PECM - Issue 21 2016 by MH Media Global

Engineering Process

Control &

Manufacturing

PECM

Global Success Through Innovation Issue 21 2016 ÂŁ3.95 www.pecm.co.uk

Precision Gas control - 26

imProved asset Performance - 96

visit Kasto at imHX 2016

Saflame was approached to design an experimental combustion rig which required precise, independent control of three gases,

The high density of rotating equipment used in refineries means that effective asset management can maintain plant up-time and achieving OEE targets.

From the 13th - 16th September visit KASTO on Stand 10H37 at IMHX 2016, the premier meeting place for the UK's intralogistics industry.

Stand: 10H37

Man and Machine Training Academy Man and Machine offer an extensive range of "VUPEFTL training courses

Man and Machine specialise in Autodesk training for Manufacturers, Engineers, Architects & Product Designers. All courses are taught with the official Autodesk courseware and includes one month’s free post training support. Autodesk AutoCAD courses include: •AutoCAD Essentials •AutoCAD Electrical Fundamentals •AutoCAD Advanced •AutoCAD 3D Drawing & Modelling •AutoCAD Mechanical Essentials

E: marketing@manandmachine.co.uk W: www.manandmachine.co.uk T: 01844 263 700

Connect Connect with with us us

Engineering Process

Sections Editors Choice News & Events AD & Biogas Show Air, Gas & Odour Control Boilers & Maintenance Calibration Software Coatings Connectors & Fittings Control & Automation Drives, Gears & Motors Electrical & Electronics Electrical Engineering Energy Efficiency Facilities Management Fixtures & Fixings Fluid Handling Gears, Drives & Motors Health & Safety Lighting Machining & Machinery Measurement & Monitoring Process Technologies Product News Pumps Sensors, Software & Systems Storage, Handling & Distribution Training & Recruitment Valves & Flow Control

8 18 19 22 24 25 28 29 30 36 40 47 48 54 55 55 62 63 69 69 72 88 93 94 99 103 107 108

Manufacturing

Control &

Inside...

Inside Issue 21 The Importance of Sensor Triggering in Production and Process Automation When measuring the position of moving targets in production and process automation environments, it is important to understand the different methods of sensor triggering, their impact on measurement cycle times and the benefits they can offer over continuous measurement. Building The Safety Case The fundamental aim of Professor Bisbys’ research is to be able to model fire in buildings, and to be able to derive and validate computer models which can be applied to the structural and fire safety design of buildings. The Big Clean-Up Links with the Royal Academy of Engineering feed valuable practical information into the NDA’s task of decommissioning the UK’s civil nuclear sites.

High Voltage Coils – Making Quality Cost Effective For industries operating and maintaining high voltage (HV) motors and generators, a cost effective, timely and planned repair schedule is crucial to maintaining productivity. Maintaining Archimedes Screw Pumps The enduring simplicity of the Archimedes screw pump continues to make it one of the most efficient pumping methods over short distances, but this efficiency should not be taken for granted. Smaller, Faster, Hotter: Optimisation of Bearings for Challenging Applications Adding new design features or applying special techniques and coatings to bearing components can optimise the performance of bearings for challenging applications.

DELIVERING STRAINERS & FILTERS TO YOUR PROJECT WITHOUT DELAY

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

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

Contact: sales@bartonfirtop.co.uk or visit our website: www.bartonfirtop.co.uk

High Voltage Coils â&#x20AC;&#x201C; Making Quality Cost Effective The The product product level level requires requires precision precision engineering engineering in in the the design design of of any any new new coils, coils, high high standards standards of of quality quality control control in in selecting selecting and and processing processing the the raw raw materials materials as as well well as as consistent consistent verification verification of of the the quality quality of of insulation insulation being being installed. installed. The The process process aspect aspect concentrates concentrates on on the the continuous continuous design design improvement improvement and and rigorous rigorous quality quality control control with with thorough thorough component component testing testing completed completed throughout throughout the the production production processes. processes.

Production to exact design specifications Quality Quality assurance assurance is is crucial crucial and and there there are are several several standards standards which which must must be be met, met, especially especially for for the the testing testing of of HV HV coils, coils,

or or industries industries operating operating and and maintaining maintaining high high voltage voltage (HV) (HV) motors motors and and generators, generators, aa cost cost effective, effective, timely timely

and and planned planned repair repair schedule schedule is is crucial crucial to to maintaining maintaining productivity. productivity. Central Central to to this this regime regime is is the the use use of of high high quality, quality, precision precision manufactured manufactured stator stator coils, coils, available available through through aa local local and and trusted trusted partner partner that that can can deliver deliver long long term term reliability, reliability, improved improved performance performance and and minimal minimal downtime. downtime. Danny Danny Fox, Fox, Coil Coil Shop Shop Manager Manager at at Sulzer's Sulzer's Birmingham Birmingham Service Service Center, Center, looks looks at at the the key key aspects aspects of of replacing replacing coils coils in in HV HV equipment. equipment. In In an an ideal ideal scenario, scenario, every every repair repair would would be be carefully carefully planned planned and and scheduled scheduled to to minimize minimize the the effects effects of of any any downtime downtime on on the the business. business. Unfortunately, Unfortunately, in in aa less less than than perfect perfect world, world, itit is is sometimes sometimes necessary necessary to to react react swiftly swiftly to to unexpected unexpected events. events. The The key key to to better better uptime uptime and and improved improved efficiency, efficiency, however, however, is is to to minimize minimize the the likelihood likelihood of of such such an an event event occurring occurring and and to to reduce reduce the the effects effects itit can can have have on on the the business business when when itit does does â&#x20AC;&#x201C;â&#x20AC;&#x201C; itit is is at at this this point point that that aa 'cost 'cost versus versus quality' quality' decision decision can can have have far far reaching reaching implications... implications...

Fast delivery is crucial in coil manufacture

which which is is carried carried out out both both in-house in-house and and

The The manufacture manufacture of of high high voltage voltage coils coils

throughout throughout the the manufacturing manufacturing process, process, aa

is is aa very very precise precise science science and and the the design design and and construction construction methods methods will will vary vary between between suppliers, suppliers, as as will will materials materials and and testing testing procedures. procedures. For For large large rotating rotating

PECM PECM Issue Issue 21 21

Starting Starting with with the the basic basic raw raw materials materials and and series series of of continuous continuous checks checks should should be be in in place place to to ensure ensure every every coil coil is is produced produced to to the the exact exact design design specification. specification.

machines machines such such as as HV HV and and MV MV motors motors and and

Sulzer's Sulzer's Birmingham Birmingham Service Service Center Center

generators, generators, testing testing the the replacement replacement coils coils

has has aa long long and and distinguished distinguished history history of of

and and balancing balancing the the rotor rotor is is key key data data that that

producing producing high high quality, quality, high high voltage voltage coils coils

evidences evidences to to the the client client the the quality quality of of the the

for for use use in in motors motors and and generators generators across across

finished finished and and repaired repaired product. product.

the the world. world. This This reputation reputation has has been been earned earned

Obviously, when repairs are unplanned, speed is crucial in returning the equipment to a running state, but this cannot be achieved to the detriment of quality, which has much longer lasting implications. The The efficiency efficiency of of high high voltage voltage equipment equipment can can be be considered considered in in aa number number of of ways; ways; cost cost efficiency efficiency is is influenced influenced by by reliability, reliability, service service lifetime lifetime and and maintenance maintenance costs, costs, while while power power efficiency efficiency depends depends on on the the intrinsic intrinsic design design as as well well as as component component reliability. reliability. Maintaining Maintaining high high efficiency efficiency levels levels depends depends on on consistent consistent quality quality assurance assurance in in both both the the product product and and process process aspects aspects of of production. production.

by by external, external, independent, independent, laboratories. laboratories.

through through its its ability ability to to meet meet and and surpass surpass the the latest latest build build quality quality standards standards including including those those used used in in the the hydro-electric hydro-electric and and nuclear nuclear industries. industries. The The Service Service Center, Center, aa hub hub for for the the wider wider service service center center network network in in supplying supplying coils coils across across Europe, Europe, the the Middle Middle East East and and the the Americas, Americas, focuses focuses on on B-stage B-stage resin resin rich rich coils coils which which are are typically typically used used on on larger larger multi-megawatt multi-megawatt machines. machines. Resin Resin rich rich coils coils are are manufactured manufactured using using aa hot hot pressed pressed slot slot section section and and an an uncured uncured end-winding end-winding section section which which requires requires coating coating and and curing curing after after the the stator stator rewind rewind has has been been completed. completed. This This produces produces aa very very tough tough coil coil which which retains retains some some flexibility flexibility at at the the ends ends that that allows allows itit to to be be transported transported safely safely and and

installed into the stator of a machine much

The process begins with

more easily.

an initial assessment of the components due for repair and

Maintaining the quality of every coil is

is followed by the design stage,

a continuous process that is applied to

which involves using the latest

all aspects of the production process,

3D CAD packages to produce a

including checks on all of the raw materials

series of manufacturing drawings

used in the manufacturing process. If there

for the coil shop. Precision and

are any perceived changes in the materials

accuracy of the drawings, coupled with

used in the insulation system, then a

the latest insulation technology allows

sample coil can be subjected, by customer

for improvements in coil design to be

request only, to voltage endurance testing

achieved.

Sulzer is the leading worldwide, independent service provider for large rotating equipment. With technically advanced and innovative service and maintenance support solutions, Sulzer provides a turnkey service that provides its customers with the peace of mind to focus on their core operations.

www.sulzer.com

in order to prove the insulation properties and reliability are unchanged. Suppliers have been known to change specifications of their materials without providing such information to the end users and so periodic sampling is also conducted to ensure the overall quality of the finished product is maintained.

Precision and accuracy improve performance The use of B-stage resin rich coils is predominant in the rewinding of larger machines but this method also delivers benefits for smaller machines. The construction of the B-stage coils allows the resin to flow in the end of the winding and bond the layers of insulating tape to produce a more homogenous insulation and sealing of the winding. In most cases, the use of modern insulating materials will improve both the dielectric and thermal performance when compared to those used by the OEM during original manufacture.

Quality starts with the raw materials and Sulzer purchases continuously cast copper rod and uses its own in-house rolling and annealing process, combined with automatic shaping machines and computer controlled heated presses. The entire process can operate 24 hours per day to deliver consistently high quality coils with very short delivery times. The coils can then be dispatched from its high-voltage coil shop, via freight service, to any location worldwide for delivery to site, ready for installation. By using the latest CAD software, the bars or coils can be precisely designed to ensure an exact fit in the stator

can be required to pass a 400 hour voltage endurance test to provide evidence to support their build quality.

slot, making the installation process

Modern insulation technology allows for

more efficient. Comprehensive testing

thinner layers that can withstand greater

techniques guarantee the reliability of the

dielectric stress and higher temperatures,

new coils, which is especially important

also allowing more space for copper within

for coils being used in marine, nuclear

the same slot area.

and hydro generators, where the coils

Issue 21 PECM

This This reduces reduces the the resistance resistance of of the the replacement replacement stator stator winding, winding, which which can can then then run run cooler, cooler, allowing allowing aa small small but but significant significant increase increase in in output. output.

Local approach for clients ensures cost-effective results In In some some cases cases the the full full extent extent of of aa repair repair does does not not become become apparent apparent until until the the generator generator is is removed removed and and examined examined closely. closely. While While the the stator stator coils coils will will usually usually be be replaced, replaced, there there can can often often also also be be an an issue issue with with the the laminated laminated core core and and the the rotor rotor assembly. assembly. ItIt is is essential essential that that the the same same level level of of skill skill and and expertise expertise is is employed employed in in the the repair repair of of these these components components as as well, well, in in order order to to complete complete an an effective, effective, long-term long-term repair. repair.

of expertise expertise and and engineering engineering skill skill within within of

The The last, last, and and maybe maybe least least well-known, well-known,

ItIt is is important important that that any any service service provider provider

the network network in in order order to to deliver deliver the the most most the

is is the the Health Health and and Safety Safety Management Management

has has the the scope scope and and ability ability to to adapt adapt to to

cost-effective results. results. cost-effective

system system that that benefits benefits the the entire entire business business

any any change change in in circumstances circumstances that that may may be be experienced experienced during during the the project. project. This This requires requires skilled skilled and and experienced experienced engineers engineers as as well well as as the the technical technical resources resources to to resolve resolve any any situation situation and and ultimately ultimately to to complete complete the the repair repair efficiently efficiently whilst whilst keeping keeping the the client client fully fully appraised appraised of of progress. progress. Access Access to to such such expertise expertise can can often often involve involve aa long long search search and and complicated complicated communications; communications; this this can can be be greatly greatly simplified simplified when when dealing dealing with with aa multinational multinational repair repair specialist specialist that that maintains maintains aa local local approach approach for for every every client. client. Sulzer Sulzer ensures ensures that that customers customers can can use use their their local local service service center center to to tap tap into into years years

Many clients require potential suppliers to demonstrate their professional credentials and standards, often in the form of compliance with various international standards. The Birmingham Service Center has invested considerably in improving both its production equipment as well as its management systems. As a result it now holds certifications for compliance with ISO 9001, ISO 14001, and BS OHSAS 18001.

by by introducing introducing an an improved improved health health and and safety safety framework. framework. This This helps helps to to minimize minimize operational operational risks risks and and hazards hazards which which ensures ensures that that not not only only the the skilled skilled staff staff have have aa safe safe environment environment to to work work in in but but also also that that the the client client has has complete complete peace peace of of mind, mind, as as well well as as improved improved productivity. productivity. For For those those involved involved in in the the operation operation and and maintenance maintenance of of large large MV MV and and HV HV rotating rotating machines, machines, there there are are many many choices choices when when seeking seeking aa repair repair or or rewind rewind of of such such equipment. equipment. The The key key to to aa successful successful project project is is ensuring ensuring that that those those involved involved deliver deliver aa high high quality quality product, product, precisely, precisely, quickly quickly and and with with the the necessary necessary support support to to ensure ensure aa timely timely and and cost cost effective effective solution. solution.

PECM PECM Issue Issue 21 21

Engineering Process

The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide. Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units. Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment. With over 300,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries. A subscription to PECM magazine is the industry's 'must have' publication.

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Manufacturing

Control &

The Team Editor Elizabeth Hutton elizabeth@pecm.co.uk

Managing Editor Antony Holter editor@mhmagazine.co.uk

CrEativE dirECtor Josh Holmes josh@mhmagazine.co.uk

assistant Editor Justine Sanders justine@pecm.co.uk

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

aCCounts dEPt. Alison Holmes accounts@pecm.co.uk Tel: 01227 392561

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

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dEsignEr Dave Dorman daved@pecm.co.uk Tel: 01227 392575

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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.

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.

Editors Choice AVT Reliability will be running two seminars

Hi-Bond Tapes Ltd Hi-Bond Hi-Bond Tapes Tapes is is aa specialist specialist technical technical adhesive adhesive tape tape company company focused focused on on high high performance performance structural structural bonding bonding tapes. tapes. The The VST VST acrylic acrylic foam foam tapes tapes have have exceptional exceptional strength strength giving giving excellent excellent load load bearing bearing performance, performance, very very good good dynamic dynamic shear, shear, tensile tensile adhesion adhesion and and peel peel values. values. Proven Proven in in the the most most demanding demanding of of applications applications in in aa wide wide range range of of industrial industrial sectors sectors with with very very high high and and low low temperature temperature resistance resistance .These .These tapes tapes will will bond bond metals,plastics metals,plastics ,, glass glass and and composites composites replacing replacing mechanical mechanical ﬁﬁxings xings and and even even spot spot welding. welding. Dimensionally Dimensionally precise, precise, quick quick ,, clean clean and and easy easy to to use use VST VST ensure ensure good good productivity productivity gains,for gains,for applications applications in in automotive, automotive, electronics electronics ,, construction, construction, aerospace, aerospace, and and engineering. engineering.

AVT AVT Reliability Reliability will will be be running running two two seminars seminars on on July July 13th 13th and and July July 14th 14th 2016 2016 for for senior senior maintenance maintenance // engineering engineering managers managers to to consider consider technical technical advances advances and and regulatory regulatory issues issues that that aff affect ect machine machine reliability. reliability. Seminar Seminar One One will will focus focus on on the the Food Food and and Beverage Beverage Industry, Industry, whereas whereas Seminar Seminar 22 will will focus focus on on the the Chemical Chemical // Petrochemical Petrochemical Industry. Industry. The The seminars seminars off offer er aa unique unique opportunity opportunity for for participants participants to to network network with with their their peers peers and and gain gain additional additional insight insight into into the the latest latest advances advances in in asset asset care care and and pump pump technology. technology. The The seminars seminars will will take take place place at at AESSEAL AESSEAL Global Global Technology Technology Centre Centre in in Rotherham Rotherham and and include include presentations presentations from from AVT AVT Reliability, Reliability, AVT AVT Pump, Pump, AESSEAL, AESSEAL, Jacobs Jacobs Consultancy, Consultancy, Mouvex, Mouvex, and and Sundyne Sundyne HMD HMD Sealless Sealless Pumps. Pumps.

Tel: Tel: 01536 01536 260022 260022 Email: Email: sales@hi-bondtapes.co.uk sales@hi-bondtapes.co.uk www.hi-bondtapes.com www.hi-bondtapes.com

For For more more information information go go to to https://www.avtreliability.com/about/ https://www.avtreliability.com/about/ news/advances-in-pump-technology-regulation-and-asset-care/ news/advances-in-pump-technology-regulation-and-asset-care/ or or contact contact Jasmine.Moore@aesseal.co.uk Jasmine.Moore@aesseal.co.uk telephone: telephone: 01709 01709 369966 369966

Virtually pulse-less flow removes the need for pulsation dampeners

Tiger Power, a Turbine Efficiency brand, can provide a gas turbine package that has a market saving of up to $1million.

The The unique unique multi-diaphragm multi-diaphragm arrangement arrangement of of Hydra-Cell Hydra-Cell metering metering & & dosing dosing pumps pumps from from Wanner Wanner is is claimed claimed to to remove remove the the need need for for pulsation pulsation dampeners dampeners in in many many circumstances. circumstances.

A A bold bold but but realistic realistic statement; statement; we we have have already already supplied supplied and and commissioned commissioned aa refurbished refurbished package package and and can can do do itit for for you. you.

Hydra-Cell Hydra-Cell pumps pumps from from Wanner Wanner have have multiple, multiple, hydraulically hydraulically balanced balanced diaphragms diaphragms in in aa single single head, head, that that operate operate sequentially, sequentially, dramatically dramatically reducing reducing system system pulsation pulsation and and the the damage damage itit causes. causes. The The cost cost of of additional additional pulsation pulsation dampeners, dampeners, along along with with ongoing ongoing costs costs of of charging charging and and maintenance maintenance is is avoided avoided in in many many instances instances and and systems systems become become more more reliable. reliable.

Tiger Tiger Power Power provides provides turbine turbine packages packages in in the the 3MWe-8MWe 3MWe-8MWe power power range range for for aa single single turbine, turbine, or or can can work work in in parallel parallel to to give give aa combined combined power power output output to to suit suit most most projects. projects.

The The Hydra-Cell Hydra-Cell pump pump range range can can accommodate accommodate measured measured flflow ow requirements requirements from from 11 to to 6360 6360 litres litres per per hour hour at at pressures pressures of of up up to to 172 172 bar bar with with virtually virtually no no pulsation. pulsation. HydraHydraCell Cell pumps pumps also also exceed exceed API API 675 675 performance performance requirements requirements in in terms terms of of repeatability, repeatability, linearity linearity and and steady steady state state accuracy. accuracy. They They are are able able to to pump pump abrasives abrasives and and liquids liquids that that contain contain solid solid particles particles and and being being seal-less, seal-less, can can pump pump hazardous hazardous liquids liquids safely safely and and can can even even run run dry dry indefi indefinitely nitely without without suff suffering ering damage. damage.

www.hydra-cell.eu www.hydra-cell.eu

SIMPLE, POWERFUL AND AFFORDABLE

Delivered Delivered to to suit suit your your speciﬁ speciﬁcation: cation: •• 24 24 month month guarantee guarantee on on aa completely completely rebuilt rebuilt and and overhauled overhauled core core engine engine •• Commissioned Commissioned for for full full 48,000 48,000 hour hour service service interval interval •• Modern Modern new new PLC PLC control control systems. systems.

Tel: Tel: +44(0) +44(0) 1522 1522 696980 696980 Email: Email: info@turbine-effi info@turbine-efficiency.co.uk ciency.co.uk www.turbine-effi www.turbine-efficiency.co.uk ciency.co.uk

SMALL PARTS. BIG IMPACT.

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8 PECM PECM Issue Issue 21 21

OPTIMAS SOLUTIONS - COMPONENTS DIVISION Tel: +44 (0) 1202 865222 Web: optimascomponents.com

5GG OQTG CV KPHQTOCVKQP EKPEQO EQO RGEO

/CKFGPJGCF 7PKVGF -KPIFQO r 6GN r KPHQGWTQRG"EKPEQO EQO

MINIFLUX, the pump for horizontal media transfer out of IBCs – now also for use in explosion hazard areas (Zone 1).

