisticated 5 Megapixel cameras, has produced a free downloadable whitepaper that guides readers through the basics of IP video network design. Written expressly for those who have analogue CCTV knowledge and who want to understand the basics of IP video system design, the whitepaper takes into account the significant changes in technology that have taken place over the past 15 years. It looks specifically at: • How the different elements of an IP video system function • How these differ from analogue CCTV • How system design impacts network requirements • And, which equipment can be utilised to ensure optimum performance, investment, and future proofing

Sound Maps Mean Safer Workplaces Noise-related hearing loss is one of the most prevalent occupational health concerns worldwide and millions of workers are exposed to hazardous noise every day. Hearing loss makes up between 30% and 40% of occupation-related illnesses.

Using simple, straightforward language and clear examples, the whitepaper takes an unbiased look at both the advantages and challenges of using IP video for surveillance installations, and illustrates the differences in approach required to design an IP video network, as opposed to the traditional analogue system.

Using sound mapping software can help businesses plan and mitigate noise emissions protecting both workers’ health, and their own reputations and legal positions. SoundPLAN – a market leader in sound and air pollution mapping software – is a versatile programme for engineers responsible for developing and testing noise and air pollution reduction strategies for road, rail and industry projects.

Download the full whitepaper on: http://www.amgsystems.com/downloads/whitepapers.htm.

For more information see: www.soundplan.com/noise-control.htm

Forgings Manufacturer Improves Efficiency with Azzure IT

CAMO Software release new version of their software for process monitoring – Unscrambler® X Process Pulse II

A company which manufactures premium metal components for global markets including aerospace, defence, energy and nuclear power is improving efficiency across the business, thanks to innovative IT & new ERP Solutions.

CAMO Software, leaders in multivariate data analysis software, announced today the release of a new version of their easy-to-use multivariate process monitoring solution, Unscrambler® X Process Pulse II. The new version provides users with many new and improved features, including parallel import and alignments of multiple data sources in real time, running and visualization of models with real time flagging of deviations, as well as data historian for simplified troubleshooting. The new version has also been updated with a new and more intuitive user interface.

Independent Forgings and Alloys, based in Sheffield, enlisted the help of local expert Azzure IT to transform its operations with a fully customisable Enterprise Resource Planning (ERP) software solution. The Microsoft Dynamics NAV software provided by Azzure IT has streamlined Independent Forgings and Alloys’ business processes across manufacturing, planning, purchasing and accounting, saving the company both time and money.

www. azzure-it.com

Unscrambler® X Process Pulse II is used in a wide range of industries and research fields, for improvement in product development, manufacturing and quality control. Read more about Unscrambler® X Process Pulse II on www.camo.com.

LEGIC chip technology opens vehicles keylessly The universal contactless reader chip from the LEGIC 4000 series is a central element in the range of innovative mobility services provided by the BMW Group: At DriveNow, the carsharing service from the BMW Group and Sixt SE, the use of keys is now unnecessary due to the contactless data transmission and NFC (Near Field Communication). BMWs and MINIs from the DriveNow fleet can now be opened and locked with the help of a contactless credit card and the LEGIC reader chip. At this year’s Consumer Electronics Show (CES) in Las Vegas, the BMW Group presented its latest development together with MasterCard: Opening the vehicle by simply holding out a BMW credit card to subsequently use it. The universal, contactless reader chip from the LEGIC 4000 series is a central element of this. All BMWs and MINIs from carsharing provider DriveNow are now equipped with a multi-card reader based on the LEGIC 4500M chip, which facilitates contactless communication between a card and the vehicle.

Email: info@legic.com

www.legic.com

Specialist engineering design consultancy services to the Process Industries Finglow was formed in 1982 to provide specialist engineering design consultancy services to the Process Industries. The company specialises in the design of pressure vessels and heat exchangers, and has successfully utilised this expertise in the development of a range of software products which perform calculations in accordance with international design codes. Finglow´s engineers are members of various international technical committees for the advancement of pressure vessel standards, including BSI, EIC, CEN/TC54 and EPERC. These engineers are the authors and developers of the programs.”