MINIFLUX, MINIFLUX, the the container container pump pump for for horizontal horizontal transfer transfer out out of of IBCs. IBCs.

MINIFLUX, MINIFLUX, now now also also for for use use in in explosion explosion hazard hazard areas areas (Zone (Zone 1). 1).

Extremely Extremely compact compact and and light. light.

The horizontally installed, extremely compact MINIFLUX container pump is now also approved for use in explosion hazard areas (Zone 1). It was designed for draining IBCs via their floor-level outlet and is an alternative to vertical immersion pumps.

hen hen accessing accessing IBCs IBCs from from

FLUX-GERÄTE FLUX-GERÄTE GMBH GMBH

above above is is impossible impossible or or

In In 1950, 1950, the the world's world's fifirst rst electric electric drum drum

very very diffi difficult, cult, such such as as when when

pump pump was was named named FLUX. FLUX. In In the the meanwhile, meanwhile,

containers containers are are stacked stacked or or

the the undisputed undisputed pioneer pioneer in in the the area area

ceilings ceilings are are low, low, the the MINIFLUX MINIFLUX enables enables

of of barrel barrel pump pump technology technology possesses possesses

pumping pumping directly directly at at the the flfloor-level oor-level outlet. outlet.

outstanding outstanding knowknow- how how and and experience experience

ItIt is is suitable suitable for for media media with with aa viscosity viscosity

in in many many other other areas areas of of pump pump technology. technology.

of of up up to to 11 000 000 mPas. mPas. In In comparison comparison to to

Our Our wide wide product product range range now now extends extends

gravity gravity draining draining via via the the IBC IBC outlet outlet tap tap the the

from from the the most most diff different erent types types of of pumps pumps

MINIFLUX MINIFLUX enables enables aa considerably considerably higher higher

with with motors, motors, flflow ow meters meters and and accessories accessories

delivery delivery rate rate and and delivery delivery head. head. Depending Depending

through through special special system system solutions solutions such such

on on the the media media and and motor, motor, either either up up to to 240 240

as as the the drum drum emptying emptying systems systems to to

l/min l/min can can be be transferred transferred or or aa delivery delivery head head

custom-designed custom-designed systems systems for for plant plant

of of up up to to 13 13 mwc mwc can can be be achieved. achieved. This This

engineering. engineering. The The internationally internationally operating operating

means means that that the the media media can can be be rapidly rapidly fifilled lled

family-owned family-owned company company with with its its seven seven

into into the the container container or or transported transported to to an an

subsidiaries subsidiaries and and numerous numerous representatives representatives

elevated elevated container. container.

delivers delivers its its products products in in more more than than 100 100 countries countries worldwide. worldwide.

The The mechanical mechanical seal seal design design separates separates the the media media area area from from the the pump pump drive. drive. This This

Contact Contact and and information: information:

means means the the shaft shaft only only comes comes into into contact contact

FLUX-GERÄTE FLUX-GERÄTE GMBH GMBH

with with the the product product in in the the rotor rotor area. area. The The

Talweg Talweg 12 12

pump pump is is only only 136 136 mm mm long, long, weighs weighs just just 1.2 1.2

D-75433 D-75433 Maulbronn Maulbronn

kg, kg, is is easy easy to to handle handle and and requires requires minimal minimal

Tel.: Tel.: +49 +49 (0)7043 (0)7043 // 101-0 101-0

space. space. ItIt can can be be easily easily connected connected to to the the IBC IBC

Fax: Fax: +49 +49 (0)7043 (0)7043 // 101-111 101-111

with with aa union union nut. nut. Ideally Ideally the the drive drive of of the the

info@fl info@flux-pumpen.de ux-pumpen.de

MINIFLUX MINIFLUX is is provided provided by by aa commutator commutator

www.fl www.flux-pumps.com ux-pumps.com

motor motor or or compressed-air compressed-air motor. motor.

PECM PECM Issue Issue 21 21

For For powerful powerful pumping pumping at at the the IBC IBC outlet outlet to to an an elevated elevated container. container.

For For fast fast fifilling lling via via the the IBC IBC outlet. outlet.

Editors Choice Hinge d e every ap sign for plication

More than just pumps

Certified since 1995

FLUX – World leader in drum & container pumps. FLUX - originator of the first electric drum pump - offers solutions for all industries with unsurpassed quality and numerous advantages over the competition such as: ` Materials (PP, PVDF, SS, AL, Hastelloy C) provide solutions for challenging fluid applications ` Offering pumps in lengths from 300 mm to 3000 mm accommodates pails, carboys, drums, totes, tanks ` Quality construction makes pumps easy to clean & maintain, providing extended service life ` Various design solutions for high viscosities, sanitary, mix & pump, 99.98 % emptying, etc. ` Vast product range including liquid meters, verticals, accessories, etc. - all from one source

Phone: 01202 823304 · sales@flux-pumps.co.uk www.flux-pumps.co.uk

# conti nuous # lift-o ff # butt a nd bac kfl # speci al purp ap ose # heavy -duty Quality hinges for over 200 years

01827 63391

www.goldwassallhinges.co.uk

FLUX is the undisputed pioneer in barrel pump technology 65 years ago, FLUX was the first German company to manufacture barrel pumps to its own patented designs. Based near Stuttgart, FLUX manufactures high quality pumps for most fluids - water, oils, solvents, flammable liquids, even food and pharmaceutical applications. Industries served include manufacturing, surface finishing, paints & lacquers, petrochemical, foods, cosmetics, pharmaceutical, water treatment & agriculture. Products include battery, air & electric operated container, barrel and IBC emptying pumps, air operated diaphragm pumps, magnetically driven centrifugal pumps, hygienic pumps and eccentric worm-drive pumps for handling high viscosity fluids. We also manufacture a range of accessories including hoses, dispense nozzles, flow meters, mixers and automated batching systems. Products are CE marked and conform to main standards (where applicable), eg. EC machinery directive, 3A, FDA, GS, UL, CSA and ATEX directive for explosion-hazardous areas. Please contact: Flux Pumps International (UK) Ltd 12 Enterprise Park, Black Moor Road, Verwood BH31 6YS Tel. +44 (0) 1202 823304

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Bowman develops new bearing test machine Bowman International’s expert team of engineers has developed a bespoke bearing test machine, providing an in-house facility that can determine bearing capabilities and provide fault analysis for plain bearings. The development of the advanced test machine means Bowman, which specialises in the manufacture and supply of bearings and sintered components including the Oilite® and BowMet® ranges, can test bearings on behalf of customers under their exact application conditions, with real time test data, remote computer operation and bearing failure onset shutdown function. Using the new facility, Bowman can test products with dry and lubricating running and accommodate a wide range of shaft diameters. Constant data acquisition of both the test bearing temperature and torque measurement are also invaluable features. The machine has been designed to run automatically and can sense the onset of bearing failure, which triggers an automatic stop procedure. This enables the failure mode to be analysed.

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Issue 21 PECM

Editors Choice

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12 PECM PECM Issue Issue 21 21

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Issue 21 PECM

The Big Clean-Up Links with the Royal Academy of Engineering feed valuable practical information into the NDA’s task of decommissioning the UK’s civil nuclear sites. The Nuclear Decommissioning

Professor Hyatt’s work has

Authority (NDA) and the Royal

been fundamental to increased

Academy of Engineering are jointly

understanding and the

supporting Professor Neil Hyatt’s

development of new techniques

Research Chair at the University

in the area of radioactive waste

of Sheffield. Dr. Darrell Morris,

management. His expertise was

Research Manager at the NDA,

utilized extensively in the

said, “As a strategic organization,

aftermath of the Japanese

a collaboration of this kind is very

earthquake and tsunami which

important to us and we have found

affected the reactors at

the outcomes to be extremely

Fukushima”.

valuable. Background of the NDA and Fellows of the Royal Academy of

establishment of a Research

Engineering who are involved

Chair with the Royal Academy of

in the nuclear industry have

Engineering.

also taken a personal interest in Professor Hyatt’s work and that

The Nuclear Decommissioning

has been a big benefit. We are now

Authority was set up by the 2004

considering whether to extend this

Energy Act to oversee the process

partnership with other institutions.” of decommissioning and cleaning up the UK sites that have been Dr. Dame Susan Ion DBE FREng, who is the Academy’s mentor to Professor Hyatt said, “It is vital that confidence is built in our ability to provide robust engineering solutions to the problem of nuclear waste disposal if we are to progress the desired new nuclear build ambitions the UK so desperately needs.

used for generating civil nuclear energy. Reporting to the Department of Energy and Climate Change, it is funded by a combination of government funding and income from its commercial operations (e.g. electricity generation from Wylfa Power Station). The NDA is responsible for developing the estate-wide strategy while decommissioning activities are delivered by the Site Licence

PECM PECM Issue Issue 21 21

Companies (SLCs) such as Sellafield Ltd. Research and development (R&D) is mostly carried out by the SLCs and their supply chains, who develop and deploy technologies that are specific to their particular sites. The NDA has overall responsibility for the mission, and has to ensure the work is underpinned by sufficient and appropriate R&D. In practice, this means that the NDA takes a technical oversight role on the site-specific R&D, while also looking out for any areas of overlap, duplication, or potential to be applied elsewhere on the estate. In addition to the site-focused R&D, the NDA also funds R&D directly through its Direct Research Portfolio (DRP) and collaborations with other organisations, such as the Technology Strategy Board. The DRP focuses on supporting the development of the NDA’s strategy, delivering multi-site innovation and maintaining key technical skills. This This is is carried carried out out through through R&D R&D projects projects commissioned commissioned through through universities universities and and research research organisations organisations such such as as the the National National Nuclear Nuclear Laboratory. Laboratory.

Professor Hyatt’s work on

research, while additional specific

radioactive waste immobilisation,

PhD projects have been funded

management and disposal applies

separately. Agreed ’soft’ metrics

to all three aspects of the NDA’s

have been developed to measure

DRP. For example, his research into

performance and impact on the

materials to immobilise plutonium

wider business.

is supporting the development of

Dr. Morris said, “We are looking

strategic options for the long-term

for Professor Hyatt to develop

management of the UK’s stock of

capabilities and engage in

civil plutonium.

activities such as securing additional funding for the group,

He has also carried out research

training students, developing

into alternative technologies

new technologies and publishing

for the management of nuclear

high quality research. We are

waste which may offer advantages

comfortable that the research

over the current approach of

being undertaken is relevant and

immobilising the waste in cement.

important to the NDA’s mission.”

Maintaining capability in nuclear waste immobilisation at an academic level is also important to the NDA. Dr. Morris said, “We are very much looking for leadership from an academic point of view. We are looking for the research to deliver postgraduates and postdoctoral researchers into the industry where they can develop and become the next generation of industry leaders. Over the next 15 years, for example, at least 30% of the UK’s nuclear workforce will reach retirement age.” The funding arrangement with Professor Hyatt provides him with freedom to pursue appropriate

The impact of research

The NDA’s joint Research Chair with the Royal Academy of Engineering: Neil Hyatt holds the NDA/RAEng Research Chair in Nuclear Waste Management and is a professor of Nuclear Materials Chemistry at the University of Sheffield. His research includes work on the immobilization of nuclear wastes in glass or ceramic materials, together with other projects across the nuclear sector.

Dr. Morris said, “The UK’s civil nuclear legacy represents the largest, most

He is also director of the

important environmental restoration

Immobilization Science Laboratory

programme in Europe and is a major

and co-director of the Nuclear

public liability. The NDA’s mission

FiRST programme. The Nuclear

is to deliver safe, sustainable and

FiRST programme was established

publicly acceptable solutions to this

to provide a national training

challenge.

centre for doctoral scientists and

Professor Hyatt’s research is

engineers in nuclear fission science

supporting the NDA in developing

and technology (Nuclear FiRST).

our strategy, developing innovative technologies and maintaining key

The programme is a £7 million

technical skills. We were particularly

scheme funded by EPSRC and it

pleased to see that the high quality

seeks to remedy skills gaps in UK

of his research was recognised by

academia and industry.

the Institute of Materials, Minerals & Mining with the Pfeil Award for 2012.”

“The UK was one of the first countries to develop civil nuclear power and, as a result, we are already more advanced in decommissioning than many other countries. There are opportunities for the UK to use this as a basis to secure business overseas and the NDA is keen to promote the UK’s expertise.” Dr. Darrell Morris Issue 21 PECM

The UK’s largest meeting place for advanced engineering professionals

Join us where the familiar and the collidecorridors to “Fantastic…I think thisunfamiliar“…the provide new opportunities supply is the best year across yet” the engineering and they are our chain. Dave Dave Withey, Withey, Graham Graham Mulholland, Mulholland, Senior Senior Project Project Engineer, Engineer, Research, Research,

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“It was fantastic to meet with likeminded people - especially in motor sports and hybrid power…We’ve got some great leads to follow up” Mark Mark Harbord, Harbord, Sales Sales && Marketing Marketing Manager, Manager, LCL LCL Electronics Electronics

Editors Choice

Hydrostatic Level Measurement T

here are many types have been full all the time, of level measurement r decision makers”technology. For

hydrographic surveys, water table and borehole measurement, hydrostatic pressure measurement is one of the most reliable.

was fantastic to meet with likended people - especially in motor orts and hybrid power…We’ve t some great leads to follow up” Harbord, Harbord, Sales Sales && Marketing Marketing Manager, Manager, LCL LCL Electronics Electronics

Hydrostatic pressure is described as being the pressure exerted by a ﬂuid at equilibrium to a given point within the ﬂuid, due to the force of gravity. A liquid column above the pressure sensor creates hydrostatic pressure, which is a direct indicator of the liquid level. In Europe the standard unit of measurement is metres of water gauge (mWG), also referred to as metres of water column (mWC), or metres of H2O (mH2O). ESI Technology design and manufacture a range of pressure transmitters for hydrostatic level applications. They are available in a range of diameters and can be calibrated to any unit of measurement.

desiccant housing at surface level is required to prevent moisture ingress over time. Stilling tubes and weighted nose cones are also available. ESI Technology can quote for individual sensors or complete systems to include cable, housing, display and other accessories. Contact details: ESI Technology Ltd, Sensor House, Wrexham Technology Park, Wrexham, LL13 7YP, UK T: +44 1978 262255 F: +44 1978 262233 E: info@esi-tec.com W: www.esi-tec.com

It is also necessary to use a special vented cable so that barometric pressure does not aﬀect the true hydrostatic pressure measurement. Also, a Issue 21 PECM

News & Events ESAB launches new series of copperfree, seamless flux-cored wires for offshore welding applications ESAB ESAB Welding Welding & & Cutting Cutting Products Products introduces introduces PrimeWeld, PrimeWeld, aa new new series series of of copper-free, copper-free, seamless seamless flflux-cored ux-cored welding welding wires wires specifi specifically cally designed designed to to meet meet the the needs needs of of the the off offshore shore construction construction industry. industry. Produced Produced using using aa unique unique seamless seamless manufacturing manufacturing process, process, PrimeWeld PrimeWeld off offers ers aa very very low low diff diffusible usible hydrogen hydrogen level level which which minimizes minimizes the the risk risk of of hydrogen-induced hydrogen-induced cold cold cracking cracking (HICC) (HICC) when when welding welding thicker thicker components, components, especially especially critical critical in in off offshore shore applications. applications. The The seamless seamless wire wire design design also also prevents prevents moisture moisture absorption, absorption, improving improving product product shelf shelf life life and and minimizing minimizing any any special special storage storage and and handling handling requirements. requirements.

Email: Email: info@esab.co.uk info@esab.co.uk

www.esab.com www.esab.com

echoENG is glad to present the sixth issue of the Machine Tools General Catalogue. The The catalogue catalogue shows shows our our production production program program which which includes includes the the following following types types of of machines: machines: Electrical Electrical discharge discharge ·· Machining Machining centers centers ·· Milling Milling machines machines ·· Slotting Slotting machines machines Parallel Parallel and and vertical vertical lathes lathes ·· Drilling Drilling machines machines ·· Bandsaws Bandsaws Grinding Grinding machines machines Shaping Shaping machine machine ·· Tool Tool grinding grinding machines machines Bench-column Bench-column grinding grinding machines machines ·· Press Press brakes brakes ·· Cutting Cutting shears shears Roll Roll bending bending machines machines and and Hydraulic Hydraulic steel steel workers workers Pipe Pipe and and profi profile le bending bending machines machines ·· Muffl Mufflee furnaces furnaces

Kasto automated warehouse forms core of new distribution centre Pipe Pipe Center Center has has opened opened aa new new distribution distribution centre centre (DC) (DC) in in Measham, Measham, Derbyshire, Derbyshire, the the newest newest and and most most technologically technologically advanced advanced distribution distribution operation operation in in the the supply supply chain chain of of parent parent company, company, Wolseley Wolseley UK. UK. The The 142,000 142,000 sq sq ft ft facility, facility, which which went went live live in in December December 2014, 2014, has has given given Pipe Pipe Center Center the the ability ability to to provide provide next-day next-day delivery delivery across across its its entire entire network network and and has has created created over over 50 50 new new jobs. jobs. At At its its heart heart is is aa bespoke, bespoke, 3,332-location 3,332-location KASTOunicompact KASTOunicompact 4.0 4.0 automated automated warehouse, warehouse, built built in in Germany Germany and and supplied supplied through through KASTO KASTO Ltd, Ltd, Milton Milton Keynes. Keynes. The The cassette-type cassette-type tube tube storage storage system system provides provides dynamic dynamic goods-to-man goods-to-man presentation presentation for for effi efficient cient picking, picking, which which reduces reduces the the amount amount of of manual manual handling handling required. required. The The KASTO KASTO system system has has reduced reduced the the distance distance warehouse warehouse operatives operatives have have to to move move when when picking, picking, speeding speeding the the consolidation consolidation of of orders. orders. The The warehouse warehouse design design also also increases increases the the height height used used for for storage storage of of Pipe Pipe Center’s Center’s SKUs SKUs (stock (stock keeping keeping units). units). The The consequently consequently reduced reduced footprint footprint represented represented signifi significant cant cost cost savings. savings.

Email: Email: sales@kasto.uk.com sales@kasto.uk.com

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HBM helps Huub take the drag out of performance! As As part part of of its its latest latest research research into into demonstrating demonstrating the the eff effect ect of of drag drag on on diff different erent suits suits for for world world class class swimmers, swimmers, Huub Huub Ltd. Ltd. is is launching launching its its new new M16 M16 Drag Drag Measurement Measurement System, System, using using PW15iA PW15iA load load cells cells from from HBM HBM –– aa market market leader leader in in the the fifield eld of of test test and and measurement. measurement. The The new new M16 M16 Drag Drag Measurement Measurement System, System, will will be be used used to to develop develop high high performance performance triathlon triathlon and and FINA FINA approved approved swimwear, swimwear, and and is is the the latest latest advanced advanced underwater underwater application application which which can can be be used used to to measure measure the the swimmer’s swimmer’s propelling propelling force force on on aa push-off push-off pad. pad.

For For further further information, information, please please contact contact our our local local dealer dealer in in the the UK: UK:

As As swimming swimming performance performance is is measured measured to to the the nearest nearest 0.01 0.01 second, second, with with swimmers swimmers in in the the top top 15 15 separated separated by by only only 0.10 0.10 seconds, seconds, athletes athletes continue continue to to look look at at factors factors or or legal legal aids aids which which could could improve improve performance performance in in water, water, such such as as individually individually tested tested swimsuits swimsuits that that reduce reduce drag; drag; this this is is where where Huub Huub dives dives in! in!

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The The echoENG echoENG Machine Machine Tools Tools catalogue catalogue can can be be requested requested by by writing writing to: to: info@echord.it info@echord.it

E. Preston Electrical Expands Franchises and Goes Online

www.hbm.com www.hbm.com

AHT supporting Quicksilver water-speed project

E. E. Preston Preston (Electrical) (Electrical) Ltd Ltd was was established established in in 1980 1980 as as aa specialist specialist distributor distributor of of switches switches and and electrical electrical components. components. Beginning Beginning with with only only 33 franchises franchises the the company company currently currently has has over over 40 40 diﬀ diﬀerent erent franchises franchises and and holds holds approximately approximately half half aa million million pounds pounds worth worth of of stock. stock. Now Now in in the the third third generation generation of of family family ownership ownership E. E. Preston Preston Electrical Electrical continues continues to to grow grow and and build build on on traditional traditional values. values.

Alloy Alloy Heat Heat Treatment Treatment (AHT) (AHT) are are delighted delighted to to be be involved involved in in the the Quicksilver Quicksilver World World Water Water Speed Speed Record Record project. project. The The project project is is aa collaborative collaborative venture venture uniting uniting highly-skilled highly-skilled people people and and fifirms rms from from across across the the broad broad span span of of British British industry, industry, drawn drawn together together by by the the man man who who founded founded the the project, project, author author Nigel Nigel Macknight. Macknight. AHT AHT are are the the UK’s UK’s fifirst rst and and only only specialist specialist in in the the heat heat treatment treatment of of aluminium aluminium alloys. alloys. With With over over 40 40 years years experience experience as as aa subcontractor subcontractor focused focused solely solely on on the the heat heat treatment treatment of of aluminium aluminium alloys, alloys, they they are are the the preferred preferred destination destination for for companies companies within within all all sectors sectors of of the the light light metal metal industry. industry.