Tel: Tel: +44 (0)1992 550 700

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www.ﬁnglow.com

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Software & Systems

Advanced CNC Machine Monitoring with CNC Applications CNC Applications provide professional services and products to CNC machine tool users. These include CNC Training, CADCAM software and shop floor CNC data collection systems. Based in Warwickshire the company was founded in 2012 by Ben Groves after his many years working in the industry for companies such as the Engineering Technology Group and Fanuc GE. The company has grown and gained a reputation for delivering a professional service and implementing solutions to help manufactures drive efficiency and cut costs. CNC Applications flagship product is a CNC Machine Monitoring system called FactoryWiz. Working alongside our clients we are helping them identify untapped production capacity in their CNC machines. Increasing our customer’s productivity by just 5%, which is normally very achievable, the return on investment is enormous; pay back can be as little as just 2 months!

We have customers who tell us the system paid for itself during their trial. We have another customer who is saving £3m a year in one cell alone! FactoryWiz Monitoring is a powerful, modern CNC Machine Tool monitoring and data collection package that allows you to see your whole factory on one screen (PC / Tablet / Smart Phone), in real time and live interactive graphs showing OEE, Part Quality, Performance and Utilisation. Look back at past events and performance with Historical PDF reporting (automatically emailed to you). For more information call Ben Groves on 0121 2883366 or go to www.cncapplications.co.uk

Is your production facility running with serious RISKS? • One major cause of downtime is the lack of appropriate hardware components • Microsoft will stop supporting Windows XP by April 1st, 2014 • 60% of industrial applications lack updates or security patches, making them a target for hackers

Is your application at risk? • • • •

Are spare parts still available? Will your software platforms be supported in 2014? Are your systems protected against intrusions? What is your backup scenario if things go wrong?

Minimize the risk of unplanned stoppages. Visit our web page to find out how - through a free “Risk Analysis Scan”.

www.ge-ip.com/hmi-risk-uk

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Man and Machine CAD Training Academy

MAN AND MACHINE’S professional training centre is a fantastic environment where customers can learn from industry experts, gain authorised qualifications and ensure that any CAD investment is utilised to its full potential.

Man and Machine were able to drop straight in as our new reseller and provide a seamless transfer from our previous supplier. They have been able to give us all we need on the software side and have also provided a flexible training program for a couple of our new starters.

ur goal is to help you optimise your design process. Whether you are in the architecture, plant or construction industries, we have the experience to understand your business and what you are trying to achieve, and we have the expertise to enable you to do it better. Established in 1989, Man and Machine is part of a pan-European group, operating in 11 countries, with over 750 staff and over 500,000 installed CAD seats. We provide expertise in digital design and data management with over 60 years of combined technical experience and extensive industry. Our specialist knowledge has allowed us to develop a wide variety of services that address the needs of our customers’ across multiple industries to enable them to design, visualise, and simulate to the highest standard. Man and Machine’s professional training centre is a fantastic environment where customers can learn from industry experts, gain authorised qualifications and ensure that any CAD investment is utilised to its full potential. If you are looking to improve design efficiency, reduce costs and bring products or infrastructure to market faster, Man and Machine’s consultative approach will help you to gain a competitive advantage and leverage your own expertise to increase productivity and innovation. Being an educationally-rich environment, the

training academy allows you to select an appropriate learning track to help you derive the most from your software investment. To ensure learning outcomes are met, all of our CAD training solutions come with post training support for one month. Students also receive an Autodesk or Man and Machine certificate on completion and all Autodesk CAD courses are taught using the official Autodesk courseware. Man and Machine are an authorised Autodesk Training Centre (ATC) and an approved Certification Centre, allowing students to receive an industry recognised Accreditation. “Man and Machine were able to drop straight in as our new reseller and provide a seamless transfer from our previous supplier. They have been able to give us all we need on the software side and have also provided a flexible training program for a couple of our new starters”. Nick Slater - ITAB Shop Concept For more information on all of the CAD services Man and Machine provide including our latest training schedule and upcoming webinars please visit, www.manandmachine.co.uk, call 01844 263700 or email marketing@ manandmachine.co.uk.

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Trommel Project Benefits From Brevini Expertise & Support Delivering robust and reliable machinery to the mining industry is a specialist task that requires components designed for the job, as well as experience in producing equipment for harsh environments. For one trommel manufacturer in the UK, this meant teaming up with Brevini in order to create a pair of 20 meter machines destined for an iron ore processing facility in Trinidad. esigned to separate materials by size, a trommel is a key piece of equipment within an ore processing facility, but dealing with hundreds of tonnes of rock every hour means that the design must be very robust. Designing and manufacturing a complete package requires several manufacturers to cooperate successfully in order to deliver a properly integrated solution that is both reliable and efficient.

For this particular trommel, the power required for normal running would be 520 kW and this would be used to power four drives that would produce a gearbox output speed of 70 rpm. Due to the size and weight of the screens, the initial startup procedure would require 680 kW for around 15 seconds in order to accelerate the machine up to working speed. This additional power requirement would affect the specification of the drives and gearboxes being supplied by Brevini.

The Holborne Group is a specialist engineering company that has considerable experience in designing and manufacturing trommels. Based in Shropshire, the engineering team has worked closely with its supply partners to design and construct the latest machine. Brevini was contracted to develop the complete drive package, which included the motors, gearboxes, couplings and electrical control system.

The gearboxes were designed around the Posired 2 helical drive units that incorporate a two stage reduction, giving an output ratio of 16:1. All of the units were supplied with identical handling of the input and output shafts, which allowed the gearboxes to be installed in any of the drive positions on the rotary screen. This rationalisation of the design simplifies the installation and reduces the amount of essential spares required.

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The reduction gears are housed in a bespoke, fabricated steel housing - as opposed to the more usual cast casing. This arrangement ensures that the gearboxes will fit easily into the restricted space of the trommel design and also eliminates the need for an angled base plate, which reduces the material costs and the manufacturing time for the components. The design of the couplings also posed a challenge to the Brevini engineers since the maximum diameter was limited to 280 mm. Considering the substantial torque that has to be transmitted, the designers created a coupling using a special hardened material that formed fully crowned and barrelled gear teeth giving Âą2 degrees of misalignment per gear mesh. The hubs and flanged covers were manufactured from high tensile steel which provided a higher torque capacity and enabled standard couplings to be used for heavy shrink fit applications. All of the components were manufactured to extremely high standards using precision machines; the tight tolerances allowing complete interchangeability.

About BREVINI Brevini UK headquarters are located in Warrington, Cheshire, at the heart of the motorway network. Our facilities include 900 sq.m. of offices, manufacturing and warehousing for the Brevini products in Warrington and 800 sq.m. of offices and manufacturing for the PIV Drives helical products in Scunthorpe, Lincolnshire. We are an enthusiastic staff with long experience in power transmissions and we offer a 'solutions based' approach. Using advanced software, our engineers are able to select gearbox units to last the machines total design life. Our UK stock of standard parts, thanks to Brevini's modular construction, allows short lead times for a larger number of variants and sizes. All of these units are supported by extensive UK technical expertise.

Each gearbox was powered by a 185 kW, 6-pole, IE3 electric motor that was fitted with an incremental encoder, thermistors, space heaters and labyrinth seals. The 6-pole design gives a running speed of 1,188 rpm, which allowed Brevini to improve the overall efficiency of the drive system by using a 2-stage reduction gearbox. The encoders were included in the design to provide feedback and position control in conjunction with the variable speed drives (VSDs) to enable load sharing, and also to prevent any individual drive trying to operate alone. In this way the drives are synchronised in their operation and the design prevents any abnormal loads being applied that could lead to premature gearbox wear. In addition to the main barrel screen drive units, Brevini also designed and supplied

the feed and discharge screw conveyor drives that used 37 kW motors connected to Posiplan gearboxes. Again, the design was based on efficiency and reliability, using IE3 motors and the proven Posiplan drive fitted with labyrinth and cassette seals. The electrical control system was designed and built as a bespoke package that would maximise the effectiveness of the drives and improve efficiency. The system provides complete integration of the control circuits and ensures safe and reliable operation of the barrel screens. This includes a progressive start-up procedure that minimises the load on the motors and achieves normal operating speed within 15 seconds. The completed trommel was fully assembled in the Holborne premises before being tested to ensure that

everything operated as designed. This required the company to bring in five generators in order to provide sufficient power to the machine for the final stages of the project. Once all the systems had been verified the vast machine was then dismantled in preparation for shipping to Trinidad. Carl Hanson, Managing Director at Holborne, comments: "This has been another great project for us that has also benefitted from the expertise and flexibility of the Brevini engineers. Their experience and manufacturing capabilities have helped to deliver a product that will provide many years' service in a very unforgiving application." www.brevini.co.uk

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One area in particular that was causing concern included a pedestrian route that passed directly in front of an opening which was to have a high speed door on it.