This This is is aa principle principle that that was was rooted rooted in in the the business business from from its its inception inception over over 30 30 years years ago ago by by founder, founder, and and grandfather grandfather to to the the current current directors, directors, Ernest Ernest Preston. Preston.

AHT AHT Director, Director, Ian Ian Perks Perks explained: explained: “We “We are are extremely extremely proud proud to to sponsor sponsor the the Quicksilver Quicksilver project project in in its its aim aim to to bring bring the the World World Water Water Speed Speed Record Record back back to to Great Great Britain, Britain, and and itit would would be be great great to to be be aa part part of of that. that. It It is is brilliant brilliant that that there there is is aa concentration concentration of of local local companies companies that that are are also also supporting supporting the the project.” project.” AHT’s AHT’s support support of of the the Quicksilver Quicksilver project project will will be be highlighted highlighted when when they they exhibit exhibit between between 11-17th 11-17th July July at at MAA MAA stand stand 1/ 1/ B90 B90 (Hall (Hall 1, 1, UK UK Pavilion) Pavilion) at at the the Farnborough Farnborough International International Airshow. Airshow.

Email: Email: sales@epreston.co.uk sales@epreston.co.uk

Tel: Tel: +44 +44 (0)1384 (0)1384 456777 456777

“We “We work work hard hard for for our our customers customers to to get get the the best best products products at at the the best best prices prices while while providing providing exceptional exceptional customer customer service. service. We We always always do do what what we we say say we we will, will, even even ifif that that is is just just aa call call back,” back,” says says Mark Mark Preston, Preston, MD. MD.

www.epreston.co.uk www.epreston.co.uk

SEEPEX pumps reduce operating costs for Thames Water Thames Thames Water Water is is the the UK’s UK’s largest largest water water and and sewage sewagetreatment treatmentcompany, company,providing providingwastewater wastewater services services to to 15 15 million million customers. customers. SEEPEX SEEPEX pumps pumps have have delivered delivered process process improvements improvements at at their their Reading Reading STW, STW, reducing reducing both both operating operating costs costs and and onward onward sludge sludge transport transport costs. costs. SEEPEX SEEPEX progressive progressive cavity cavity pumps pumps replaced replaced piston piston pumps pumps transferring transferring de-watered de-watered digested digested sludge sludge to to storage storage silos. silos. Thames Thames engineers engineers identiﬁ identiﬁed ed aa large large saving saving in in disposal disposal costs costs by by increasing increasing the the ds ds content content of of the the dewatered dewatered sludge sludge to to 25%, 25%, however however they they needed needed reliable reliable pumps pumps to to transfer transfer the the dewatered dewatered sludge sludge over over 80metres, 80metres, with with aa static static head head of of 30m, 30m, without without increasing increasing system system costs. costs. SEEPEX SEEPEX open open hopper hopper pumps pumps transfer transfer the the higher higher ds% ds% sludge sludge with with 50% 50% reduced reduced power power consumption consumption (15KW) (15KW) and and up up to to 75% 75% reduced reduced discharge discharge pressure. pressure. The The SEEPEX SEEPEX system system has has delivered delivered aa hat-trick hat-trick of of cost cost reductions: reductions: lower lower sludge sludge disposal disposal costs, costs, lower lower energy energy use use and and reduced reduced maintenance maintenance costs. costs.

Tel: Tel: +44 +44 1935 1935 472376 472376 Email: Email: sales.uk@seepex.com sales.uk@seepex.com

18 PECM PECM Issue Issue 21 21

www.seepex.com www.seepex.com

www.alloyheat.co.uk www.alloyheat.co.uk

Campaigning for product traceability Hot Hot on on the the heels heels of of announcing announcing the the stamping stamping of of CE CE Marking Marking on on their their leaf leaf chain chain range, range, Donghua Donghua has has confi confirmed rmed that that all all leaf leaf chain chain will will now now come come with with aa DEKRA DEKRA certifi certificate, cate, where where applicable. applicable. Donghua Donghua Limited, Limited, the the UK UK arm arm of of one one of of the the world’s world’s largest largest chain chain manufacturers, manufacturers, CE CE Marking Marking plate plate is is available available either either in in black black or or silver silver for for ID ID purposes. purposes. announced announcedrecently recentlythat thatthey theyare arestamping stamping CE CE marking marking on on all all their their leaf leaf chain chain products products sold sold across across the the European European Economic Economic Area Area (EEA). (EEA). CE CE Marking Marking reassures reassures customers customers that that the the manufacturer manufacturer takes takes responsibility responsibility for for the the conformity conformity of of their their product product to to applicable applicable EC EC safety safety directives. directives. The The company company is is supporting supporting this this move move even even further further by by issuing issuing aa DEKRA DEKRA certifi certificate cate alongside alongside their their usual usual product product test test certifi certificate. cate. DEKRA DEKRA provides provides an an independent independent review review of of whether whether the the product product complies complies with with relevant relevant European European criteria. criteria. www.donghua.co.uk/leaf-chain, For For more more information information visit visit www.donghua.co.uk/leaf-chain, email email sales@donghua.co.uk sales@donghua.co.uk or or call call 01902 01902 866 866 200 200

Building a world class ad industry:

the only dedicated gloBal anaeroBic digestion and Biogas trade show Be part of the industry’s premier event Having grown by 600% since the first exhibition in 2010, UK AD & Biogas is now the world’s leading biogas trade show dedicated to anaerobic digestion and the growing biogas industry. Showcasing the very best AD technology for sewage treatment, food waste, farm and small-scale plants as well as community and micro-scale AD plants, the latest innovations, gas upgrading and biomethane vehicle technology. The high-profile conference will outline the key drivers for the AD industry around the world, the opportunities for AD to address some of the world’s biggest issues, including energy security, climate change, food security, wastewater and sanitation, as well as assessments of the largest growing AD markets.

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• Learn what value there is in AD digestate and see the future technology which can harness it • Review the Infrastructure for Biomethane (gas grid connectivity) • Find out how the UK market compares with other countries and the export opportunities available • Network with Local Authorities, Food and Drink companies, Waste and Water companies

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Location

UK AD & Biogas 2016 is based at the NEC Birmingham, just minutes away from Birmingham Airport (BHX) with excellent transport links to the rest of the UK and international connections. Media partners

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Innovative technology for the renewable energy sector NutromexÂŽ Biopack boosts Anaerobic Digester performance and stability OMEX OMEX Environmental Environmental Ltd. Ltd. are are introducing introducing their their new new powder powder additive additive for for the the anaerobic anaerobic digestion digestion and and biogas biogas market, market, ÂŽ Biopack. ÂŽ Nutromex NutromexÂŽ Biopack. Nutromex NutromexÂŽ Biopack Biopack is is aa unique unique mix mix of of biobioavailable available trace trace elements elements and and specially specially selected selected bacteria bacteria which which is is used used to to supplement supplement the the existing existing microbial microbial populations populations in in Anaerobic Anaerobic Digesters Digesters and and Biogas Biogas plants. plants. This This addition addition improves improves overall overall plant plant functionality, functionality, leading leading to to optimum optimum performance. performance. ÂŽ Biopack Biopack has has an an advantage advantage over over current current products products in in the the Nutromex NutromexÂŽ market market due due to to itsâ&#x20AC;&#x2122; itsâ&#x20AC;&#x2122; easy easy application. application. It It is is aa water water soluble soluble powder powder available available in in 250g 250g biodegradable biodegradable bags bags which which are are administered administered directly directly into into the the feeder feeder on on aa daily daily basis. basis.

Each Each individual individual digester digester needs needs essential essential metals metals to to create create the the perfect perfect balance balance for for microbial microbial populations populations to to thrive thrive and and break break down down feedstock feedstock eďŹ&#x20AC; eďŹ&#x20AC;ectively ectively and and itsâ&#x20AC;&#x2122; itsâ&#x20AC;&#x2122; performance performance and and cost cost eďŹ&#x20AC; eďŹ&#x20AC;ectiveness ectiveness ÂŽ is is highly highly dependent dependent on on the the microbe microbe strains strains present. present. Nutromex NutromexÂŽ Biopack Biopack provides provides both both bacteria bacteria and and trace trace elements elements in in one one hit. hit. Available Available in in 10kg 10kg plastic plastic pails pails containing containing 40 40 xx 250g 250g bags, bags, ÂŽ Biopack Biopack can can be be used used in in anaerobic anaerobic plants plants for for aa variety variety of of Nutromex NutromexÂŽ substrates substrates from from grass grass silage silage to to food food waste waste and and is is currently currently proving proving to to be be very very successful successful in in trials trials on on several several farms farms throughout throughout the the UK. UK.

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For For more more information information please please contact contact us us on on +44 +44 (0)1553 (0)1553 770092 770092 or or visit visit us us at at www.omex.co.uk www.omex.co.uk

There is an easier way to detect oil in your food.

METPOINT METPOINT OCV OCV measures measures remaining remaining oil oil vapour vapour content content down down to to 0.001 0.001 mg/m3 mg/m3 which which isis better better than than ISO8573-1 ISO8573-1 Class Class 1. 1. Monitor Monitor and and control control the the risk risk of of contamination contamination of of your your compressed compressed air air supply. supply. BEKO BEKO Technologies, Technologies, 22 West West Court, Court, Buntsford Buntsford Park Park Road, Road, Bromsgrove, Bromsgrove, Worcs, Worcs, B60 B60 3DX 3DX,, Fax: Fax: 01527 01527 575779 575779 email: email: info.uk@beko.de info.uk@beko.de website: website: www.bekotechnologies.com www.bekotechnologies.com BA0159 BA0159

20 PECM PECM Issue Issue 21 21

AD & Biogas Show

Packo High Shear Pump Series SFP2 & SFP3 T

he new, efficient high shear mixing method developed by Packo is based on the proven EHEDG certified pump series FP2 with open impeller and series FP3 with closed impeller. The Packo shear mixer pump is mainly used for inline mixing, homogenisation and dispergation applications. The shear is generated between the rotor and an innovative and optimized perforated stator (patent pending). The shear can be optimized and increased by raising the speed of rotation. Shear rates up to 40.000 s-1 can be achieved at a maximum speed of 3600 rpm! The final goal is to achieve a homogeneous solution of two liquids with high difference in viscosity and/ or density and to obtain a particle size reduction for emulsions and particles.

The smooth operational performance achieved by this conforms with the unique precision and quality you have come to expect from all Packo components. Thanks to the special designed stator (patent pending) together with small clearance between rotor and stator an important shear will be generated resulting in a signiﬁcant particle size reduction (from 1.4 up to 2 µm)! A smaller particle size will result in a more stable ﬁnal product.

• Monobloc execution, easy installation. • Easy to clean (CIP and SIP). • ‘Self’ pumping. • High mechanical & hydraulic shear. • Rapid solid dissolving. • Particle size reduction leading to a stable product. For complete mixing and homogenizing units, please contact Packo Pumps.

The benefits of the Packo High Shear Pump Series SFP2 & SFP3 include: • High efficient so less energy cost! • Use of std. components, easy maintenance. • Several seal configurations available. • Atex available

We optimize your ow Tel: +32 51 51 92 80 Email: pumps@packo.com www.packopumps.com

Our Contribution to Your Carbon Benefit We optimize your flow

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ADBA Biogas Watch the Packo Pumps video.

Stand D601 Birmingham, UK 6-7 July 2016

Packo Pumps Belgium Tel. +32 51 51 92 80 • pumps@packo.com

www.packopumps.com

Issue 21 PECM

As As they they are are stackable, stackable, less less storage storage space space isis taken taken up, up, and and large large handles handles enable enable eff effortless ortless manoeuvrability. manoeuvrability. Anti-skid Anti-skid rubber rubber feet feet ensure ensure steady steady operation, operation, and and the the rugged rugged build build of of the the machines machines means means they they are are durable durable and and weather weather resistant. resistant.

The Professional Choice for Portable Fume Extraction and Confined Space Ventilation T

he he combination combination of of dependable dependable power power and and practical practical design design makes makes the the Miniveyor Miniveyor Air Air VAF VAF series series fans fans and and ventilators ventilators the the professional professional choice choice for for portable portable dust dust and and welding welding fume fume extraction. extraction. As As they they are are stackable, stackable, less less storage storage space space is is taken taken up, up, and and large large handles handles enable enable eﬀ eﬀortless ortless manoeuvrability. manoeuvrability. Anti-skid Anti-skid rubber rubber feet feet ensure ensure steady steady operation, operation, and and the the rugged rugged build build of of the the machines machines means means they they are are durable durable and and weather weather resistant. resistant. Designed Designed with with aa twin twin wall, wall, rotationally rotationally moulded moulded fan fan body, body, made made from from high high density density polythene, polythene, means means the the products products can can absorb absorb bangs bangs frequently frequently experienced experienced with with industrial industrial use, use, eliminating eliminating costly costly maintenance maintenance procedures. procedures. Compare Compare this this with with conventional conventional metal metal bodied bodied fans fans that that typically typically don’t don’t last last very very long long in in the the workplace, workplace, as as the the sheet sheet metal metal bodied bodied fans fans tend tend to to dent dent easily easily when when knocked, knocked, so so they they will will need need replacing. replacing. The The plastic plastic moulded moulded fans fans from from VAF VAF Air Air are are highly highly resistant resistant so so they they can can last last aa much much

longer longer time. time. Additionally, Additionally, all all of of the the parts parts are are replaceable replaceable so so if if anything anything does does get get damaged damaged then then they they can can be be changed changed easily.” easily.” The The portable portable and and reliable reliable fans fans and and blowers blowers are are both both safe safe and and suitable suitable for for use use in in confi confined ned spaces. spaces. Where Where fumes, fumes, smells smells or or dust dust occur, occur, the the axial axial fans fans can can extract extract contaminated contaminated air air out out of of the the building, building, and and blow blow fresh, fresh, clean clean air air into into aa workspace. workspace. The The VAF VAF series series range range has has recently recently been been extended extended with with the the introduction introduction of of the the VAF-200C VAF-200C Canister Canister blower. blower. Based Based on on its its popular popular VAF-200, VAF-200, the the compact compact VAF-200C VAF-200C is is ideal ideal for for confi confined ned space space ventilation ventilation and and fume fume extraction extraction and and benefi benefits ts from from a, a, simple simple to to attach, attach, Duct Duct Canister Canister that that neatly neatly clips clips onto onto the the fan fan body body and and houses houses 7.5 7.5 metres metres of of fl flexible exible duct. duct. Designed Designed for for manhole manhole work, work, It It is is great great for for telecoms telecoms of of utilities utilities contractors contractors that that have have limited limited storage storage space space in in service service vehicles vehicles and and can can be be carried carried to to the the job job site site with with ease. ease. Visit Visit us us online online at at www.vaf-air.com www.vaf-air.com

Designed with a twin wall, rotationally moulded fan body, made from high density polythene, means the products can absorb bangs frequently experienced with industrial use, eliminating costly maintenance procedures. 22 PECM PECM Issue Issue 21 21

World’s First Astronaut Whiskey Glass

he world’s first whiskey glass

The finished model looked extremely

Ogle were asked to develop the prototype

suitable for use in outer

realistic and we’re hugely proud to have

by Trillium Technologies, which is a

space has been developed

been involved in creating this world-first

company dedicated to developing systems

with the help of a leading

project.”

and technologies that tackle today’s grand

prototyping company.

challenges. The model was eventually hand-finished

Ogle, which is based in Letchworth, was

inside and out using 800 wet grade paper

Jordan McRae, Co-Founder and Chief

asked to create a model which would

to remove any layering and provide a

Technology Officer of Trillium, said: “These

withstand rigorous testing suitable for use

smooth texture. To create a glass-like

days it’s not that difficult to find a shop

beyond the earth’s atmosphere. Ogle’s

appearance it was then masked and clear

that will 3D print something for you.

stereolithography (SLA) machines – a form

lacquered on both sides. The glass, which

of 3D printing ¬– were used to create

comprised of six component parts, was

However, it’s tough to beat the level of

the precise specifications needed for the

subject to many pre and post production

professionalism, expertise, and attention

microgravity friendly object.

checks by the Ogle team.

to detail that we get when we work with Ogle which is why they were our first

To ensure the prototype was visually

This included applying a rose gold plated

choice for the 3D printed ClearVue glass

realistic and durable, a plastic called

base to ensure the thread, which brings

used in Space Glass.”

ClearVue was selected for production

the liquid to the top of the glass and

because, once the part is finished, it resists

prevents the whiskey from spilling, would

Trillium was approached by premium

humidity and moisture well.

fit correctly with enough clearance for the

whiskey brand Ballentine’s to create

paint team.

the whisky glass which would work in

Dave Bennion the Marketing and Sales Director for Ogle, said: “The accuracy needed for this project was significant and it was imperative that every single measurement was correct as there was no room for error. It’s not every day you get asked to create a model of an item which may eventually be used in outer space, so

Gold is a common material for use in space due to its deflective radiation components, but in this case it was chosen to prevent the materials used to make the glass from affecting the taste of the whisky.

microgravity. The prototype was tested in micro gravity at the ZARM Drop Tower in Germany where it was approved for space flight. www.oglemodels.com

this was hugely exciting for the team. Issue 21 PECM

Boilers & Maintenance Babcock Wanson provides new boiler house & plant for Stolthaven terminals

Babcock Babcock Wanson Wanson has has designed designed aa new new thermal thermal ďŹ&#x201A;ďŹ&#x201A;uid uid system system to to accommodate accommodate its its high high eďŹ&#x192; eďŹ&#x192;ciency ciency Thermal Thermal Fluid Fluid Heaters Heaters at at Stolthaven Stolthaven Dagenham Dagenham Ltd Ltd bulk bulk liquid liquid terminal terminal situated situated on on the the river river Thames Thames in in Dagenham, Dagenham, Essex. Essex. Babcock Babcock Wanson Wanson worked worked closely closely with with Stolthaven Stolthaven Dagenhamâ&#x20AC;&#x2122;s Dagenhamâ&#x20AC;&#x2122;s consultants consultants to to provide provide the the ďŹ ďŹ nal nal design design of of the the boiler boiler house house and and then then install install and and ďŹ ďŹ tt itit out out with with its its EPC EPC ES ES and and TPC TPC B B Thermal Thermal Fluid Fluid Heaters. Heaters. A A large large proportion proportion of of the the thermal thermal design design was was also also carried carried out out by by Babcock Babcock Wanson Wanson with with the the supply supply of of all all the the system system valves valves and and ancillary ancillary equipment equipment to to provide provide aa complete complete system system with with single single point point of of responsibility. responsibility. The The system system also also incorporates incorporates aa secondary secondary circuit circuit to to provide provide lower lower temperature temperature thermal thermal ďŹ&#x201A;ďŹ&#x201A;uid uid for for the the bitumen bitumen pump pump casing casing heating. heating. The The project project was was aa fast fast moving moving one one with with tight tight deadlines, deadlines, all all of of which which Babcock Babcock Wanson Wanson met. met.

Tel: Tel: 020 020 8953 8953 7111 7111

www.babcock-wanson.co.uk www.babcock-wanson.co.uk

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(PDLO 3(&0#EURZQPDF FRP (PDLO 3(&0#EURZQPDF FRP CERTUSS CERTUSS (UK) (UK) Limited Limited ! ! Unit Unit 45 45 Gravelly Gravelly Ind Ind Park Park ! ! # $ # $ Tyburn Tyburn Road Road $ " $ " Birmingham Birmingham B24 B24 8TG 8TG

24 PECM PECM Issue Issue 21 21

Tel Tel :: 0121 0121 327 327 5362 5362

Fax Fax :: 0121 0121 328 328

2934 2934 sales@certuss.co.uk sales@certuss.co.uk www.certuss.co.uk www.certuss.co.uk

Stand Number P486 Fluid Power & Systems 2016

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

Precision Gas Control For Experimental Combustion Rig

Designing Designing and and manufacturing manufacturing one-off one-off pieces pieces of of equipment equipment requires requires considerable considerable

The first first was was of of paramount paramount importance importance The

engineering engineering skill, skill, especially especially when when that that equipment equipment is is required required to to control control combustible combustible gases gases

and is is aa constant constant feature feature in in any any Saflame Saflame and

and and deliver deliver precisely precisely repeatable repeatable results. results. So So when when Saflame Saflame was was approached approached to to design design an an

design, while while connectivity connectivity was was also also aa design,

experimental experimental combustion combustion rig rig which which required required precise, precise, independent independent control control of of three three gases, gases,

long-standing element element of of its its control control long-standing

itit turned turned to to B端rkert B端rkert Fluid Fluid Control Control Systems Systems to to provide provide the the solution. solution.

panels. The The level level of of gas gas control control which which panels. would be be required required in in this this particular particular project project would

Saflame Saflame is is aa manufacturer manufacturer and and supplier supplier of of

The The design design process process started started with with the the

needed some some expert expert assistance, assistance, which which was was needed

thermal thermal processing processing and and control control equipment equipment

initial initial consultation consultation where where the the university university

provided by by B端rkert. B端rkert. provided

to to aa wide wide range range of of industries industries and and has has

provided provided an an outline outline of of the the purpose purpose of of the the

considerable considerable expertise expertise in in designing designing the the

rig, rig, the the gases gases involved involved and and the the limiting limiting

control control mechanisms mechanisms including including the the use use

factor factor of of size size which which was was determined determined by by

of of PLC's, PLC's, SCADA SCADA and and fieldbus fieldbus systems. systems.

the the dimensions dimensions of of the the fume fume cupboard cupboard in in

This This experience experience led led to to aa request request from from the the

which which the the test test rig rig would would be be operating. operating.