Klimate Provides Fire Doors and High Speed Doors to a Major Producer of Tissue Products

limate High Speed Doors have been installing their UK made range of high speed, rapid roll doors now for over 20 years. In that time they have installed them in a wide variety of places from car production plants and food process lines to highways salt stores and even underground. The latest batch of installations took place at SCA in Skelmersdale, Lancashire. SCA approached Klimate with a number of problems that they wanted to get around. Due to a reassignment of the factory it was required for extra walls to be built including rapid roll doors and fire roller shutter doors. As Klimate and their parent company BID Group have been working on this site and other SCA sites around the country for many years it was natural that they would be considered for the work. Ian Smith, Project Engineer says that Klimate were chosen to supply the doors on this occasion as they were already present on site and are known for their excellent service. â&#x20AC;&#x153;Most high

speed doors act in similar ways but the reliability of the Klimate doors coupled with the response time offered by the company made the choice a very easy one. The fact that they are very competitively priced is an added bonusâ&#x20AC;?.

The fact that they are very competitively priced is an added bonus.

pedestrians were within the opening the door could not operate. Due to the effectiveness of this system the company are now considering rolling out this system across the site and perhaps the business. In total this project included 5 Rapid Roll Doors and 5 Fire Roller Shutter Doors with 3 of each already being installed and a further 2 due over the next couple of weeks/months as the project progresses.

www.klimate.co.uk

One area in particular that was causing concern included a pedestrian route that passed directly in front of an opening which was to have a high speed door on it. This could have caused many near misses between foot traffic and passing fork lift trucks. However, due to their many years experience within the door market Klimate were able to work with the client and other contractors on site to incorporate their door with a pedestrian crossing system so when Issue 17 PECM

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Storage, Handling & Equipment SAME DAY EXPERTS

OUR SERVICES

OUR PROMISE

Sameday Express Freight is a privately owned and well established same day delivery specialist with bases throughout the UK and sub departments in Europe.

Our vast fleet of delivery vehicles enable us to offer the most suited type to meet our customersâ&#x20AC;&#x2122; needs. We pride ourselves in being experts in time critical, same day deliveries and here are just some of the reasons why Sameday Express Freight is the right choice for you:

To guarantee we will deliver on time, confident that we can meet your requirements and provide 100% customer satisfaction.

Having started as a family business more than 20 years ago, Sameday has grown rapidly to offer an unbeatable one point of contact service, operating on a 24 hour basis. Over the years Sameday Express Freight has built up a customer base to be proud of. This includes customers within the automotive industry for whom we perform time critical deliveries on a daily basis. Our Company ethics mean we respect and understand the urgency of our customersâ&#x20AC;&#x2122; requirements and we always partner with them to meet their expectations and ensure goods are at the final delivery point on time, every time with no exception.

CONTACT US U Same day, time sensitive delivery specialists U UK nationwide and European mainland deliveries U Vehicles from small parcel vans to 26 pallet trailers U Air charter service available U Hand to hand delivery service for time/data sensitive consignments U 24 hour standby couriers for emergency jobs U Free quoting service U Any job considered, regardless of size or weight U Extremely competitive pricing structure U Specialists in undertaking and operating logistics contracts

For further information regarding our services and pricing or to enquire about how we can help you with a specific logistical problem, please call us on: 0844 800 5211 or email: sales@samedayexpressfreight.com We will respond the Same Day with a tailored solution to meet your needs! Alternatively, we can arrange for a representative to visit you to discuss your requirements.

pecialists in time sensitive deliveries ny size urgent consignments ulti-purpose dedicated vehicles urope-wide same day service epots throughout the UK ir charter service available our consignment is safe & secure

UK Head Office: The Barley Butt, Station Road Ditton Priors, Shropshire WV16 6SS

Sameday Logistics Specialists T: 0844 800 5211 E: sales@samedayexpressfreight.com

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PECM Issue 17

Switches & Sensors

WTF: Water Tank Full The new language of SMS for the IIoT

RAM® industrial cellular RTUs keep you in control of remote assets.

Join us in hall 8 booth 422 to learn remote automation tips and tricks

Businesses need visibility to make the rapid changes that can be the difference between cashing in and missing out. Red Lion’s Sixnet® series RAM industrial cellular RTUs bring remote monitoring to the Industrial Internet of Things (IIoT), delivering the insight you need to remain in control of remote assets regardless of location. Using an intuitive web-based interface and a variety of connectivity options, our rugged RAM RTUs provide a secure all-in-one platform that seamlessly integrates with existing equipment to enable data visibility. Whether a tank level is too high or valve pressure out of range, the RAM event engine will take action and send you an SMS text notification to keep you in the know. Visit www.redlion.net/control to learn more.