Chemistry Chemistry Department Department at at the the University University of of

Beyond Beyond this this basic basic list list of of parameters, parameters, the the

Liverpool Liverpool for for Saflame Saflame to to develop develop aa special special

detailed detailed design design was was left left in in the the hands hands of of

laboratory laboratory combustion combustion rig rig to to assist assist with with

the the engineers engineers at at Saflame. Saflame. Three Three major major

research research into into flame flame deposition deposition of of chemical chemical

design design areas areas were were established established first, first, safety, safety,

films films onto onto various various materials. materials.

precision precision and and connectivity. connectivity.

PECM PECM Issue Issue 21 21

The basic concept of the combustion rig was provide a platform which would allow oxygen, nitrogen and liquefied petroleum gas (LPG) to be mixed at precise ratios and ignited to produce a consistent flame. Once a stable flame is established, a test chemical is introduced into this flame and then deposited onto a sample material plate which is positioned in front of the flame.

Gary Williams, Technical Director at Saflame, comments: "There were a number of design hurdles that needed to be overcome but thankfully flow control for the gases was easy to solve. The support from Bürkert was excellent which meant that our design team could spend more time on the other aspects of the project. "The Bürkert product really was a plug & play item with its connectivity allowing direct control through our GRX SCADA system, which allows the parameters of each experiment to be recorded and Once the design specification had been

or actual value changes within 100ms and

finalised with the university, the project

also maintain its high sensitivity, even at

needed to become a reality which

low flow rates. Three Type 8713 MFC's, one

meant sourcing all of the components

for each gas, were incorporated into the

to build the rig and making sure that

design and connected to the GRX SCADA

the finished product would deliver the

system, which allowed each MFC to be

precision required for scientific research

independently programmed, controlled

data. Saflame approached Bürkert with

and monitored during each experiment.

replicated if necessary. The MFC's proved to be easy to set up and following some commissioning and training with the university, the combustion rig has been performing perfectly."

the specifications for the gas control system and following the consultation, Bürkert suggested the Type 8713 mass flow controller (MFC) for gases, which was ideally suited to this project. The Type 8713 is a compact device which is designed to provide precise and consistent results, based on Bürkert's 60 years of experience in measuring, controlling and regulating fluids. It uses CMOSens® technology to accurately measure the gas flow rate allowing it to control a set point

Dr Troy Manning, who gave the initial design specification to Saflame, commented "We have worked closely with Saflame to ensure that the finished rig would fulfil our requirements. As part of a research project, it is crucial that we can record all of our base data and also repeat experiments with a level of precision that allows meaningful, reproducible results to be collected."

Coatings ® coating extends lifetime of LOCTITE® flue gas duct … and eliminates the cost of repair and downtime Conditions Conditions in in aa flflue ue gas gas duct duct are are extreme. extreme. Heightened Heightened exposure exposure to to heat heat and and aggressive aggressive chemicals chemicals can can cause cause the the steel steel structure structure to to crack crack or or fracture fracture resulting resulting in in leakage. leakage. In In the the worst worst case, case, this this can can lead lead to to plant plant shutdowns shutdowns and and expensive expensive repairs. repairs. As As aa manufacturer manufacturer itself, itself, Henkel Henkel fully fully understands understands the the problem problem and and has has chosen chosen to to take take aa proactive proactive approach approach by by treating treating the the flflue ue gas gas duct duct at at its its own own ® ® power power plant plant in in Düsseldorf Düsseldorf with with LOCTITE LOCTITE PC PC 7255. 7255. This This protective protective coating coating is is aa sprayable, sprayable, ceramic ceramic reinforced reinforced epoxy epoxy that that has has proven proven its its ability ability to to extend extend the the lifetime lifetime of of aa wide wide variety variety of of plant plant from from tanks tanks and and chutes chutes to to heat heat exchangers, exchangers, centrifuges centrifuges and and impellers. impellers.

Tel: Tel: 01442 01442 278000 278000 Email: Email: technicalservice.loctite@uk.henkel.com technicalservice.loctite@uk.henkel.com www.loctite.co.uk www.loctite.co.uk

New coatings will help limit contamination in crucibles

Mate’s Mate’snew newSuperMax™ SuperMax™tool toolcoating coating answers answers today’s today’s requirements requirements for for high high performance, performance, longer longer lasting lasting punch punch press press tooling. tooling. Providing Providing aa hard, hard, wear wear resistant resistant and and lubricious lubricious coating, coating, SuperMax SuperMax acts acts as as aa barrier barrier between between the the punch punch and and sheet sheet metal, metal, greatly greatly improving improving stripping stripping and and extending extending tool tool life. life. A A proprietary proprietary coating, coating, SuperMax SuperMax provides provides more more hits hits between between sharpening, sharpening, which which reduces reduces machine machine downtime. downtime. SuperMax SuperMax also also reduces reduces galling, galling, slug slug pulling pulling and and corner corner breakdown breakdown enhancing enhancing the the quality quality and and effi efficiency ciency of of the the punching punching process. process. Outperforming Outperforming currently currently available available premium premium coatings coatings by by 22 to to 88 times, times, SuperMax SuperMax is is applied applied using using the the very very latest latest nano-layer nano-layer technology. technology. It It is is aa harder, harder, denser denser fifilm lm that that greatly greatly increases increases wear wear resistance resistance and and aa much much lower lower friction friction coeffi coefficient cient of of approximately approximately 20 20 percent. percent. This This lower lower friction friction means means less less heat heat build-up, build-up, less less galling galling (adhesion) (adhesion) and and much much longer longer tool tool life. life.

Morgan Morgan Advanced Advanced Materials Materials has has made made two two new new additions additions to to its its extensive extensive range range of of crucible crucible coatings coatings for for the the foundry foundry sector. sector. Contamination Contamination of of molten molten metals metals by by crucible crucible materials materials during during melting melting operations operations can can be be minimised minimised by by coating coating the the interior interior surface surface of of the the crucible, crucible, helping helping to to prevent prevent reactions reactions between between the the metal metal and and the the crucible crucible while while acting acting as as aa diff diffusion usion barrier barrier to to reduce reduce impurities. impurities. PRO™ PRO™ and and STAR™ STAR™ Coatings Coatings from from Morgan’s Morgan’s Molten Molten Metal Metal Systems Systems business business have have been been formulated formulated to to reduce reduce impurities impurities and and so so optimise optimise the the quality quality of of the the molten molten metal metal and and the the fifinal nal cast cast product. product.

www.morganmms.com/coatings www.morganmms.com/coatings

New Mate SuperMax™ Tool Coating Outperforms Other Coatings 2 To 8 Times

SuperMax SuperMax works works well well on on Mate’s Mate’s M4PM™, M4PM™, M2 M2 and and Durasteel™ Durasteel™ punches punches in in round, round, rectangle, rectangle, oval oval and and square square punch punch confi configurations. gurations. Its Its application application eff effectiveness ectiveness includes includes 3000 3000 and and 5000 5000 series series aluminum, aluminum, galvanized galvanized and and stainless stainless steels, steels, pre-painted pre-painted material, material, vinyl vinyl coated coated material material and and fifiberglass. berglass. “Mate “Mate SuperMax SuperMax is is aa real real breakthrough breakthrough and and the the next next generation generation in in tool tool coating,” coating,” stated stated John John Galich, Galich, Mate Mate marketing marketing manager. manager. “It “It increases increases tool tool performance performance beyond beyond anything anything that’s that’s currently currently available, available, further further substantiating substantiating Mate’s Mate’s mission mission of of providing providing superior superior solutions solutions for for sheet sheet metal metal fabricators.” fabricators.” For For more more information information on on what what SuperMax SuperMax tool tool coating coating can can do do for for your your punching punching operations, operations, in in USA USA and and Canada Canada call call 1-800-328-4492. 1-800-328-4492. Outside Outside USA USA and and Canada, Canada, call call 1-763-421-0230. 1-763-421-0230.

Stahl launches RelcaSilTM: next gen weatherstrip coatings offering best-in-class performance

tahl tahl launched launched its its latest latest innovation innovation RelcaSil™ RelcaSil™ during during the the opening opening of of its its new new Center Center of of Excellence Excellence for for Automotive Automotive in in the the Netherlands. Netherlands. Relcasil™ Relcasil™ is is the the next next generation generation hybrid hybrid silicone silicone urethane urethane coatings, coatings, oﬀ oﬀering ering premium premium weatherstrip weatherstrip performance performance in in aa sustainable sustainable way. way. As As aa result result of of dedicated dedicated research research and and innovative innovative power, power, the the RelcaSil™ RelcaSil™ weatherstrip weatherstrip range range has has been been developed developed in in close close cooperation cooperation with with partners partners and and customers customers in in order order to to meet meet market market demands. demands. Resulting Resulting in in luxurious luxurious haptics, haptics, low low gloss gloss and and excellent excellent noise noise performance. performance. “As “As aa leading leading company company in in process process chemicals chemicals for for leather, leather, coatings coatings and and other other substrates substrates for for the the automotive automotive industry, industry, we we know know what what counts counts for for car car manufacturers. manufacturers. Our Our new new Center Center of of Excellence Excellence for for Automotive Automotive is is equipped equipped with with state-of-the-art state-of-the-art testing testing and and pilot pilot equipment equipment for for Elastomer Elastomer coatings. coatings. Emphasizing Emphasizing recent recent industry industry trends trends

28 PECM PECM Issue Issue 21 21

and and addressing addressing technical technical challenges, challenges, our our automotive automotive elastomer elastomer coatings coatings feature feature the the most most technically technically advanced advanced polymers polymers in in the the world. world. In-house In-house polymer polymer development development has has allowed allowed our our formulators formulators to to utilize utilize the the latest latest advancements advancements in in resin resin technology technology to to develop develop RelcaSil™: RelcaSil™: coatings coatings with with unrivaled unrivaled haptics, haptics, low low gloss gloss and and superior superior noise noise performance,” performance,” says says Mel Mel Micham, Micham, Global Global Market Market Manager Manager Automotive Automotive Elastomer Elastomer & & Plastic Plastic Coatings Coatings at at Stahl. Stahl. Exceptionally Exceptionally versatile versatile coatings coatings Being Being the the market market leader leader in in high high performance performance coatings coatings for for dynamic dynamic applications, applications, Stahl Stahl developed developed the the next next generation generation of of weatherstrip weatherstrip coatings. coatings. The The RelcaSil™ RelcaSil™ products products do do not not contain contain any any toxic toxic classifi classified ed substances substances and and off offer er the the leading leading performance performance OEMs OEMs are are used used to. to. The The latest latest innovative innovative RelcaSil™ RelcaSil™ additions additions are are water-based, water-based, NMP-free, NMP-free, NEP-free NEP-free and and single single component. component. Utilizing Utilizing next next generation generation silicone silicone technology, technology, RelcaSil™ RelcaSil™ off offers ers exceptionally exceptionally versatile versatile

coating coating solutions solutions with with best-in-class best-in-class noise noise characteristics, characteristics, soft soft touch touch and and unrivaled unrivaled cost cost performance. performance. The The luxurious luxurious haptics haptics go go hand hand in in hand hand with with squeak squeak and and itch itch performance performance and and friction friction reduction. reduction. The The secret secret lies lies in in the the implementation implementation of of innovative innovative solutions. solutions. RelcaSil™ RelcaSil™ is is the the outcome outcome of of years years of of dedicated dedicated research research and and unremitting unremitting developments. developments. As As always, always, Stahl Stahl worked worked closely closely together together with with partners partners and and customers customers by by the the premise premise “think “think global, global, act act local”. local”. The The high high quality quality results results are are exactly exactly what what the the American, American, European European and and Asian Asian markets markets are are looking looking for. for. Thorough Thorough testing testing in in one one of of Stahl’s Stahl’s Centers Centers of of Excellence Excellence for for Automotive Automotive is is key. key. With With RelcaSil™ RelcaSil™ the the highest highest standards standards of of OEMs OEMs are are met: met: premium premium performance performance without without traditional traditional constraints. constraints. Email: Email: vivian.peters@stahl.com vivian.peters@stahl.com Tel: Tel: T T +31 +31 416 416 689 689 259 259

Control & Automation

Even more room for manoeuvre! Space is precious – especially when it comes to high packing densities in electrical engineering.

pace pace limitations limitations mean mean that that panel panel builders builders and and switchgear switchgear manufacturers manufacturers have have to to accommodate accommodate more more and and more more mechanical mechanical and and electrical electrical components components in in enclosures. enclosures. Now, Now, aa smart smart new new enclosure enclosure accessory accessory from from Rittal Rittal can can provide provide far far greater greater scope scope for for the the interior interior confi configuration guration of of compact compact enclosures. enclosures. The The planning planning and and confi configuration guration of of interior interior installations installations within within compact compact enclosures enclosures can can be be both both time-consuming time-consuming and and complicated. complicated. It It can can also also lead lead to to actions actions which which compromise compromise the the integrity integrity of of the the

enclosure enclosure and and add add to to the the cost cost of of installation. installation.

The limited available installation space inside the enclosure can also cause problems around the best use of the existing mounting surfaces. Additional Additional holes holes often often have have to to be be drilled drilled in in areas areas such such as as the the side side panels panels to to fasten fasten components components outside outside of of the the mounting mounting plate. plate. This This

not not only only lowers lowers the the enclosure’s enclosure’s protection protection category, category, it it is is also also adds adds signifi significantly cantly to to the the setting-up setting-up costs. costs. The The limited limited available available installation installation space space inside inside the the enclosure enclosure can can also also cause cause problems problems around around the the best best use use of of the the existing existing mounting mounting surfaces. surfaces. In In response, response, Rittal Rittal has has developed developed an an interior interior installation installation rail. rail. The The rail rail can can be be easily easily mounted mounted to to the the side, side, fl floor oor or or roof roof areas areas of of the the AE AE compact compact enclosure, enclosure, without without any any need need for for additional additional drilling drilling through through the the enclosure enclosure panels. panels. This This neat neat solution solution saves saves time time and and preserves preserves the the enclosure’s enclosure’s protection protection category. category. It It can can be be

Control & Automation

In response, Rittal has developed an interior installation rail. The rail can be easily mounted to the side, floor or roof areas of the AE compact enclosure, without any need for additional drilling through the enclosure panels.

as punched sections, enclosure lights, the afore-mentioned dooroperated switches, door stays, cable conduit holders and a range of other components. Use of the rail can easily double the available mounting surface inside an AE compact enclosure.

placed wherever it is needed in the enclosure and is easily ﬁxed (with a screw) and it will support static loads of up to 100 N. A door-operated switch can also be ﬁtted to the rail using an adapter (supplied). This means that rail mounting is easy even if the mounting plate has already been installed. The rail has two rows of system punchings to create an additional mounting surface for items such

And because it has also been designed to use the accessories for the tried-and-tested modular TS 8 enclosure system, there is

no longer any need to keep a duplicate stock of accessories. More details can be found in a video at: http://www.rittal.com/com_ en/ae/videos.php?lng=de Further information at www.rittal.co.uk and www.friedhelm-loh-group.com, or on twitter @rittal_ltd.

World’s first. The

principle – amazingly efficient.

■ ■

Up to 75% energy savings with hybrid technology

■ ■

Multi-voltage capability enables global use

■ ■

Intuitive touch display

The Blue e+ series of cooling units.

www.rittal.co.uk

Control & Automation

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ϬϬϴϬϬ Ϯϰ ϮϬϭϭ Ϯϰ ϬϬϴϬϬ Ϯϰ ϮϬϭϭ Ϯϰ ;ĨƌĞĞͿ Žƌ ;ĨƌĞĞͿ Žƌ нϰϰ ϭϳϴ ϰϴϵ ϱϬϬϲ нϰϰ ϭϳϴ ϰϴϵ ϱϬϬϲ ŝŶĨŽΛĂƵƚŽŵĂƟŽŶϮϰ͘ĐŽ͘ƵŬ ŝŶĨŽΛĂƵƚŽŵĂƟŽŶϮϰ͘ĐŽ͘ƵŬ ǁǁǁ͘ĂƵƚŽŵĂƟŽŶϮϰ͘ĐŽ͘ƵŬͬƐϳͲϭϮϬϬ ǁǁǁ͘ĂƵƚŽŵĂƟŽŶϮϰ͘ĐŽ͘ƵŬͬƐϳͲϭϮϬϬ ƵŬͬƐϳͲϭϮϬϬ ƵŬͬƐϳͲϭϮϬϬ

www.strobotics.com www.strobotics.com

Low Cost Robotics R12 R12 –– the the lowest lowest cost cost professional professional robot robot arm arm in in the the world! world! Designed Designed like like aa sports sports car car itit is is fast fast and and light light but but accurate accurate and and reliable. reliable. 500mm 500mm reach. reach. Available Available in in 5-axis 5-axis and and 6-axis 6-axis versions. versions. R17 R17 –– 750mm 750mm reach reach articulated articulated arm, arm, available available in in 55 and and 66 axis axis versions versions plus plus high high payload payload and and high high speed speed versions. versions. R19 R19 –– AA 4-axis 4-axis cylindrical cylindrical format format robot, robot, accurate accurate and and clean, clean, ideal ideal for for laboratory laboratory applications. applications. COLLABORATIVE COLLABORATIVE –– ST ST robots robots can can work work with with humans humans as as well well as as any any other other robot robot bearing bearing in in mind mind that that aa robot robot moving moving at at speed speed with with any any kind kind of of load load will will hurt hurt you you no no matter matter what what make make of of robot robot you you choose choose (so (so don’t don’t be be fooled fooled by by claims claims you you may may see). see). ST ST provides provides full full guidance guidance for for safety safety and and risk risk assessment. assessment. RELIABLE RELIABLE –– ST ST robots robots work work for for years years before before any any kind kind of of attention attention is is required. required. Meanwhile Meanwhile the the robots robots are are maintenance maintenance free. free. SOFTWARE SOFTWARE –– For For most most people people the the biggest biggest reason reason for for not not getting getting in in to to robotics robotics is is the the perceived perceived risk risk that that the the software software will will be be too too diffi difficult. cult. ST’s ST’s software, software, RoboForth, RoboForth, is is probably probably the the easiest easiest to to use use on on the the planet. planet. It’s It’s aa fact fact –– see see the the testimonials testimonials on on our our website. website. We We provide provide acclaimed acclaimed manuals manuals and and tutorials tutorials plus plus unlimited unlimited free free technical technical support. support. ST ST Robotics Robotics are are at at Orwell Orwell House, House, Cambridge, Cambridge, CB4 CB4 0PP 0PP Tel: Tel: +44 +44 1223 1223 420288, 420288, sales@strobotics.com sales@strobotics.com

32 PECM PECM Issue Issue 21 21

Control & Automation

Cygnet 2/3-inch sCMOS camera provides full HD up to 60Hz

Effective, economic corrosion protection: nsd tupH for aluminum drives

The The Cygnet Cygnet 2/3-inch 2/3-inch sCMOS sCMOS camera camera provides provides full full HD HD up up to to 60Hz. 60Hz. Scientifi Scientificc CMOS CMOS (sCMOS) (sCMOS) technology technology stands stands to to gain gain widespread widespread recognition recognition across across aa broad broad range range of of demanding demanding imaging imaging applications, applications, due due to to its its ability ability to to simultaneously simultaneously deliver deliver extremely extremely low low noise, noise, fast fast frame frame rates, rates, wide wide dynamic dynamic range, range, high high quantum quantum effi efficiency, ciency, high high resolution resolution and and aa large large fifield eld of of view. view.