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Tooling and advanced lightweight component solutions A trusted partner for world-class customers from a range of demanding industries

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W O R L D - C L A S S M A N U FAC T U R I N G S O LU T I O N S

Head Office: 1 Dakota Business Park, Havant, Hampshire PO9 2NJ Tel:+44 (0)2392 499276 Email: info@formaplex.com www.formaplex.com

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Introducing the ICE-LBG-SR Super Rotation Load Ring RUD are proud to be the first manufacturer & supplier of offer this truly innovative lifting point solution

he ICE-LBG-SR maintains the design of RUDâ&#x20AC;&#x2122;s popular VLBG series. The VLBG offers numerous advantages; it can be turned 360Â° and is loadable in all directions. The NEW ICE-LBG-SR possesses an array of innovative designs. Firstly, the double SR ball bearing offers the ultimate solution for turning and flipping at high working load limits (WLL) without affecting the mounting bolt stability. It enables the load to rotate 360Â° in all directions under load. The advanced ball bearing technology is arranged in a double way which transfers the forces of the WLL into a rotation movement without jerks. Avoiding unintentional slackening of the fastening bolt. The ICE-bolts are made of fine grain steel which guarantees a high static and dynamic strength with the smallest bolt diameter.

Safety is paramount across all RUD products and the ICE-LBG-SR is a great example of this. The lifting point is clearly marked with the minimum WLL for all loading directions. Patented markings indicate to the user when the product is no longer suitable of service. The clamping spring works as a noise reduction device and holds the suspension ring permanently in the requested position of the lift. RUD supply the ICE-LBG-SR in standard sizes M8 up to M30. RUD offer a wide range of lifting and lashing applications covering a working load capacity range from 0.6 to 200 tonne. For more information please call 01227 276 611 or visit www.rud.co.uk

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Training & Recruitment

The World’s Most Used Project Management Method

RINCE2® (Projects in a Controlled Environment) is a structured project management method that can be applied regardless of project scale, type, organisation, geography or culture. With over 2 million qualiﬁed professionals worldwide, it is the most widely used method for managing projects. It isolates the management aspects of project work from the specialist contributions, such as design, development, etc. which are easily integrated with the PRINCE2® method. This provides a secure framework for any type of project, including business change, construction, engineering, IT, research and product development.

Beneﬁts There are many beneﬁts of using PRINCE2® but primarily it: • Ensures that the project management is focused on the continuing viability of the project in relation to its Business Case • Involves senior management in the project at the right time and in the right place. • Focuses on Products which provides clarity for all parties involved on what the project must deliver, why, when by whom - and for whom. • Facilitates controls at all levels of management. • Makes the project’s progress more visible to management. • Provides a communication medium

for all project staﬀ. • Ensures that work progresses in the correct sequence. • Allows the project to be stopped and, if required, re-started completely under management control, at any time in the project’s life. PRINCE2® is an integrated framework of processes and themes which address the planning, delegation, monitoring and control of the six variables involved in any project, those of Costs, Timescales, Quality, Scope, Risk and Beneﬁts. For more information on PRINCE2, and to register for free online learning, email SPOCE on info@spoce.com.

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PECM Issue 17

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KINGSWAY

The Centre building

English Language Courses for Engineering Don’t be afraid of speaking English! Kingsway English Centre in the UK specialises in bringing engineering staff up to speed in English language. Rick Johns, an electrical engineer himself, explains more. Globalisation is a word we hear every day – and very often at work, experience every day. As larger companies swallow up smaller ones finding a common method of communication becomes more and more important. And in the majority of cases English is the chosen language. The problem comes particularly with those in the age range 40 – 65 years old. You may even recognise yourself here! If you are younger than 35 – 40 you probably had a reasonable exposure to English at school; if you are older than 40 you probably didn’t. But don’t worry, help is at hand. Kingsway English Centre is a family owned and run

English training centre for midcareer professionals. “It’s what we do” says Rick. “We provide a safe, comfortable and relaxed environment in which you can make mistakes, laugh and learn”. As the minimum age at Kingsway is 25 years, and the average age 45 years, you won’t be surrounded by teenagers. So you can relax, and enjoy unlocking and developing your speaking and listening. If you would like to see how Kingsway can help you just email Rick at rick@kingsway-english. com and he will get straight back to you – by email, so you won’t have to speak in English. Well not yet, anyway!