NORD NORD DRIVESYSTEMS DRIVESYSTEMS manufacture manufacture permanently permanently corrosion-resistant corrosion-resistant drives drives by by means means of of the the nsd nsd tupH tupH sealed sealed surface surface conversion conversion system. system. Aluminum Aluminum drives drives are are thereby thereby given given aa smooth, smooth, ultra-hard ultra-hard surface surface that, that, in in contrast contrast to to paint, paint, is is unaﬀ unaﬀected ected by by blows blows or or scratches. scratches. The The drives drives are are tested tested and and proven proven in in applications applications with with aa maritime maritime atmosphere. atmosphere. Previous Previous to to that, that, they they have have proven proven their their resilience resilience against against blistering blistering per per ASTM ASTM D714, D714, corrosion corrosion per per ASTM ASTM D610-08, D610-08, and and scribe scribe per per ASTM ASTM D1654-08 D1654-08 according according to to DIN DIN EN EN ISO ISO 2409. 2409. Additionally, Additionally, ASTM ASTM D3170 D3170 Gravelometer Gravelometer test test showed showed absolutely absolutely no no loss loss of of adhesion adhesion or or chipping. chipping. The The ASTM ASTM B117-09 B117-09 salt salt spray spray test test according according to to DIN DIN EN EN ISO ISO 9227 9227 produced produced no no corrosion corrosion even even after after 2,000 2,000 hours. hours.

The The 2.1MP 2.1MP 2/3 2/3 inch inch Scientifi Scientificc CMOS CMOS sensor sensor with with 5.5µm 5.5µm xx 5.5µm 5.5µm pixels pixels enables enables ultra ultra sharp sharp image image resolution resolution and and with with aa Quantum Quantum Effi Efficiency ciency of of over over 63% 63% @ @ 500nm 500nm and and greater greater than than 34% 34% @ @ 850nm, 850nm, the the Cygnet Cygnet off offers ers optimum optimum photon photon collection collection and and is is available available in in both both monochrome monochrome and and colour colour versions. versions.

Tel: Tel: 01992 01992 637211 637211

www.premierelect.co.uk www.premierelect.co.uk

In In demanding demanding atmospheres, atmospheres, nsd nsd tupH tupH drives drives can can be be used used much much beyond beyond the the usual usual service service life life of of paint-coated paint-coated systems. systems. Their Their resilience resilience and and prolonged prolonged service service life life signiﬁ signiﬁcantly cantly reduces reduces the the service service and and maintenance maintenance requirements requirements placed placed on on customers. customers.

Email: Email: info@nord.com info@nord.com

www.nord.com www.nord.com

Your dedicated specialist for factory automation. For For the the last last 60 60 years years the the world’s world’s No. No. 11 in in factory factory automation automation has has been been at at the the forefront forefront of of innovation, innovation, continually continually pushing pushing back back the the boundaries boundaries of of automation automation to to increase increase productivity productivity and and drive drive down down costs costs across across aa whole whole range range of of industries. industries. Boasting Boasting 99.9% 99.9% reliability, reliability, aa customer-centric customer-centric approach, approach, world-class world-class service service and and infi infinite nite solutions solutions for for industrial industrial robots, robots, CNC CNC systems systems and and purpose-built purpose-built machines machines for for wire wire cut cut EDM, EDM, electric electric injection injection moulding moulding and and milling milling and and drilling, drilling, we’re we’re there there to to help help you you make make the the most most of of your your automation. automation. All All you you need need is is yellow. yellow.

www.fanuc.eu

34 PECM PECM Issue Issue 21 21

Oilgear Manufacturing Investment Leads to Expansion of Variable Displacement Pump Range

new range of variable displacement pumps has been launched to the EMEA market as a result of a multi-

million pound investment made by Oilgear to its manufacturing facilities. The new

The range of performance capabilities within the range is vast, truly offering a solution for almost any application from mobile plant equipment through to steel forging presses.

range of axial piston pumps complement

Available as part of our bespoke engineered packages or as individual components from any of our licensed distributors, we're able to use the new range to respond quickly to our customer's needs with short delivery times and top class reliability."

Oilgear's existing product range and

The accuracy and reliability of the pumps

add greater flexibility and efficiency for

allow them to integrate seamlessly with

The Leeds-based manufacturing and

the company's market leading, bespoke

larger hydraulic systems and improve the

assembly plant is one of Oilgear's

electro-hydraulic packages; suitable for

overall efficiency of the package. Their

leading European facilities. It is a centre

industries as diverse as construction,

compact design makes them easy to

of engineering excellence for design

marine and defence.

retrofit to existing packages to deliver the

and aftermarket services of complete

same benefits to applications where the

electro-hydraulic packages, with an on-

Oilgear's variable displacement, axial-

hydraulic system is midway through its

time delivery rate of 97%. As part of its

piston pumps are well known for offering

service life.

commitment to customer satisfaction it

reliable, long lasting performance in some

is working with distributors around the

of the harshest operating conditions

Kieran Doyle, Managing Director for

EMEA region to ensure the new range is

on the planet. Having invested in a

Oilgear UK, comments: "The Oilgear range

available to all end-users.

fully automated production plant at

of hydraulic piston pumps uses advanced

its manufacturing facilities in Fremont,

manufacturing techniques to reduce wear

To learn more about the new variable

Nebraska, it is now able to offer a larger

internally and extend the overall service

displacement pumps from Oilgear and

range of products than ever before; with

life â&#x20AC;&#x201C; making them some of the most

how they can be used to maximise the

exceptionally low lead times on all orders

durable pumps on the market.

performance of your hydraulic package,

globally, even on non-standard orders.

contact the UK sales team or visit www.oilgear.com. Issue 21 PECM

Drives, Gears & Motors

KTR started up a new test bench

LEARN FROM THE BEARING EXPERTS SCHAEFFLER TRAINING COURSES

KTR started started up up aa new new test test bench bench for for large large couplings couplings

covering covering aa performance performance range range up up to to 500,000 500,000 Nm Nm at at the the headquarters in in Rheine. Rheine. The The test test bench bench allows allows to to calculate calculate headquarters mechanical mechanical coupling coupling parameters parameters and and perform perform service service life life testing. Testing Testing sample sample of of the the initial initial testing testing series series is is aa testing. torque torque limiter limiter intended intended to to be be used used on on an an 8 8 MW MW oﬀ oﬀshore shore wind wind energy energy plant. plant.

Schaeffler Schaeffler UK UK has has developed developed flexible flexible training training programs programs that that support support the the needs needs of of engineers engineers from from initial initial bearing bearing selection selection and and reliable reliable in-service in-service operation operation through through to to correct correct maintenance maintenance and and condition condition monitoring. monitoring. Our Our courses courses are are delivered delivered by by qualified qualified engineers engineers with with aa wealth wealth of of expertise expertise in in rolling rolling bearing bearing technology, technology, vibration vibration analysis analysis and and condition condition monitoring monitoring techniques. techniques. Training Training takes takes aa modular modular form, form, and and courses courses can can be be tailored tailored to to meet meet specific specific requirements. requirements. Our Our Facilities Facilities At At our our Sutton Sutton Coldfield Coldfield site site we we have have aa full full range range of of facilities facilities to to provide provide classroom classroom based based learning learning and and hands-on hands-on experience. experience. We We also also offer offer courses courses at at your your own own premises. premises.

Courses Courses include: include: Introduction Introduction to to Rolling Rolling Bearings Bearings Rolling Rolling Bearing Bearing Technology Technology Rolling Rolling Bearing Bearing Lubrication Lubrication Bearing Bearing Failure Failure Analysis Analysis Mounting Mounting of of Bearings Bearings Bearings Bearings for for Electric Electric Motors Motors Condition Condition Monitoring Monitoring Vibration Vibration Analysis Analysis

Tel: Tel: 0121 0121 313 313 5870 5870 || Email: Email: info.uk@schaeffler.com info.uk@schaeffler.com

www.schaeffler.co.uk

The The new new test test bench bench is is provided provided with with an an electrical electrical variablevariablespeed speed drive drive generating generating aa maximum maximum testing testing torque torque of of 500,000 500,000 Nm Nm via via several several gears. gears. The The torque torque is is measured measured on on the the gear gear output output side side through through aa calibrated calibrated measuring measuring shaft shaft via via DMS DMS technology technology while while the the twisting twisting angle angle is is calculated calculated on on the the drive drive side side through through aa pulse pulse encoder encoder or or aa position position sensor sensor which which is is installed installed directly directly on on the the testing testing sample. sample. The The data data acquired acquired allow allow to to calculate calculate the the torsion torsion spring spring stiff stiffness. ness. Apart Apart from from recording recording mechanical mechanical coupling coupling fi figures, gures, testing testing of of component component strength strength and and service service life life is is performed performed on on the the new new test test bench. bench. In In addition addition positive-locking positive-locking and and frictionally frictionally engaged engaged overload overload systems systems will will be be tested tested and and set set here. here. With With the the new new test test bench bench KTR’s KTR’s testing testing capacities capacities in in Rheine Rheine have have been been increased increased fi five ve times. times. „The „The availability availability of of such such kind kind of of test test bench bench is is particularly particularly important important in in an an age age during during which which the the performance performance level level of of drive drive components components for for machinery machinery and and plant plant engineering engineering is is continuously continuously increasing“, increasing“, Dipl.-Ing. Dipl.-Ing. Reinhard Reinhard Wibbeling, Wibbeling, Head Head of of Designing/Research Designing/Research & & Development Development in in KTR KTR explains. explains. „This „This allows allows KTR KTR to to further further expand expand its its position position as as the the world’s world’s leading leading manufacturer manufacturer of of mechanical mechanical couplings couplings and and overload overload systems.“ systems.“ KTR’s KTR’s test test bench bench for for mechanical mechanical couplings couplings and and overload overload systems systems at at the the headquarters headquarters in in Rheine Rheine currently currently comprises comprises 24 24 rotating rotating and and non-rotating non-rotating test test benches benches operated operated hydraulically, hydraulically, servo-hydraulically servo-hydraulically or or electrically. electrically. The The test test benches benches cover cover aa test test range range from from 0.2 0.2 Nm Nm to to 500,000 500,000 Nm Nm and and allow allow for for practical practical testing testing conditions conditions with with dynamic dynamic or or static static load load of of the the testing testing sample. sample. The The testing testing capacity capacity includes includes determination determination of of coupling coupling parameters, parameters, adjustment adjustment of of overload overload systems systems and and endurance endurance testing testing regarding regarding component component strength strength and and service service life. life. www.ktr.com/uk www.ktr.com/uk

36 PECM PECM Issue Issue 21 21

Drives, Gears & Motors

ROTEX® SH with T-PUR®

Reduce Your Downtime

ROTEX ROT RO OTEX O OT TEX EX® GS GS & 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

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

Issue 21 PECM

The Importance of Sensor Triggering in Production and Process Automation

hen hen measuring measuring the the position position

downstream monitoring monitoring and and control control downstream

This This type type of of sensor sensor set set up up provides provides savings savings

of of moving moving targets targets in in

units, aa permanent permanent measurement measurement output output units,

in in terms terms of of the the memory memory of of the the evaluation evaluation

production production and and process process

is is often often not not the the best best approach. approach. Instead, Instead,

system. system.

automation automation environments, environments,

the the sensor sensor should should wait wait for for aa signal signal from from an an

itit is is important important to to understand understand the the different different

external external source source that that specifies specifies the the time time for for aa

ItIt is is important important to to understand understand the the different different

methods methods of of sensor sensor triggering, triggering, their their impact impact

measurement to to take take place, place, thus thus initiating initiating measurement

triggering triggering methods methods available available and and their their

on on measurement measurement cycle cycle times times and and the the

the the output output of of data. data. Triggering Triggering is is therefore therefore

relationship relationship to to sensor sensor measurement measurement rate rate

benefits benefits they they can can offer offer over over continuous continuous

often initiated initiated by by an an external external signal. signal. often

and and cycle cycle time, time, particularly particularly in in fast-moving fast-moving

measurement, measurement, says says Chris Chris Jones, Jones, Managing Managing Director Director at at Micro-Epsilon Micro-Epsilon UK. UK. Triggering Triggering is is aa term term often often used used in in sensing sensing and and measurement measurement technology technology and and includes includes all all the the different different methods methods of of initiating initiating aa measurement measurement or or aa controlled controlled output output of of measurement measurement data. data. Particularly Particularly in in production production and and process process automation automation environments, environments, in in order order to to reduce reduce the the system system load load on on any any

PECM PECM Issue Issue 21 21

For example, consider a target object in a high speed production line, which passes a sensor every five seconds for a period of one second. If the sensor has a trigger function, the output of the sensor only needs to be switched on (initiated) every 5s for a duration of 1s. The measurements between the target objects are of no interest and so do not need to be evaluated.

processes. processes. Non-contact Non-contact laser laser sensors sensors are are often often installed installed in in production production and and process process automation automation environments environments to to measure measure displacement, displacement, distance distance or or position. position. These These sensors sensors can can be be triggered triggered both both via via the the‘edge’ ‘edge’or or the the‘level’ ‘level’of of the the trigger trigger signal. signal. The The following following are are implemented implemented as as trigger trigger conditions: conditions: rising rising edge edge (positive (positive edge), edge), falling falling edge edge (negative (negative edge), edge), High High level level (H (H level) level) and and Low Low level level (L (L level). level).

Edge triggering After the triggering edge, provided by

Time offset of trigger and output signal

an initiator switch or PLC, the analogue

The sensor subdivides the processing and

output is updated, or if a digital output has

output of the measurements into cycles.

been selected, only a digital measurement

Assuming a maximum measuring rate of

is output via an RS422 interface (see Fig 1).

2.5kHz, 400Âľs is taken up with cycles for exposure, reading in, computation and controlling.

In this example, only measurements for a particular range of positions are to be examined more closely. The trigger signal (green) initiates the measurement in the sensor. The time offset of the trigger signal and output signal of the sensor (blue) can be seen clearly on the oscilloscope. The sensor needs this time for the internal processing and output of the

A total period of approx. 1.6ms passes

measurement results. Encoders are also

before the first measurement is available

suitable as trigger signal sources.

at the output. As the processing occurs

Level Triggering Level triggering, sometimes referred to as gating, causes the sensor to output measurements until the trigger condition is satisfied (see Fig 2).

sequentially in time and parallel in space,

Rotary transducers can be found in all

the next measurement is available at

numerically controlled industrial systems.

the output after a further 400Âľs. The

The rotational speed or the closeness of

sensor time pattern therefore requires

the pulses from the encoder is a direct

a chronological interval between two

measure of a linear change, e.g. of a

consecutive trigger signals of at least four

conveyor belt. If an encoder, for example,

cycles with edge triggering, or five cycles

supplies 1,000 pulses per revolution and

for level triggering. Thus a measurement

if the internal processing time of 1.6ms in

is not output that was valid four cycles

the sensor is taken into account, then the

ago, but instead the measurement object

encoder may revolve at a maximum of

position is acquired exactly at the time of

0.625 revolutions per second (or 37.5rpm),

the trigger.

so that the maximum trigger frequency for the measuring rate of 2.5kHz is not

Trigger pulse values

As a result, a maximum trigger frequency

The trigger pulse duration ti must be at

kHz. There remains a time uncertainty of a

Summary

least one cycle period (= 1/measuring

maximum of one cycle because the sensor

rate). With a slower measuring rate, the

continues operating in its cycle sequence

Edge triggering supplies single

trigger pulse duration must therefore

and the trigger edge can be located within

also be extended (e.g. from ti = 400Âľs at a

the first cycle, i.e. from the start to the

measuring rate of 2.5 kHz, to ti = 3.2ms at a

end of the first cycle. The trigger input is

measuring rate of 312.5 Hz).

interrogated within this period. The leads

The necessary level adaptation to the

to a minimum length of the trigger pulse

LVDS specification (see Fig 3) of the sensor

of at least one cycle.

occurs via a controller that permits trigger levels from 2.4V to 24V.

of 625Hz occurs for a measuring rate of 2.5

Application

exceeded.

measurements on the output of a sensor and so replaces sampling operation. Also, the typical memory overflow associated with continuous measurement is also prevented, which ensures an exact alignment between the measurement and the time. If the sensor is combined with a controller, taking into account the maximum trigger frequencies, an

A typical measurement application with

economically practical measurement unit

triggering is the bridging of gaps with

is produced for production and process

single parts on a conveyor belt (see Fig 5).

automation applications. For more information, please call the Micro-Epsilon sales department on 0151 355 6070 or email: info@micro-epsilon.co.uk www.micro-epsilon.com

Issue 21 PECM

Electrical & Electronics Connectors for harsh environmental conditions Foremost Foremost Electronics Electronics is is now now stocking stocking the the new new 696 696 Series Series HEC HEC (Harsh (Harsh Environment Environment Connector) Connector) which which has has been been speciďŹ speciďŹ cally cally developed developed for for outdoor outdoor applications. applications. HighHighgrade gradematerials materialsas aswell wellas asinnovative innovativeconstruction constructiondetails detailsensure ensurereliable reliableperformance performance of of this this new new connector connector in in harsh harsh and and demanding demanding environmental environmental conditions. conditions. The The 696 696 HEC HEC connector connector design design has has UL UL and and VDE VDE approval approval and and excellent excellent resistance resistance to to UV, UV, temperature temperature ďŹ&#x201A;ďŹ&#x201A;uctuations, uctuations, acid acid rain, rain, salt salt spray, spray, ozone ozone and and other other pollutants. pollutants. Primary Primary applications applications include include but but are are not not limited limited to, to, agricultural agricultural and and construction construction equipment, equipment, traďŹ&#x192; traďŹ&#x192;cc and and signalling signalling equipment, equipment, process process engineering, engineering, water water puriďŹ puriďŹ cation cation and and recycling recycling equipment. equipment. A A three-point three-point bayonet bayonet locking locking design design makes makes for for aa safe safe and and secure secure fast-locking fast-locking action, action, while while aa robust robust coding coding mechanism mechanism prevents prevents incorrect incorrect orientation orientation and and is is suitable suitable for for over over 1000 1000 mating mating cycles. cycles.

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40 PECM PECM Issue Issue 21 21

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www.fischerconnectors.com 42 PECM PECM Issue Issue 21 21

(Left (Left to to right) right) The The Fischer Fischer Rugged Rugged Flash Flash Drive Drive USB USB 2.0 2.0 on on UltiMate UltiMate size size 08 08 and and new new versions versions UltiMate UltiMate size size 07 07 and and MiniMax MiniMax size size 08 08 with with USB USB 3.0. 3.0.

Fischer Rugged Flash Drive now five times faster with USB 3.0 ischer ischer Connectors, Connectors, the the worldwide worldwide innovator innovator in in push-pull push-pull circular circular connectors connectors and and cable cable assembly assembly solutions, solutions, has has launched launched the the USB USB 3.0 3.0 version version of of its its ultra-portable, ultra-portable, miniature, miniature, lightweight lightweight and and extremely extremely tough tough Fischer Fischer Rugged Rugged Flash Flash Drive. Drive. This This memory memory stick stick has has been been specially specially designed designed for for the the safe safe transportation transportation and and storage storage of of sensitive sensitive data data in in harsh harsh environments. environments.

The The USB USB 3.0 3.0 Fischer Fischer Rugged Rugged Flash Flash Drive Drive is is even even faster, faster, smaller smaller and and more more user-friendly user-friendly than than the the USB USB 2.0 2.0 product product introduced introduced to to the the market market in in 2011. 2011. The The read read speed speed is is now now up up to to fifive ve times times faster; faster; standard standard memory memory sizes sizes are are 32, 32, 64 64 or or 128 128 GB; GB; the the body body is is shorter; shorter; and, and, in in order order to to guarantee guarantee secure secure access, access, it it is is now now TM available available not not only only with with the the Fischer Fischer UltiMate UltiMateTM Series Series interface, interface, TM but but also also with with the the Fischer Fischer MiniMax MiniMaxTM Series Series interface. interface. The The activity activity LED LED is is aa further further feature feature of of the the new new product product to to improve improve usability. usability. Miniature Miniature – – the the size size of of aa key key ring ring – – and and lightweight, lightweight, the the Fischer Fischer Rugged Rugged Flash Flash Drive Drive has has proven proven to to be be the the durable durable solution solution for for people people on on the the go go who who need need to to download download and and securely securely transfer transfer confi confidential dential data, data, images images or or videos videos from from devices devices used used in in extreme extreme environmental environmental conditions conditions or or in in hard-to-reach hard-to-reach areas. areas. It It is is perfectly perfectly adapted adapted for for applications applications where where data data security security and and confi confidentiality dentiality are are critical, critical, such such as as the the defense defense and and security, security, fifinancial, nancial, medical, medical, industrial, industrial, energy, energy, underwater, underwater, motor motor and and extreme extreme sport sport sectors, sectors, e.g. e.g. for for civil civil or or military military UAVs, UAVs, ROVs, ROVs, test test & & measure measure equipment equipment or or rugged rugged computers. computers. Safe Safe and and Secure Secure The The Fischer Fischer Rugged Rugged Flash Flash Drive Drive is is both both safe safe and and secure. secure. Its Its rugged rugged casing casing provides provides full full protection protection against against extreme extreme environmental environmental conditions. conditions. The The flflash ash drive drive is is waterproof waterproof down down to to 120 120 meters meters and and is is resistant resistant to to extreme extreme operating operating temperatures temperatures (-40°C (-40°C to to +85°C). +85°C). Thanks Thanks to to the the unique unique proprietary proprietary Fischer Fischer Connectors’ Connectors’ circular circular connector connector interface interface combined combined with with aa durable durable encapsulation encapsulation technique, technique, it it guarantees guarantees data data security security in in case case of of loss loss or or theft. theft. Performance Performance and and Flexibility Flexibility “At “At times times when when privacy privacy and and confi confidentiality dentiality are are of of paramount paramount importance, importance, you you need need the the right right product product to to protect protect your your critical critical information information against against the the elements elements and and the the potential potential risk risk of of loss loss or or theft,” theft,” explains explains Wim Wim Vanheertum, Vanheertum, Product Product Manager Manager at at Fischer Fischer Connectors. Connectors. “Technology “Technology moves moves fast, fast, and and both both performance performance and and flflexibility exibility are are required required when when designing designing highhighspeed speed applications applications using using video. video. The The new new Rugged Rugged Flash Flash Drive Drive increases increases data data transfer transfer speed speed by by fifive, ve, and and its its flflexible exible modular modular design, design, which which includes includes aa large large selection selection of of body body styles, styles, sizes, sizes, contact contact confi configurations gurations and and memory memory capacities, capacities, off offers ers high high customization.” customization.” sales@fi sales@fischerconnectors.co.uk scherconnectors.co.uk www.fi www.fischerconnectors.com scherconnectors.com

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New ETA Enclosures 2016 Product Overview Brochure Hot Hot oďŹ&#x20AC; oďŹ&#x20AC; the the press press for for 2016 2016 is is a a new new 44 44 page page product product overview overview brochure brochure from from ETA ETA Enclosures Enclosures UK UK Limited. Limited. This This new, new, easy easy to to navigate navigate publication publication shows shows ETAâ&#x20AC;&#x2122;s ETAâ&#x20AC;&#x2122;s range range of of ex-stock ex-stock enclosure enclosure products products and and thermal thermal management management solutions solutions and and it it is is the the ideal ideal user user friendly friendly tool tool from from which which to to select select in in stock stock products products for for quick quick no no delay delay delivery. delivery.

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44 PECM PECM Issue Issue 21 21

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Slewing Rings and Spherical Roller Bearings from Schaeffler Ensure Reliability of Gaia-Wind Turbines A A manufacturer manufacturer of of high high performance performance small small wind wind turbines turbines based based in in Scotland Scotland has has specified specified slewing slewing rings rings and and spherical spherical roller roller bearings bearings from from Schaeffler Schaeffler UK UK for for use use on on its its 133 133 wind wind turbine turbine –– the the quietest quietest wind wind turbine turbine in in its its class. class. Based Based in in Port Port Dundas, Dundas, Glasgow Glasgow in in Scotland, Scotland, Gaia-Wind Gaia-Wind is is aa leading leading manufacturer manufacturer of of high high performance, performance, small small wind wind turbines turbines designed designed for for moderate moderate wind wind speed speed sites. sites. The The turbines turbines are are ideally ideally suited suited to to farms, farms, rural rural properties, properties, businesses businesses and and community community projects. projects. Designed Designed in in Denmark Denmark and and manufactured manufactured in in Scotland, Scotland, the the Gaia-Wind Gaia-Wind 133 133 turbine turbine has has

Slewing rings In In order order to to optimise optimise operating operating efficiency, efficiency, wind wind turbines turbines need need to to be be aligned aligned to to wind wind conditions. conditions. In In order order to to achieve achieve this, this, the the slewing slewing rings rings (yaw (yaw bearings) bearings) adjust adjust and and optimise optimise the the position position of of the the nacelle nacelle to to the the direction direction of of the the wind. wind. The The wind wind loads loads and and the the dynamic dynamic inertia inertia forces forces are are transferred transferred via via the the bearing bearing raceways raceways and and screw screw connections connections into into the the head head of of the the tower. tower. Schaeffler Schaeffler develops develops and and manufactures manufactures slewing slewing rings rings with with outside outside diameters diameters up up to to 1,250mm. 1,250mm. Due Due to to their their design, design, these these slewing slewing rings rings can can transmit transmit radial radial and and axial axial forces, forces, as as well well as as tilting tilting moments. moments.

raceway, raceway, solid solid inner inner rings rings and and barrel barrel rollers rollers with with cages. cages. The The inner inner rings rings have have cylindrical cylindrical bores bores and and are are supplied supplied to to be be fitted fitted into into aa housed housed unit unit to to suit suit the the 133 133 turbine. turbine. The The bearings bearings are are manufactured manufactured to to Schaeffler’s Schaeffler’s premium premium X-life X-life quality quality standard. standard. The The E1 E1 range range includes includes eight eight bearing bearing series series with with bore bore diameters diameters from from 20mm 20mm up up to to 1,220mm. 1,220mm. Mike Mike Addington, Addington, regional regional sales sales engineer engineer (Scotland) (Scotland) at at Schaeffler Schaeffler UK UK commented: commented: “The “The INA INA slewing slewing rings rings and and FAG FAG E1 E1 spherical spherical roller roller bearings bearings are are high high performance performance bearings bearings that that provide provide the the high high quality quality and and reliability reliability that that Gaia-Wind Gaia-Wind requires requires on on its its 133 133 turbine. turbine.

an an oversized oversized rotor, rotor, allowing allowing itit to to capture capture significantly significantly more more energy energy than than similarly similarly

As As well well as as supplying supplying bearings, bearings, Schaeffler Schaeffler

rated rated machines. machines. With With more more than than 1400 1400

UK UK also also provides provides valuable valuable technical technical

installed installed worldwide, worldwide, these these turbines turbines are are the the

support, support, advice advice and and guidance guidance to to GaiaGaia-

quietest quietest wind wind turbines turbines in in their their class class and and

Wind, Wind, for for example, example, how how to to simplify simplify and and

have have aa long long track track record record of of reliability. reliability.

speeding speeding up up the the assembly assembly procedures procedures

Owen Owen Paterson, Paterson, Operations Operations Manager Manager at at Gaia-Wind Gaia-Wind commented: commented:“We “We work work with with Schaeffler Schaeffler as as they they are are recognisably recognisably one one of of the the world world leaders leaders in in bearing bearing technology. technology. Their Their massive massive range range of of applications applications helps helps them them to to understand understand our our particular particular

The The slewing slewing rings rings supplied supplied for for the the 133 133 turbine turbine are are four-point four-point contact contact bearings, bearings, enabling enabling precise precise angular angular adjustment adjustment at at varying varying loads. loads.

E1 spherical roller bearings

at at Gaia-Wind Gaia-Wind by by considering considering alternative alternative designs. designs. Currently, Currently, Gaia-Wind Gaia-Wind is is working working towards towards aa 20% 20% improvement improvement in in the the efficiency efficiency of of its its 133 133 turbine turbine by by the the year year 2020, 2020, and and we we are are therefore therefore looking looking at at how how Schaeffler’s Schaeffler’s bearing bearing technology technology can can support support this this requirement. requirement.””

requirements requirements and and to to come come up up with with

In In aa wind wind turbine, turbine, the the design design of of the the rotor rotor

solutions solutions unique unique to to our our needs. needs. For For many many

shaft shaft bearing bearing is is critical, critical, as as this this bearing bearing is is

For For more more information, information, please please contact contact

years, years, Schaeffler Schaeffler has has been been our our first first choice choice

directly directly exposed exposed to to the the loads loads and and forces forces

Schaeffler Schaeffler UK’s UK’s Communications Communications &&

due due to to their their ongoing ongoing commitment commitment to to keep keep

induced induced by by the the wind. wind. Alternating Alternating loads loads

Marketing Marketing Department Department on on

us us up-to-date up-to-date with with the the latest latest in in technology technology

with with extreme extreme peaks peaks and and troughs, troughs, as as well well

info.uk@schaeffler.com info.uk@schaeffler.com

and and their their flexibility flexibility in in delivering delivering against against aa

as as fluctuating fluctuating operating operating temperatures temperatures

www.schaeffler.co.uk www.schaeffler.co.uk

very very demanding demanding and and changeable changeable supply supply

represent represent further further challenges challenges to to the the

requirement. requirement.””

bearing bearing designer. designer. Ideal Ideal for for heavy heavy duty, duty, harsh harsh operating operating environments environments and and where where

Schaeffler Schaeffler UK UK has has been been working working with with

there there is is aa need need to to compensate compensate for for shaft shaft

Gaia-Wind Gaia-Wind for for over over five five years, years, supplying supplying

misalignment, misalignment, E1 E1 spherical spherical roller roller bearings bearings

precision precision engineered engineered slewing slewing rings rings and and

from from Schaeffler Schaeffler support support the the main main shaft shaft

E1 E1 spherical spherical roller roller bearings bearings for for the the 133 133

of of the the 133 133 turbines. turbines. These These bearings bearings are are

turbine. turbine.

double-row, double-row, self-contained self-contained units units that that comprise comprise solid solid outer outer rings rings with with aa concave concave

PECM PECM Issue Issue 21 21

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SteamBio enabling sustainable carbon for industry SteamBio is a Horizon 2020 project funded by the European Union research and innovation programme under grant agreement No 636865

anrochem anrochem Limited Limited is is aa key key member member of of SteamBio SteamBio an an Horizon Horizon 2020 2020 [H2020] [H2020] collaborative collaborative research research project, project, providing providing technical technical management management to to aa consortium consortium of of eleven eleven specialist specialist commercial commercial and and research research organisations organisations throughout throughout Europe Europe located located in in the the UK, UK, Germany, Germany, Spain Spain and and Scandinavia. Scandinavia. The The project project is is funded funded by by the the European European Union Union under under the the Horizon Horizon 2020 2020 Research Research and and Development Development Programme. Programme. SteamBio SteamBio H2020 H2020 project project is is fi financed nanced within within the the “bio “bio economy” economy” theme theme of of the the current current funding funding round round with with the the aim aim being being to to increase increase the the value value of of bio bio derived derived source source materials materials that that are are currently currently not not being being eff effectively ectively utilised. utilised. The The ultimate ultimate aim aim is is to to replace replace mineral mineral derived derived coal, coal, oil oil and and gas gas with with renewable renewable source source ingredients; ingredients; the the challenge challenge being being to to replace replace on on aa “like “like for for like like basis” basis” i.e. i.e. provide provide material material into into the the supply supply chain chain that that the the existing existing supply supply chain chain organisations organisations will will recognise. recognise. Biochemical Biochemical production production currently currently amounts amounts to to approximately approximately $100 $100 billion billion per per annum, annum, which which is is an an extremely extremely big big number number but but is is actually actually quite quite small small in in comparison comparison to to the the existing existing total total chemical chemical market market size size of of about about $3 $3 trillion. trillion. Currently Currently bio bio based based supply supply to to market market is is mainly mainly “1st “1st generation”, generation”, which which means means that that biochemical biochemical source source material material competes competes with with available available food food supplies, supplies, either either directly directly by by using using say say corn corn starch starch or or sugar sugar or or indirectly indirectly through through land land use. use.

48 PECM PECM Issue Issue 21 21

This This is is not not sustainable sustainable long long term term and and has has led led to to research research and and investment investment into into what what is is known known as as 2nd 2nd and and 3rd 3rd generation generation sources, sources, which which is is where where the the SteamBio SteamBio project project is is positioned positioned to to provide provide platform platform technologies technologies within within the the bio-energy bio-energy and and biochemical biochemical fi fields elds of of endeavour. endeavour. The The bio-energy bio-energy market market is is currently currently the the better better developed developed arena arena within within the the bio-industry bio-industry fi field eld and and is is expanding. expanding. From From 2008 2008 EU EU wood wood pellet pellet use use for for energy energy generation generation has has increased increased from from 2.5 2.5 million million tons tons of of oil oil equivalent equivalent [MTOE] [MTOE] and and is is projected projected to to reach reach 20 20 to to 32 32 MTOE MTOE or or as as source source biomass biomass approximately approximately 50 50 to to 80 80 million million metric metric tons tons by by 2020 2020 [source [source European European Biomass Biomass Association]. Association]. As As the the demand demand for for bio-energy bio-energy has has grown grown the the fragility fragility of of the the current current supply supply model model has has become become apparent apparent which which has has aa deleterious deleterious impact impact on on 2nd 2nd generation generation bio-chemicals bio-chemicals production. production. •• Existing Existing forestry forestry resources resources in in Europe Europe are are insuffi insufficient cient to to meet meet market market demand, demand, resulting resulting in in signifi significant cant imports imports from from North North America America and and other other regions regions with with competition competition for for supplies supplies emerging emerging from from East East Asia Asia and and elsewhere. elsewhere. Concerns Concerns have have been been expressed expressed on on imported imported supplies supplies with with regards regards ecological ecological stress, stress, environmental environmental impact impact of of shipping shipping around around the the globe globe and and competition competition from from other other use. use. •• There There is is abundant abundant biomass biomass resource resource across across Europe Europe that that is is not not currently currently

being being used used to to supply supply the the market. market. For For instance, instance, it it has has been been estimated estimated that that there there are are potentially potentially 100 100 MTOE MTOE of of agricultural agricultural residues residues alone. alone. However, However, these these residues residues are are not not in in aa form form that that can can be be readily readily accessed accessed by by aa large large scale scale bio-economy. bio-economy. So So what what does does SteamBio SteamBio hope hope to to achieve? achieve? The The project project has has two two themes: themes: •• Bio-energy Bio-energy – – converting converting agricultural agricultural residues residues into into valuable valuable fuel fuel with with suffi sufficiently ciently high high energy energy value value to to make make it it worthwhile worthwhile transporting transporting the the material material from from its its source source location location to to its its demand demand location. location. It It is is this this problem problem that that has has prevented prevented anything anything other other than than “local “local solutions” solutions” being being applied applied to to the the source source material material with with the the limit limit to to exploitation exploitation being being local local demand demand is is insuffi insufficient cient for for the the total total available available local local material. material. •• Biochemical Biochemical – – all all biomass biomass is is made made up up of of carbon, carbon, hydrogen hydrogen and and oxygen oxygen bound bound together together in in structures structures that that make make the the material material aa solid solid rather rather than than aa liquid. liquid. If If the the fundamental fundamental molecules molecules of of the the biomass biomass can can be be re-arranged re-arranged then then the the source source material material can can be be converted converted into into aa gas gas or or aa liquid. liquid. It It is is these these future future gasses gasses and and liquids liquids that that the the existing existing supply supply chain chain recognises recognises and and wants. wants. SteamBio SteamBio partners partners from from industry industry and and academia academia have have aa common common purpose; purpose; to to create create aa viable viable business business based based on on benefi beneficiation ciation of of forestry forestry and and agricultural agricultural residues residues and and will will demonstrate demonstrate economic economic viability viability in in diff different erent rural rural locations locations for for the the recovery recovery of of usable usable bio-carbon bio-carbon from from indigenous indigenous forestry forestry and and farming farming residues residues in in tonnage tonnage quantities. quantities. In In SteamBio SteamBio this this bio-carbon bio-carbon will will be be demonstrated demonstrated as as aa coal coal replacement replacement for for an an industrial industrial lime lime kiln kiln and and as as aa carbon carbon source source in in pilot pilot scale scale biobiorefi refineries. neries.

MAJOR MAJOR EUROPEAN EUROPEAN oil oil and and gas gas pipe pipe networks networks

Recovered Recovered liquid liquid streams streams from from the the process process have have already already been been shown shown to to contain contain commercially commercially relevant relevant quantities quantities of of bio-chemicals bio-chemicals even even before before the the treated treated solid solid mass mass has has been been further further processed processed for for the the inherent inherent material material it it contains. contains.

you you have have aa source source material material you you think think might might be be suitable suitable for for exploitation exploitation then then please please contact contact Edward Edward Jennings Jennings of of Manrochem. Manrochem.

that that bio-carbon bio-carbon is is sustainable sustainable with with functionalities, functionalities, availability availability and and costs costs comparable comparable to to the the fossil fossil carbon carbon it it displaces. displaces.

Background Background note note on on enabling enabling sustainable sustainable carbon carbon for for industry industry

Within Within the the fi first rst phase phase of of the the project project SteamBio SteamBio has has carried carried out out aa range range of of selection selection studies studies and and has has shortlisted shortlisted six six diff different erent reference-materials reference-materials that that are are abundant abundant and and available available from from European European forestry forestry and and farming farming operations. operations. These These six six materials materials will will be be characterised characterised within within the the demonstration demonstration phase phase to to determine determine yield yield and and fi financial nancial viability viability of of the the primary primary and and secondary secondary processes processes needed needed to to show show aa complete complete value value map map from from fi field eld to to factory factory to to consumer. consumer.

Bio-carbonisation Bio-carbonisation not not de-carbonisation: de-carbonisation: There There is is much much talk talk nowadays nowadays about about “decarbonising” “decarbonising” the the economy, economy, would would it it be be more more appropriate appropriate for for us us to to use use aa greener greener form form of of carbon carbon instead? instead? Carbon Carbon has has helped helped to to shape shape the the world world we we live live in in today, today, in in fuels fuels and and in in chemicals. chemicals. In In the the modern modern world world it it is is primarily primarily supplied supplied from from unsustainable unsustainable fossil fossil sources; sources; coal coal mines, mines, oil oil wells wells and and gas gas ﬁ ﬁelds, elds, creating creating environmental environmental impacts impacts in in both both extraction extraction and and use. use. With With the the majority majority of of fossil fossil carbon carbon now now imported imported into into Europe Europe there there are are assorted assorted concerns concerns relating relating to to security security of of supply. supply. To To create create aa more more secure secure and and sustainable sustainable future future we we need need to to use use carbon carbon from from nature: nature: “bio-carbon”; “bio-carbon”; using using it it to to create create biodegradable biodegradable bio-plastics, bio-plastics, other other biobiochemicals chemicals and and for for renewable renewable energy energy generation generation that that is is available available when when required. required. However, However, it it is is important important

Whilst Whilst bio-carbon bio-carbon is is an an abundant abundant natural natural resource, resource, it it is is not not always always available available in in the the appropriate appropriate condition condition or or location. location. The The infrastructure infrastructure associated associated with with fossil fossil carbon carbon has has been been developed developed over over aa number number of of years, years, based based around around centralised centralised refi refineries. neries. The The bio-refi bio-refineries neries of of the the future future cannot cannot ignore ignore existing existing infrastructure. infrastructure. For For bio-carbon bio-carbon to to become become established established it it must must be be able able to to be be stabilised, stabilised, stored, stored, transported transported and and used used with with cost cost and and functional functional equivalent equivalent to to fossil fossil carbon. carbon.

A A demonstration demonstration unit unit with with aa throughput throughput of of 500kg/hour 500kg/hour is is currently currently in in design design with with construction construction due due to to start start by by mid mid 2016. 2016. Manrochem Manrochem and and key key members members of of the the consortium consortium are are fi finalising nalising diff different erent rural rural locations locations for for deployment deployment of of the the test test unit unit which which will will be be deployed deployed by by January January 2017. 2017. If If you you want want to to see see this this unit unit in in operation operation during during 2017 2017 or or if if

www.manrochem.co.uk www.manrochem.co.uk Tel: Tel: +44(0)1484 +44(0)1484 715781 715781 Fax: Fax: +44(0)1484 +44(0)1484 719813 719813

Issue 21 PECM

Separating The Good From The Bad: Prioritise Your Storage Tank Maintenance Risk-based Risk-based inspection inspection systems systems and and advanced advanced non-destructive non-destructive testing testing methods methods are are

But But active active cracking cracking is is not not the the only only source source

helping helping storage storage tank tank owners owners comply comply with with ever-increasing ever-increasing stringent stringent regulations, regulations, as as well well as as

of of AE. AE. Chemical Chemical processes processes such such as as

reducing reducing maintenance maintenance costs, costs, says says Tim Tim Bradshaw, Bradshaw, General General Manager, Manager, MISTRAS MISTRAS GROUP, GROUP, UK UK

corrosion corrosion spalling, spalling, fracture fracture and and debonding debonding

Operations. Operations.

are are very very emissive. emissive. or or owners owners of of above above ground ground

ItIt also also considers considers the the consequences consequences of of such such

The The AE AE arising arising from from the the corrosion corrosion process process

process process storage storage tanks, tanks,

aa failure. failure. As As aa result, result, out-of-service out-of-service tanks tanks

on on the the floor floor of of aa storage storage tank, tank, for for example, example,

including including both both atmospheric atmospheric

that that exhibit exhibit potential potential problems problems can can be be

will will travel travel through through the the product product in in the the tank, tank,

and and pressurised pressurised storage storage

inspected, inspected, while while continuing continuing to to operate operate

through through the the tank tank wall wall and and into into the the sensors sensors

assets assets that that are are in in‘good’ ‘good’condition. condition.

attached attached to to the the outside. outside.

based based around around EEMUA EEMUA 157 157 and/or and/or API API 653. 653.