KINGSWAY

Sylwester Puhacz is a 45 year old Production Manager with RPC Promens Vehicles, manufacturing tanks and other plastic containers in Poland. When he grew up the only language taught at school was Russian. Since then Sylwester has gained a basic knowledge of English from watching TV, reading technical articles and listening to music. Increasingly he has found the need to use English for work, taking part in multinational meetings with his colleagues at RPC. Sylwester made the decision to study English intensively at Kingsway English Centre for 4 weeks to give his English speaking and listening skills the boost needed to get him using English with confidence. He is already becoming a relaxed and comfortable speaker of English and now expects to be able to take part in meetings proactively.

Student Lounge

Kingsway English Centre Ltd 40 Foregate Street, Worcester WR1 1EE, UK Tel : +44 1905-619877 Fax : +44 1905-613388 Skype : kingsway-english Email : info@kingsway-english.com Web: www.kingsway-english.com

KINGSWAY

Rick and some of the team

Keeping Up With Demand Mordor Intelligence, the global market research and consulting firm, recently released a study assessing the global water treatment chemicals market. The report valued the overall global market at $35 billion in 2014, predicting a continual annual growth rate (CAGR) of 7.4% till 2020. emand for water treatment technology and equipment is set to increase by 5.2 per cent to $14.7 billion by 2019 in the US alone according to research. This clearly demonstrates the growing need for feasible solutions to a costly problem. With increasingly stringent regulations around the disposal of waste water, and the associated expenditure of meeting, or failing to meet, these policies, companies of all shapes and sizes are looking for cost effective solutions.

Regulation driving costs The report by Mordor Intelligence highlights industrial water treatment as the fastest growing sector, and it’s easy

to see why. In Europe, the Urban Waste Water Directive governs the disposal of water, “to protect the water environment from the adverse effects of discharges of urban waste water and from certain industrial discharges”. Under the directive, any business wishing to dispose of waste water is charged a municipal waste water charges, calculated using the Mogden formula in the UK. The formula takes into account how much sludge and solids are in water being deposited into the local sewage system, the level and type of treatment the effluent has been exposed to and the volume of water to be disposed of. An appropriate charge for waste water

disposal is then calculated. Add in the costs of water transport, storage and off-site treatment and the management of effluent water from an industrial operation, a food or pharmaceutical manufacturing plant, or even a hotel, can be a major drain on any business. As the report states, there is a lack of awareness in general around the waste water treatment sector. However, at NCH we’ve noticed that companies are particularly unaware of the various technologies available that can help to reduce these annual fees. Businesses simply accept them as a fact of life – this needn’t be the case.

A 21st century solution The Mordor Intelligence study highlights the fact that a lot of 21st century biochemistry, such as pesticides and pharmaceutical products, in use today cannot be removed by 19th century filtration technology, leading to a need for new technology. At NCH Europe, we’ve invested a great deal of effort in developing an answer to the strain of modern chemistry that also dramatically reduces the cost of waste water management. Our waste water treatment solution, which comprises the BioAmp delivery system and the FreeFlow product, uses live, naturally occurring bacteria to break down fats, oils, greases, suspended solids and other contaminants in water. FreeFlow bacteria actually digest contaminants, unlike solvents and free enzyme products. With traditional treatments, most bacteria get flushed through the pre-treatment system before they even become active. FreeFlow bacteria are live and begin feeding and multiplying the instant they enter the waste water stream or drain system. By the time they are finished, the waste water you release into the local sewage system is cleaned – meaning dramatic reductions in those Waste Water Directive fees.

The BioAmp delivery system enables companies to bring waste water treatment in-house, cutting cost of off-site treatment. Our computer controlled microbial fermentation units are installed on site and deliver a large amount of active bacteria directly into drains, grease traps, lift stations and more.

effluent that is less harmful to the environment without costly off-site treatment. Something NCH Europe already has down to a fine art.

While the study highlights developing a 21st century solution as an area of future opportunity, NCH Europe already has the answer to cost effectively, easily, and safely making waste water treatment a smoother process.

Bilston West Midlands, WV14 0QL,

Our solution generates an average of 30 per cent reduction is waste water costs.

Facebook: www.facebook.com/ pages/ncheurope

Ready for tomorrow Over 40 per cent of the report’s non-utility respondents believed that the water industry was not prepared to meet the financial needs of managing waste water, given increased urbanization and regulation. There is a clear need for long-term investment in wastewater treatment infrastructure. However, the immediate answer to managing the financial pressures lies in a smarter approach to waste water that enables companies to release

For further information contact: Catriona Whitford, NCH Europe NCH House, Springvale Avenue, United Kingdom Telephone: +44 (0)1902 510254 www.ncheurope.com mailto:cat.whitford@nch.com Twitter: twitter.com/nch_europe

LinkedIn: www.linkedin.com/ company/nch-europe

Mario Kelly, VP of the waste water Innovation Platform of global water, energy and maintenance solutions provider NCH Europe, takes a look at what is driving this growth and the key challenges the sector is facing.