A A combination combination of of inspection inspection methods methods

A A ring ring of of sensors sensors can can be be used used to to pinpoint pinpoint

According According to to both both of of these these standards, standards, the the

can can be be used used to to monitor monitor and and grade grade

the the location location of of the the AE AE from from within within the the

purpose purpose of of an an inspection inspection is is to to determine determine

the the condition condition of of tanks. tanks. One One of of these these is is

tank tank and and so, so, in in the the space space of of an an hour hour or or so, so,

ifif tanks tanks are are safe safe for for continued continued service service

techniques techniques is is acoustic acoustic emission emission (AE). (AE). The The

provide provide aa very very detailed detailed picture picture of of where where

in in terms terms of of their their mechanical mechanical integrity. integrity.

application application of of mechanical mechanical or or thermal thermal stress stress

the the corrosion corrosion is, is, and and how how bad bad itit is. is.

Originally, Originally, inspection inspection plans plans were were strictly strictly

to to aa material material results results in in elastic elastic energy energy being being

regulatory regulatory compliant, compliant, utilising utilising traditional traditional

stored stored in in that that material. material.

systems systems such such as as bullets bullets and and spheres, spheres, tank tank inspection inspection programmes programmes are are normally normally

manual, manual, non-destructive non-destructive testing testing (NDT) (NDT)

Tank Tank floors floors remain remain largely largely unseen unseen and and are are traditionally traditionally uninspectable uninspectable during during

The The stress stress field field sustained sustained by by the the material material

operation. operation. Normally, Normally, this this involves involves

tends tends to to concentrate concentrate at at localised localised

costly costly shutdown shutdown and and decontamination decontamination

mechanical mechanical instabilities, instabilities, which which exist exist in in

followed followed by by detailed detailed local local inspection. inspection.

almost almost all all practical practical mechanical mechanical structures. structures.

Often, Often, this this is is executed executed from from an an inspection inspection

IfIf the the applied applied stress stress is is high high enough, enough,

schedule schedule according according to to aa predetermined predetermined

To To help help tank tank owners owners comply comply with with everever-

the the material material will will fail fail at at such such local local stress stress

period period of of time time in in service. service. To To know know when when

increasing increasing stringent stringent regulations, regulations, risk-based risk-based

concentrations concentrations and and crack, crack, until until the the

the the condition condition of of aa tank tank justifies justifies being being

inspection inspection (RBI) (RBI) systems systems and and advanced advanced

propagation propagation of of the the crack crack is is such such that that the the

taken taken offline offline and and cleaned cleaned out, out, in in order order

non-destructive non-destructive testing testing (ANDT) (ANDT) methods methods

material material has has become become stress stress free free and and the the

to to prioritise prioritise and and target target inspection inspection and and

can can be be used used to to assess assess the the condition condition and and

stored stored elastic elastic energy energy has has been been dissipated. dissipated.

maintenance maintenance activity activity accordingly, accordingly, is is of of

techniques techniques such such as as visual, visual, ultrasonic ultrasonic and and settlement settlement surveys, surveys, which which were were used used for for both both in-service in-service and and out-of-service out-of-service inspections. inspections.

mechanical mechanical integrity integrity of of an an individual individual tank tank or or aa complete complete tank tank farm. farm. This This tank-specific tank-specific RBI RBI approach approach enables enables owners owners to to focus focus their their inspection inspection on on those those assets assets that that have have the the highest highest probability probability of of potential potential problems. problems.

The continued operation of healthy tanks, along with large reductions in budget spent on preparing tanks for traditional internal inspections (including cleaning, degassing and waste disposal) provides tank owners with better profitability and improved operational effectiveness.

The method by which this energy is released is a step-like process, where the crack grows in a chaotic cascade of distinct, discrete snaps. Each snap provides a discrete pulse of energy that propagates throughout the surrounding material in the form of a transient elastic wave. The frequency content of these pulse-like transient waves is broadband, ranging from a few KHz to a few MHz. Much of this is in the ultrasonic region, detectable by using specialised AE sensors. The The identification, identification, location location and and evaluation evaluation of of structural structural defects defects and and active active cracks cracks in in pressure pressure vessels, vessels, pipelines pipelines and and storage storage tanks tanks is is now now routinely routinely applied applied to to process process plants. plants.

huge huge economic economic (and (and environmental) environmental) benefit benefit to to tank tank owners. owners.

AE process for tank floors AE AE sensors sensors are are mounted mounted on on the the wall wall around around the the tank’s tank’s circumference circumference and and connected connected to to aa data data acquisition acquisition system. system. To To assess assess the the condition condition of of the the tank tank floor, floor, aa window window of of one one hour hour is is required required to to gather gather enough enough data data for for aa valid valid statistical statistical assessment assessment of of the the floor. floor. To To achieve achieve aa‘quiet ‘quiet hour’ hour’all all activity activity likely likely to to cause cause product product movement movement must must have have been been stopped stopped and and the the tank tank allowed allowed to to settle settle for for aa period period of of 66 to to 12 12 hours. hours. Agitators, Agitators, heater heater coils, coils, level level measurement measurement systems, systems, etc. etc. must must all all be be turned turned off. off. Disruption Disruption to to operations operations is is thus thus no no more more than than one one working working day day per per tank. tank.

The result of the condition monitoring exercise is a tank floor grading, from A (no damage) to E (major repair required). Also, plots are presented to show the location(s) of any particularly active areas and/or potential leak sites. MISTRAS has conducted more than 1,000 such tests on tanks in Europe alone and more than 3,000 worldwide.

Huge savings to be made The overall tank floor and potential leak grades can be used by plant management to prioritise tank inspection and maintenance programmes. Cost savings from the use of this technology are very clear. If the vessel is in good condition, leading to the deferral of internal inspection, savings are enormous. The cost of preparing a large crude oil tank for internal inspection can reach £350,000 and for large cryogenic tanks up to £750,000. More than 50% of the ‘suspect’ tanks inspected by MISTRAS were proven not to require subsequent offline inspection and maintenance, saving millions of pounds for refinery and distribution terminal operators. For pressure vessels, the figure increases to 95%. This reveals how poorly targeted most shutdown maintenance is. At the other end of the scale, the skeptic might suggest that a £7,000 AE assessment which confirms that a suspected poor vessel does not need to be opened for repair is money wasted. However, costs can be measured in safety and environmental terms, as well as in pounds.

Complementary methods It is important to treat the AE method as complementary to other methods. This is because, unlike ultrasonic testing, AE integrity assessment does not detect static, non-growing defects, nor does it measure their size.

The system wall needs to be free of obstructions. The method involves sending long range ultrasonic signals into the tank from the outside annular (which must be in reasonable condition). The tank itself does not need to be removed from service. Indications are compared to a test plate in order to evaluate the severity of corrosion.

On the other hand, it will detect and

This technique can be used on steel and

locate regions of overstress or areas where

fiberglass tanks and vessels.

micro structural problems exist, which are structurally significant and which are easily missed by conventional localised methods. The effectiveness of both methods is improved by using them together.

AE should thought of as condition monitoring for static plant: a tool for determining which tanks need conventional inspection, where and when. It should not be assigned to, or used by, inspection departments.

Remote UT crawlers and cameras can also be used to map the thickness of hard to reach areas.

Magnetic Flux Exclusion To more accurately determine the extent of potentially flawed areas, Magnetic Flux Exclusion (MFE) or Low Frequency Electromagnetic Technique (LFET) scanning tools can be used to inspect 100% of the tank floor. Characterisation of defects is performed using traditional nondestructive testing techniques including

It is a management tool to be employed

ultrasonics, penetrant, magnetic particle

by senior maintenance personnel with a

and vacuum box inspections.

direct interest in managing maintenance budgets and directing inspection

Conclusions

personnel to where they are really

The most effective approach to tank

needed. There is often a temptation to repair tanks simply because they are offline, particularly when inactive cracks not identified by AE are found by other methods. Unnecessary repair often introduces new stresses to the vessel which were otherwise not present.

Annular ultrasonic testing

inspection blends the regulatory compliance to current codes and standards with Risk Based Inspection and Advanced Non Destructive Testing methods. The Tank Specific RBI ap¬proach allows owners to concentrate inspection on those assets that have the highest probability of potential problems. It also considers the consequences of such a failure. As a result,

Tank Annular Long Range Ultrasonic

Out-of-Service inspection of tanks can

Testing (TALRUT) is an automated long

be recommended that exhibit potential

range ultrasonic technique developed

problems, while continuing to operate

by MISTRAS to qualitatively map the

assets that are in good condition.

condition of the annular.

www.mistrasgroup.co.uk Issue 21 PECM

Facilities Management Partex launches Partex MarkOnline

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www.industrialflooring.co.uk 54 PECM PECM Issue Issue 21 21

www.neumo.co.uk

Fixtures & Fittings

Schwer Fittings leads the way in stainless steel connection technology as a manufacturer and supplier of high precision stainless steel tube components and hose fittings, compression fittings, twin ferrule fittings, clino-aseptic fittings, various valves and seamless tube with a technically trained sales team to help with all enquiries. Schwer enjoys an enviable reputation in the stainless steel industry for unrivalled service levels, components built for longevity and guaranteed 100 % traceability across all products. Using laserengraved test numbers to match parts to original material and produce 3.1B certificates many years after production. In addition to holding German Lloyds classification for the past decade, Schwer also holds DNV, ABS, GOST and RINA certification amongst others. Celebrating 20 years UK trading in 2014, Schwer has expanded and refitted the Warrington office, and increased production capacity with the introduction of new CNC, crimping and bending machinery. There are new training facilities in house, used for BFPA courses. Customers are informed about latest news, discounts and offers in our monthly Newsletter. Schwer Fittings Ltd Tel: 01925 639006 Fax: 01925 639007 Email: info@schwer.co.uk

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ZZZ URWDӿRZ FRP Issue 21 PECM

The Impact of Signal-to-Noise Ratio on Guided Wave Radar Transmitter Performance

transmitter transmitter signal signal amplitude amplitude is is suffi sufficient cient to to detect detect aa given given dielectric, dielectric, amplitude amplitude plays plays virtually virtually no no role role in in the the detected detected SNR. SNR. In In fact, fact, ifif too too many many sources sources of of unwanted unwanted refl reflections ections are are present, present, aa larger larger transmit transmit pulse pulse amplitude amplitude will will simply simply elevate elevate the the noise noise at at the the same same rate rate it it elevates elevates the the level level signal. signal. The The resulting resulting change change to to the the SNR SNR is is zero zero – – the the larger larger pulse pulse provides provides no no benefi benefitt in in and and of of itself itself to to SNR. SNR.

in in diffi difficult cult applications applications is is the the signalsignalto-noise to-noise ratio ratio (SNR), (SNR), which which essentially essentially describes describes the the diff difference erence between between the the desired desired signal signal and and the the unwanted unwanted noise. noise. If If the the amplitude amplitude of of the the noise noise approaches approaches that that of of the the level level signal, signal, loss loss of of accuracy accuracy or or linearity linearity is is the the fi first rst observed observed eff effect ect due due to to distortion distortion of of the the level level signal signal as as it it passes passes through through and and interacts interacts with with the the noise. noise. Worse Worse yet, yet, ifif SNR SNR is is bad bad enough, enough, the the adverse adverse signal signal interaction interaction can can actually actually result result in in aa loss loss of of the the level level signal. signal.

n n recent recent years, years, much much has has been been said said in in the the industry industry about about the the importance importance of of the the amplitude amplitude (size) (size) of of the the guided guided wave wave radar radar (GWR) (GWR) transmit transmit pulse. pulse. While While the the size size of of the the transmitted transmitted radar radar pulse pulse is is certainly certainly important, important, it it is is aa fact fact that that pulse pulse amplitude amplitude alone alone will will not not always always yield yield accurate accurate level level measurement measurement under under all all process process conditions. conditions. A A far far more more important important parameter parameter in in reliable reliable level level measurement measurement

While While it it would would be be desirable desirable to to eliminate eliminate all all the the unwanted unwanted impedance impedance discontinuities, discontinuities, it it is is simply simply not not possible. possible. The The good good news news is is that that today’s today’s most most advanced advanced GWR GWR solutions solutions address address this this critical critical design design issue. issue. Transmit Transmit Pulse Pulse Amplitude Amplitude and and Signal-to-Noise Signal-to-Noise Ratio Ratio Many Many GWR GWR manufacturers manufacturers talk talk about about transmit transmit pulse pulse amplitude; amplitude; however, however, beyond beyond the the point point at at which which the the

The The only only role role of of aa larger larger transmit transmit pulse pulse is is to to assure assure that that noise noise in in the the system system does does not not become become dominant dominant in in the the overall overall SNR SNR in in low low signal signal return return cases cases (such (such as as long long probes probes under under low low dielectric dielectric conditions). conditions). Too Too small small of of aa transmit transmit signal signal would would result result in in too too small small of of aa received received signal signal in in these these cases, cases, requiring requiring excessive excessive signal signal ampliﬁ ampliﬁcation cation in in the the level level transmitter. transmitter. Diode Diode Switched Switched Front Front End End Design Design ® The The new new Eclipse Eclipse® Model Model 706 706 uses uses aa new new design design concept concept called called the the diode diode switched switched front front end, end, which which enhances enhances front-end front-end performance. performance. The The design design of of this this advanced advanced GWR GWR transmitter transmitter features features front-end front-end circuitry circuitry innovations innovations that that enhance enhance the the transmitted transmitted pulse pulse amplitude, amplitude, improve improve the the received received signal signal strength strength and, and, most most importantly, importantly, increase increase the the SNR. SNR. For For more more information, information, download download our our free free white white paper, paper, The The Impact Impact of of SignalSignalto-Noise to-Noise Ratio Ratio on on Guided Guided Wave Wave Radar Radar Performance, Performance, at at http://marketing. http://marketing. magnetrol.com/acton/media/8231/ magnetrol.com/acton/media/8231/ impact-of-signal-to-noise-ratio-onimpact-of-signal-to-noise-ratio-ongwr-magnetrol gwr-magnetrol

break through the

NOISE Better Signal-to-Noise Ratio Means Better Level Control Performance 4.40 Higher

Model 706 SNR

1.57

While transmit pulse amplitude (signal size) has helped to make guided wave radar technology the standard for accurate, reliable level measurement, the fact is signal-to-noise ratio (SNR) represents a far more critical indicator of level control performance. For superior SNR in all process conditions, no other GWR device beats the Eclipse ® Model 706 transmitter from Magnetrol ®.

Competitor SNR The ECLIPSE Model 706 transmitter has a signal-to-noise ratio nearly 3 times higher than competitors.

To learn more about the breakthrough ECLIPSE Model 706 GWR transmitter visit eclipse.magnetrol.com or contact your MAGNETROL representative today.

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Fluid Handling

CONVEYING CAPACITY

UP TO 130 M3/H

SCT REDUCES OPERATING COSTS SEEPEX progressive cavity pumps fitted with Smart Conveying Technology (SCT): y Can be adjusted to extend the stator’s life by up to 200% y Use up to 25% less energy than conventional progressive cavity pumps y Enable planned predictive maintenance without unexpected downtime

PRESSURE

UP TO 8 BAR

y Reduce maintenance time by up to 85% y Improve health and safety by reducing spare component weight The end result; productivity is improved by reduced downtime and faster maintenance.

SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com

SEEPEX Smart Conveying Technology reduces costs for Severn Trent Water SEEPEX Progressive cavity pumps fitted with Smart Conveying Technology (SCT) were put to the test recently against conventional design progressive cavity (PC) pumps at Minworth WwTW.

evern Trent Water costs for PC pump maintenance were increasing – particularly for those pumps feeding a gravity belt thickener with primary sludge. Frequent maintenance (every 4-6 months) was needed to replace the rotor and stator, increasing labour and spares costs for the equipment. SEEPEX oﬀered pumps ﬁtted with Smart Conveying Technology SCT as a direct replacement for cost comparison purposes. The SCT design has a stator split in half axially, held in place with 4 retaining segments. The pump can be

dismantled in place, enabling removal of blockages, and replacement of either the stator, the rotor, or both, without dismantling pipework. The quick release rotor means that universal joints do not need to be dismantled to change the rotor either. This design reduces maintenance time by up to 85% when compared to conventional PC pumps. SCT pumps have other advantages however, particularly when dealing with abrasive products, which have been proven to improve service life. The adjustable nature of the retaining segments allows re-tensioning of

the stator as wear occurs, regaining optimum output each time and extending the stator life by up to 300%. Ragging issues are also reduced where SCT is used. At Minworth, the test was successful with the SEEPEX SCT pump outperforming conventional PC pump design by over 100%. An example of how Smart Conveying Technology extends pump life and reduces operating costs. Tel: +44 1935 472376 Email: sales.uk@seepex.com www.seepex.com Issue 21 PECM

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Transferring Transferring aggressive aggressive chemicals chemicals is is by by nature nature challenging. challenging. You You don’t don’t just just want want aa pump pump that’s that’s safe. safe. You You want want one one that’s that’s durable. durable. With With virgin virgin or or antistatic antistatic PTFE PTFE wetted wetted parts. parts. And And stainless stainless steel steel and and polypropylene polypropylene non-wetted non-wetted components. components. In In certain certain conditions conditions you’ll you’ll need need an an ATEX ATEX approved approved version*. version*. You’ll You’ll almost almost certainly certainly want want ease ease of of maintenance. maintenance. That’s That’s aa given given with with Flotronic’s Flotronic’s air-operated, air-operated, double double diaphragm diaphragm pumps pumps with with their their pioneering pioneering ‘ONE-NUT’ ‘ONE-NUT’ design. design. And And you’ll you’ll definitely definitely want want the the affordability affordability that that Flotronic’s Flotronic’s new new and and unique unique ‘ONE-BLOCK’ ‘ONE-BLOCK’ design design gives. gives. In In fact fact … … you’ll you’ll want want the the new new Flotronic Flotronic Minichem. Minichem. *A *ATE TEXX Ga Gass Gr Grou oupp II IICC co com mplpliaiant nt ve vers rsioions ns ar aree av avaiailalablbl ee

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Flotronic Flotronic Pumps Pumps Ltd. Ltd. Ricebridge Ricebridge Works Works Brighton Brighton Road, Road, Bolney, Bolney, West West Sussex Sussex RH17 RH17 5NA. 5NA. UK UK Sales:+44(0) Sales:+44(0) 1444 1444 881871 881871 Email: Email: sales@flotronicpumps.co.uk sales@flotronicpumps.co.uk

Electromechanical Active Roll Control System From Schaeffler Wins German Innovation Award

Precision bearing and automotive

to traditional hydraulic systems, as well

resistance has to be compensated for in

systems manufacturer Schaeffler

as simplifying assembly in automotive

order to maintain the force (moment).

has been presented with the 2016

production plants. The first large-scale

Schaeffler has installed two state-of-the-

German Innovation Award in the

application for the electromechanical

art production lines at its Schweinfurt site

‘large companies’ category for its

active roll control system was in a luxury

for the volume production launch of the

innovation and development of an active

class sedan and in the powerful, dynamic

new system. The facilities have a modular

electromechanical roll control system. The

luxury SUV class. The latter even included a

design in accordance with Industry 4.0

awards ceremony was held on 8th April

48-volt electrical system.

criteria. This will allow subsequent product

2016 in Munich. Prof. Peter Pleus, CEO Automotive Schaeffler AG, commented: “Schaeffler has a tradition of being the most innovative company in Germany. This is also documented by the latest figures with more than 2,300 patent applications in 2015. The electromechanical active roll control system convinced the high-profile German Innovation Awards committee of our innovative capacity. The product adds

Technical details Schaeffler’s electromechanical active roll control system consists of a gearbox and a control motor with an electronic system

launches and future, refined generations of this technology to be integrated without any problems.

The German Innovation Award

as well as an integrated torque sensor.

Accenture, EnBW, Evonik and

The control motor with its high-ratio,

WirtschaftsWoche magazine established

three-stage planetary gearbox twists the

the “German Innovation Award“ initiative

two halves of the roll control in opposite

in 2010 to recognise outstanding,

directions to produce a torque that has a

trend-setting innovations by German

stabilising effect on the vehicle body.

companies whose innovative capacity changes business and markets. The group

to Schaeffler’s range of electromechanical

The torque is measured precisely using

actuators that provide significant

is in under the auspices of the German

a non-contact torque sensor, which

contributions to power and efficiency in

Federal Ministry for Economic Affairs and

regulates the actuator quickly and

vehicles.”

Energy. The German Innovation Award is

accurately. To increase comfort, the

organised by the Handelsblatt publishing

Schaeffler solution also includes an

group.