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Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk for global service locations

Following the release of our latest, issue 15, priced catalogue, the team at Leengate Valves, the UKs market leading valve wholesaler, are keen to emphasise the expansion of our Actuation and Engineering Department. ur new catalogue showcases our expanded actuation section including a range of new lines like the entire Max-Air rack & pinion pneumatic range of actuators in 90, 120 & 180 degree operation, a 3 stage centre return pneumatic actuator and the full stainless steel body & the GRPP body types. We also introduce the new MaxAir SHD & CHD Scotch Yoke actuators with torques of up to 250,000nm and can now proudly offer the brand new Valbia electric actuator with aluminium enclosure.

Stainless Steel ball valves in three way configuration, Flanged PN16, Carbon Steel and Stainless Steel three piece, full bore, ATEX Rated ball valves, screwed BSPP, NPT and Socket Weld. We exclusively bring to the UK market the full range of Ghibson double offset high performance butterfly valves in Carbon and Stainless Steel materials, RTFE & Inconel seating options, which include ATEX Rated and Firesafe Certified wafer pattern and fully lugged PN16 and ANSI 150 options.

To compliment the new actuator oﬀerings, we oﬀer a full process range of actuated packages

When ordering actuated products, please remember that here at Leengate Valves we offer an exceptionally fast turnaround on stock products plus a bespoke service which means we can tailor to your most detailed specification.

To compliment the new actuator offerings, we offer a full process range of actuated packages, including ATEX Rated and Firesafe Certified Carbon Steel and Stainless Steel two way ball valves Flanged PN16 and ANSI 150, ATEX Rated Carbon Steel and

Leengate Valves’ products are available from our network of UK-wide resellers; contact our sales team on (0044) 01773 521555 or email info@ leengatevalves.co.uk and we will point you towards our nearest and most suitable distributor.

LEENGATE VALVES the UKs market leading valve wholesaler

Issue 17 PECM

127

Waste Management

Treatment plant protected Treatment plant protected by effluent monitor at major drinks factory

he installation of a HACH LANGE BioTector continuous TOC (Total Organic Carbon) monitor to police the front end of Cobevco’s wastewater treatment plant has enabled tight control of the treatment process. Delivering results 20 times faster than laboratory techniques, the monitor at the Elton facility in Cheshire provides advance notice of organic overload so that the plant is able to instantly divert carbonrich waste and protect the treatment process. The recently rebranded Cobevco ﬁlling division operates a state of the art bottle ﬁlling and wastewater treatment plant at their manufacturing site at Elton in Cheshire, which includes a large biological wastewater treatment facility, operating 24/7 between 3

staggered Sequential Batch Reactors (SBR). This process relies on the activity of bacteria which break down the organic content in the waste stream. However, if the organic load is too strong or too weak, the bacteria are unable to function efficiently, so monitoring is necessary. Historically, laboratory analysis has taken too long to allow proactive intervention and the ability to measure organic load continuously has not been possible because instruments have been unable to cope with the strength of the effluent without filtration. However, the patented two-stage chemical oxidation process employed by the BioTector completely resolves this problem and has enabled Cobevco to protect the treatment plant and dramatically improve efficiency.

Tel: +44(0)161 872 1487 Email: info@hach-lange.co.uk www.hach-lange.co.uk

Waste Managers Extend Oil Recovery Operation Independent waste management company Cleansing Service Group (CSG) is extending its national network of specialist oil recovery and aqueous treatment plants with the opening of a new facility at Worcester. The company says it will begin treatment of waste at the site – a former hazardous waste transfer station purchased from Augean last year – in October following a £200,000-plus infrastructure upgrade to bring facilities up to meet CIRIA’s pollution prevention containment standard 736 and make them suitable for waste treatment. CSG hopes to be receiving and treating more than 150 tonnes of oily water waste and aqueous waste per day at the new facility.

Tel: 0800 048 0622 www.csg.co.uk

Email: technicalsales@csg.co.uk

F&R Products Ltd have in excess of 40 years experience in the design and manufacture of industrial water cooling equipment, specialising in bespoke designs off a standard range of equipment. We are ISO9001 and Refcom approved. UK agents for the Hyfra-Pedia range of refrigerated water and oil chillers plus the Decsa range of evaporative cooling towers. The products and services we are able to offer with regard to water cooling systems are:• Coil-in-tank water chillers • Dry air coolers flat bed • Dry air coolers packaged boxed type • Adiabatic coolers • Oil coolers • Evaporative cooling towers • Maintenance and repair of industrial cooling equipment • Annual refrigerant checks in compliance with EU Directive 842/2006 Contact F&R Products Ltd for further information.

Email: sales@fandrproducts.co.uk

www.fandrproducts.co.uk

Issue 17 PECM

129

Know Your Enemy! Did you know that a 200 tonne cooling tower can accumulate in excess of 275 Kg of suspended matter over the course of just one year? Allowing a cooling system to get weighed down by bacterial growth and slime build-up leaves it vulnerable to corrosion and fouling and is not worth the risk to plant operation. But do you know the enemy well enough to effectively keep microbial growth at bay? By Brian Booth, VP of Chem-Aqua, the Water Treatment Innovation Platform of global water, energy and maintenance solutions provider NCH Europe. Stagnant water in cooling tower systems and closed cooling water systems is an ideal breeding ground for microbial growth, which can lead to costly problems within your cooling system like accumulation of slime, circulation issues and even corrosion. These issues can result in a cooling system that is, at best, inefficient, and at worst, completely shutdown. The downtime and potential loss of revenue makes treating the water in your cooling system vital, and there are many ways to do this. However, chemical treatment, when done properly, can be a bespoke solution for your specific system.

Foaming - While not a common problem, foaming is caused by contamination of the circulation water and can cause operational problems such as overflowing. Foam depressant chemicals are used to settle the process water. Be precise Unfortunately, there isn’t a ‘one size fits all’ solution to chemical treatment. With so much to take into consideration it’s important to get the best biocide treatment for your system’s specific needs. A custom designed water treatment solution from Chem-Aqua can significantly reduce energy, water, and maintenance costs while ensuring safe and reliable operation. Chem-Aqua’s survey engineers test samples from every cooling system the company treats to determine the exact nature and optimum measure of biocides for each system. Precisely establishing the threats, by determining pH levels, half life, and organic loading on the system, means Chem-Aqua can tailor the treatment to target specific problems.

For instance, in the steel industry water is used to cool molten steel, and it is common for slag and oil to contaminate the water coolant. In this situation, typical oxidising biocides, such as sodium hypochlorite (chlorine), may be ineffective and chlorine dioxide could be more suitable. Testing done during the survey process would highlight this before treatment began. Available in liquids, solid pastes, tablets, powders and granules, Chem-Aqua oxidative solutions are delivered in appropriate measures to ensure complete dispersion throughout a system and levels are continually monitored. Bespoke treatment can increase the life of a water cooling system, not to mention the whole plant, and reduce operating costs. If you’re in any doubt that you need to treat your cooling system in such a targeted manner it’s worth remembering that a mere 0.005 inches of microbiological fouling in a 1,000 tonne cooler can increase annual electricity costs by £30,000! The cost of the 275 Kg of suspended matter you might collect over a year doesn't bear thinking about. www.ncheurope.com

Chemical treatment programs Using chemicals is an ideal way to manage key problems, such as: Scale Build Up - A major scale forming contaminant found commonly in cooling water is calcium carbonate. Corrosion - Another problem is corrosion control, as circulation water often contains corrosion inducing chemical contaminants, which can be due to high oxygen content, carbon dioxide, low pH, or the contact of dissimilar metals within the system. Microbiology - Control of biological growth also causes problems, as algae or green moss and slime, made up of gelatinous organic material, can result in loss of functionality.

130

PECM Issue 17

Allowing a cooling system to get weighed down by bacterial growth and slime build up leaves it vulnerable to corrosion and fouling and is not worth the risk to plant operation. Brian Booth, VP of Chem-Aqua, the water treatment innovation platform of global water, energy and maintenance solutions provider NCH Europe delves deeper.

Inline vortex flow meter with display Cost-effective flow metering for water flows up to 100l/min, using the vortex principle as a reliable alternative to mechanical paddles. Indicates flow and temperature as standard analogue signals, frequency or switched output, or via IO-Link. The display can be rotated and colours are selectable. Process fittings with either parallel or tapered threads

www.ifm.com / uk/ vortex ifm Telephone 020 8213 2222

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