The electromechanical active roll control system

innovative decoupling element made from high-strength elastomer. Fast

For more information, please contact

Schaeffler’s volume production of the

data transmission and a state-of-the-

Schaeffler UK’s Communications &

electromechanical active roll control

art software architecture also allow the

Marketing Department on

system has opened up a new chapter in

system to be used in networked driving

info.uk@schaeffler.com

chassis technology. This new technology

applications.

www.schaeffler.co.uk

adjusts the chassis to any driving situation as quick as a flash and absorbs

Unlike hydraulic systems,

irregularities in the road, thus minimising

electromechanical active roll control only

the vehicle’s rolling motions, particularly

uses electric power on an as-needed basis

when cornering at high speeds. This

(“power on demand”). One of the key

increases comfort, safety and dynamics.

factors here is the electric motor, which

This innovation helps reduce fuel consumption and emissions compared

only consumes power when the swivel actuator twists and builds up torque. Only a relatively low electrical loss of Issue 21 PECM

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62 PECM PECM Issue Issue 21 21

The The digital digital models models link link directly directly to to the the CAD-CAM CAD-CAM systems systems to to facilitate facilitate aa quick quick turnaround turnaround from from design design to to manufacture. manufacture. Cross+Morse Cross+Morse use use the the 3D 3D digital digital prototyping prototyping of of customersâ&#x20AC;&#x2122; customersâ&#x20AC;&#x2122; special special parts parts as as aa cost-eďŹ&#x20AC; cost-eďŹ&#x20AC;ective ective way way to to validate validate the the design design and and guarantee guarantee the the absolute absolute best best solution solution is is always always the the one one put put in in place. place. One One of of our our main main objectives objectives is is to to keep keep investment investment in in the the latest latest technologies technologies aa priority, priority, both both in in and and out out of of the the factory, factory, to to fulďŹ fulďŹ ll our our aims aims of of continual continual progression progression in in line line with with our our ISO ISO 9001 9001 accreditation. accreditation. Want Want to to know know more more about about what what Cross+Morse Cross+Morse can can do do for for your your application? application? Visit Visit www.cross-morse.co.uk www.cross-morse.co.uk or or e-mail e-mail sales@crossmorse.com sales@crossmorse.com for for more more info. info.

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Invertek Elevator drive helps residents park safely

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Building The Safety Case Research area Luke Bisby is The Arup Professor of Fire and Structures at the BRE Centre for Fire Safety Engineering at Edinburgh University. He graduated originally in structural engineering and his PhD research

His own postdoctoral research focused on the issues raised, “As a structural engineer, I was trying to figure out if we could have – or should have – prevented what happened, and how structural engineers should think about fire and design for different scenarios as part of their duty of care.

looked into the use of advanced polymer composites as new

” With his emphasis gradually

materials for strengthening

moving away from composite

reinforced concrete in buildings.

materials, and, keen to back

Part of this research entailed

his structural fire engineering

investigation into the fire

research with data from realistic

performance of new materials

tests, he moved to the Edinburgh

and the bond that fixes them to

centre. Here, he started working

existing structures. Fire research

alongside subject specialists in

was only part of his work at that

fire science and engineering, and

early stage.

broadened his research into real fire events and analysing their

The work has profound implications for international building design codes and the ways that fire is treated in structural engineering, and Professor Bisby said that norms that have been accepted for more than a century are now being exposed as inefficient or inadequate in some cases. As a result, the top structural re engineers now operate in a design space where the building codes are simply used as tools within a performance-based framework, rather than as static, prescriptive requirements.

Academy support

effects on real structures.

Professor Bisby is currently

on 11 September 2001 were not a

The fundamental aim of his

Chair. “The Academy’s support has

mainstream or typical fire event

research is to be able to model fire

in terms of structural engineering,

in buildings (and vice versa), and

but that it rightly raised the subject

to be able to derive and validate

of structural performance in fire up

computer models which can be

the research agenda at the same

applied to the structural and fire

time.

safety design of buildings. The

Professor Bisby said that the terrorist attacks on the Twin Towers

models will look into various factors, ie the dynamics of the fire itself, other ignition sources, the

“Our research can be used to great advantage to safely optimise buildings, and in most cases it can save clients’ money and allow architects to do more interesting things, all while preserving or even enhancing safety.” Professor Luke Bisby

effects of other elements such as glazing and heat transfer into the structure, all as a dynamic transient event where the heat generated by the fire affects the response of the building structure.

supported by an RAEng Research made a fundamental difference to me professionally”, he said. “More importantly, the support of the Academy has given me independence to develop my research career which will help society at large”. The Academy is also sponsoring further sociological research at Edinburgh that will investigate how the university can make its technology important in ‘a regulatory and practical enactment sense’ – Professor Bisby said this is fundamentally important, since his work is intended to lead to new design codes, but these will be of limited value unless enacted.

Other support Arup’s Fire Engineering practice currently co-sponsors the work of Professor Bisby and his team, and Arup is a principal collaborator in the overall project. Professor Bisby spends time each year in Arup’s offices and Arup engineers collaborate with Edinburgh in both education and research contexts, to the benefit of both parties.

“It means that there is a massive opportunity to optimise buildings for fire and in many cases to make structures lighter, more beautiful and sustainable,” he said. Overdesign implies higher cost in terms of initial construction and of the building lifecycle. And in those fewer cases where the current codes under-estimate the negative impacts of fire, there may be safety issues.

Research impact

In order to be able to treat fire as

Luke Bisby’s work is redefining

to model a specific building, the

the way fire is treated in the structural design of buildings. He said, “Fire should be considered as a design load in the same way that wind, gravity, and seismic effects are treated. Current codes for new buildings are based on data collated more than a century ago and, even if they were state-of-theart then, they take little account of the many advances since.” The research he and his colleagues at Edinburgh have done so far indicates that the current definition of a credible worst-case design fire leads in many cases to a significant overestimation of risk and effects – although in some cases it produces under-estimation.

a design load, “you need to be able specific construction techniques, the materials and then design for that load”, he said. “So that means you need computational tools to do that and you need to validate those computation tools with experimental data. That is essentially what we are doing.”

Future challenges

Biography / Career Progression 1993–1997 Undergraduate degree in Civil Engineering and Applied Mechanics, McGill University, Montreal, Québec 1997–1999 Master of Science degree in Structural Engineering, Queen’s University, Kingston, Ontario 1999–2003 PhD in Structural Engineering, focusing on structural and re performance of polymer composite structural strengthening materials, Queen’s University, Kingston, Ontario 2003–2008 Assistant Professor and Undergraduate Chair, Queen’s University, Kingston, Ontario

A big challenge for the future, Professor Bisby said, will be to

2008–2013 The Ove Arup

persuade regulators that design

Foundation/ RAEng Senior

codes and regulatory processes

Research Fellow in Structures

for significant buildings should

and Fire, School of Engineering,

be changed. “Often when we try

Edinburgh University

to take an innovative approach to re safety we come up against

2013–Present Arup /RAEng

a regulatory process that doesn’t

Research Chair in Structures

want to hear it,” he said.

and Fire, School of Engineering, Edinburgh University

The current methodologies are a century old and the numbers they’re based on are decades old as well. There is a lot of inertia in practice, and we know that it will take time to affect real and lasting change.

Two Layers to increase your Profit Double layer rupture disc KUBV: Unique rupture disk design solves Safety & Control Issues – by Stefan Penno, REMBE Germany

ssues ssues of of safety safety and and control control are are frequently frequently on on the the agenda agenda within within the the Oil Oil and and Gas Gas industry industry particularly particularly in in challenging challenging times times such such as as these. these. One One of of the the most most interesting interesting products products in in this this fi field: eld: the the innovative innovative double double layer layer rupture rupture disc disc from from Germany’s Germany’s REMBE REMBE GmbH GmbH Safety Safety + + Control. Control. According According to to Stefan Stefan Penno, Penno, REMBE’s REMBE’s Managing Managing Director, Director, the the KUB KUB V V rupture rupture disc disc improves improves on on ordinary ordinary single single layer layer designs designs by by eliminating eliminating the the disadvantages disadvantages common common to to many many reverse reverse acting acting rupture rupture disks. disks. These These traditionally traditionally designed designed discs discs often often exhibit exhibit premature premature failure failure because because of of fatigue, fatigue, pre-weakening pre-weakening of of the the disc’s disc’s dome dome as as the the result result of of scoring scoring of of the the fragile fragile burst burst membrane, membrane, and and even even installation installation diffi difficulties culties caused caused by by the the sensitivity sensitivity of of some some single single layer layer disks disks to to torque torque levels. levels.

The The KUB KUB V V solves solves the the conundrums conundrums of of the the single single disc disc design design by by the the addition addition of of aa single single vital vital feature, feature, aa specially specially re-inforced re-inforced second second protection protection layer layer capable capable of of withstanding withstanding twice twice the the pressure pressure in in reverse reverse direction direction as as it it does does in in the the venting venting direction. direction. The The disk’s disk’s fi first rst layer layer handles handles the the burstpressure burstpressure by by incorporationg incorporationg buckling buckling pin pin elements elements added added to to the the dome dome by by high-precision high-precision laser laser cutting. cutting. The The second second layer layer acts acts as as aa sealing sealing membrane membrane that that isolates isolates the the fi first rst layer layer from from the the harsh harsh process process conditions conditions found found in in the the off offshore, shore, chemical, chemical, food, food, pharmaceutical pharmaceutical and and other other process process industries. industries. This This general general description description of of this this unique unique rupture rupture disc disc doesn’t doesn’t do do full full justice justice to to aa number number of of technical technical features features developed developed by by REMBE’s REMBE’s engineers. engineers. The The KUB KUB disc disc has has aa burst burst layer layer 8 8 times times thicker thicker than than scored scored designs designs and and the the buckling buckling pin pin formula formula and and

the the number number and and shape shape of of buckling buckling pins pins precisely precisely determine determine the the burst burst pressure, pressure, which which is is independent independent of of the the material material thickness. thickness. In In essence, essence, the the burst burst layer layer is is completely completely unaff unaffected ected by by the the reverse reverse force force when when put put under under backpressure. backpressure. Only Only the the sealing sealing layer, layer, which which protects protects the the burst burst membrane membrane under under normal normal process process conditions, conditions, holds holds the the backpressure backpressure and and is is subject subject to to negative negative pressure. pressure. The The design, design, says says Stefan Stefan Penno, Penno, makes makes it it possible possible to to stretch stretch maintenance maintenance intervals intervals and and eliminate eliminate downtime. downtime. The The disc’s disc’s sosocalled called VIP-feature VIP-feature (Valve (Valve Inspection Inspection in in Place), Place), allows allows operators operators to to check check their their safety safety valves valves without without having having to to shut shut down down the the process, process, and and then then dismantle dismantle the the valve valve and and bring bring it it to to the the workshop. workshop. In-situ In-situ maintenance maintenance with with the the KUB KUB V V saves saves both both time time and and money. money. REMBE REMBE can can also also supply supply aa Volution-unit, Volution-unit, aa ready-to-use ready-to-use device device fi fitted tted between between the the rupture rupture disc disc and and the the valve valve that that can can link link up up with with an an operator’s operator’s in-house in-house air-pressure air-pressure system. system. By By putting putting the the space space between between the the rupture rupture disc disc and and valve valve slowly slowly under under pressure, pressure, users users can can monitor monitor the the performance performance of of safety safety valve valve easily easily and and quickly quickly with with nothing nothing more more than than aa pressure pressure gauge. gauge. This This feature feature alone alone reduces reduces maintenance maintenance times times from from hours hours to to minutes. minutes.

Author: Author: Stefan Stefan Penno, Penno, MBP MBP BA BA IBA IBA REMBE REMBE GmbH GmbH Safety Safety + + Control, Control, Brilon Brilon * * Germany Germany Contact: Contact: info@rembe.de; info@rembe.de; T: T: +49 +49 2961 2961 74050 74050

66 PECM PECM Issue Issue 21 21

T +49 2961 7405-0

Made in Germany

Your Specialist for PRESSURE RELIEF and EXPLOSION 6$)(7<

Canadian Passenger Ferry Equipped with Glamox LED Lighting

VV Veteran, Veteran, the the first first of of two two

as as offering offering excellent excellent heat heat management management

Their Their rudders, rudders, hull hull and and propellers propellers are are

new new 80-metre, 80-metre, Ice Ice Class, Class, rollroll-

and and low low energy energy consumption. consumption.

therefore therefore strengthened strengthened and and fitted fitted with with

on, on, roll-off roll-off passenger passenger ferries ferries

extra extra thick thick plating plating to to cope cope with with the the heavy, heavy, By By using using the the latest latest LED LED technology, technology,

harsh harsh winter winter conditions. conditions. Both Both ferries ferries can can

routes routes in in Newfoundland Newfoundland and and Labrador Labrador in in

the the FL60 FL60 floodlights floodlights offer offer aa virtually virtually

operate operate in in harsher harsher conditions conditions than than the the

Canada, Canada, has has been been equipped equipped with with aa range range

maintenance-free maintenance-free solution solution for for all all high high

current current vessels vessels operating operating these these routes. routes.

of of lighting lighting solutions solutions from from Glamox. Glamox. The The new new

intensity intensity lighting lighting requirements. requirements. The The FL60 FL60

ItIt is is hoped hoped that that the the improved improved reliability reliability

state-of-the-art state-of-the-art ferry ferry is is named named in in honour honour of of

is is available available as as aa four-module four-module version version

will will promote promote business business and and tourism tourism in in the the

all all those those who who have have served served in in the the Canadian Canadian

and and is is an an excellent excellent choice choice of of luminaire luminaire

region. region.

armed armed forces, forces, past, past, present present and and future. future.

for for demanding demanding applications applications where where

that that will will service service island island

illumination illumination over over longer longer distances distances is is The The two two vessels vessels are are being being constructed constructed

required. required. The The FL60 FL60 operates operates in in ambient ambient

by by Damen Damen Shipyards Shipyards in in Galati, Galati, Romania, Romania,

temperatures temperatures ranging ranging from from -30ºC -30ºC to to +45ºC. +45ºC.

at at aa cost cost of of around around 50 50 million million Canadian Canadian dollars dollars each. each. MV MV Veteran Veteran has has already already been been completed completed and and was was officially officially put put into into service service in in December December 2015. 2015. The The sister sister ship, ship, MV MV Legionnaire, Legionnaire, is is scheduled scheduled for for completion completion in in the the spring spring of of 2016. 2016. MV MV Veteran Veteran and and MV MV Legionnaire Legionnaire are are both both equipped equipped with with lighting lighting solutions solutions from from Glamox. Glamox. Each Each vessel vessel has has more more than than 900 900 luminaires luminaires installed installed from from Glamox, Glamox,

Other lighting solutions supplied by Glamox include the 70M series of double lens navigation lights, LED linear lighting for the main car deck, explosion-proof Ex e fluorescent light fittings for Zone 1 and Zone 2 hazardous areas, fluorescent recessed ceiling lights for the wheelhouse, passageways, stairways, entrances and crew accommodation areas.

A truly global project MV MV Veteran Veteran is is the the first first vessel vessel design design that that stems stems from from aa Canadian-Danish Canadian-Danish partnership partnership between between Fleetway Fleetway and and Knud Knud E. E. Hansen. Hansen. The The ferry ferry is is built built in in Romania Romania by by Damen Damen Shipyards Shipyards for for Canadian Canadian authorities, authorities, and and is is equipped equipped with with lighting lighting produced produced in in Germany Germany by by Norwegian-owned Norwegian-owned Glamox Glamox Aqua Aqua Signal, Signal, installed installed by by aa Dutch Dutch technology technology company, company, and and now now locally locally supported supported by by Glamox Glamox Canada, Canada, based based in in St St John’s, John’s, Newfoundland. Newfoundland.

Glamox AS The The Glamox Glamox Group Group is is aa global global organisation organisation with with 1300 1300 employees employees and and sales sales and and production production in in several several European European countries, countries, as as well well as as in in Asia Asia and and North North America. America. The The annual annual turnover turnover is is EUR EUR 268 268 million million (2014). (2014). The The Group Group owns owns aa range range of of quality quality lighting lighting brands brands including including Glamox, Glamox, Aqua Aqua Signal, Signal, Luxo, Luxo, Høvik Høvik Lys Lys and and Norselight. Norselight. Glamox Glamox is is committed committed to to meeting meeting customer customer needs needs and and expectations expectations by by providing providing quality quality products products and and solutions, solutions, service service and and

which which range range from from energy-efficient energy-efficient LED LED

MV MV Veteran Veteran will will service service both both Fogo Fogo

luminaires, luminaires, including including aa high high number number of of

Island Island and and Change Change Island Island –– the the second second

1445 1445 LED LED waterproof, waterproof, multi-purpose multi-purpose

busiest busiest route route in in the the province, province, moving moving

luminaires. luminaires. The The vessels’ vessels’floodlights floodlights are are

approximately approximately 169,000 169,000 passengers passengers

powerful powerful Glamox Glamox FL60 FL60 series series floodlights floodlights

annually. annually. MV MV Legionnaire Legionnaire will will operate operate on on

with with long-life long-life LED LED light light sources. sources. The The FL60 FL60

the the busy busy short-haul short-haul route route from from Portugal Portugal

Spot Spot beam beam floodlights floodlights are are mounted mounted on on

Cove Cove to to Bell Bell Island. Island. Since Since this this region region is is

the the bridge bridge wings wings (rear (rear facing) facing) and and provide provide

located located near near the the Arctic, Arctic, the the vessels vessels have have to to

instantaneous, instantaneous, high high intensity intensity light, light, as as well well

manouvre manouvre in in drifting drifting ice ice at at aa speed speed of of up up to to 44 knots. knots.

PECM PECM Issue Issue 21 21

support. support. www.glamox.com/gmo www.glamox.com/gmo

Lighting Dialight Introduces High Efficiency Zone 1 SafeSite® High Bay Dialight (LSE: DIA.L), the global leader in LED lighting technology, today unveiled the first-ever High Efficiency ATEX/IECEx Zone 1 SafeSite® High Bay. Each high bay feature Dialight’s latest world class in-house designed power supply and a full 10-year, full performance warranty and up to 110 lm/W efficiency. The high output 23,500 to 9,650 lumen SafeSite ATEX/IECEx Zone 1 High Bays offer superior illumination and efficiency for oil, gas, chemical, petrochemical, pharmaceutical and other hazardous area applications. The ATEX Zone 1 certified SafeSite High Bays include an integrated power supply with 6kV surge protection, and their light weight and low profile makes for easy installation. Options for 3 meter cable or integrated wiring junction box. With typical mounting heights up to 13 meters, the SafeSite LED High Bays represents the ideal retrofit for conventional 400W HID fixtures. The ATEX/IECEx SafeSite LED High Bays are L70 lifetime rated for more than 150,000 hours and operates in temperatures ranging from -40oC to +60oC. For more information about Dialight’s complete line of SafeSite LED lighting solutions for hazardous locations including IES files, LM79 reports and technical datasheets, visit www.dialight.com.

New lighting rental scheme aids cash flow Using LED lighting with the latest in lighting management systems, it is now relatively easy to achieve 50% to 80% energy savings on most projects with these energy savings paying for the systems and installation. With this in mind, Aura Light has launched a ‘Rent Your Lighting’ scheme which eliminates investment in equipment and reduces an organisation’s energy costs from day one. Simon Taylor, Aura Light UK’s Managing Director comments, “This is an exciting development with big benefits for UK commerce and industry. The concept is likely to appeal to all business directors and accountants as the scheme aids cash flow keeping costs off the balance sheet and also takes advantage of the tax benefits.”

Email: simon.taylor@aura-light.co.uk www.aura-light.co.uk

Machining Washing machine supplied by Armstrong gets the smell out of artificial latex body parts! Limbs & Things, is a medical simulation company that manufactures artiﬁcial body parts for use in clinical and surgical skills training. The manufacturing process involves the use of various chemicals, and when the latex material comes out of the ovens it has a very strong and unpleasant smell. In order to get rid of the smell, and also to improve the colour of the ﬁnished items, they are washed, using ordinary washing powder, in a machine supplied by Armstrong Commercial Laundry Systems. The machine, which the company bought in 2013, is a Schulthess 7kg washerextractor and, according to Mark Brown, Manufacturing Maintenance Engineer at Limbs & Things, who works in the engineering department, is in use every day, often three times a day. “The material is poured into the moulds, goes into the ovens and from there the production line operators put it straight to the washing machine to get rid of the smell”, he told us.

Tel: 01635 263410

www.armstronglaundry.com

New double pulse MIG Welder from Jasic New from Global Welding Manufacturer Jasic, the Pro MIG 350P Multi Process Separate is an IGBT inverter designed for industrial use in MIG/MAG, pulse, double pulse and DC MMA processes. DSP digital technology provides optimum welding performance as well as featuring easy parameter settings for the operator. This model oﬀers an abundance of features; synergic control with pre-programming of common materials and wire diameters for time saving as well as self-diagnostic protection systems for extreme reliability. This 3 phase inverter oﬀers 350 Amps at 60% duty cycle. The package includes power source, wire feed unit, 2m interconnecting cable, trolley, water cooler, MIG torch, earth return & gas regulator. Free product demonstrations are available through authorised Jasic Distributors Readily available through Jasic UK equipment distributors, this machine is supported by a 5 year warranty when registered at jasic.co.uk. Wilkinson Star Limited is the Sole UK Importer of Jasic Welding and Industrial equipment. Tel: 0161 793 8127

Roll grinding machine receives elastic bearing from Getzner

Manufacturer of High Quality

Anti Vibration Products

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

To ensure the precision of an industrial grinding machine weighing 170 metric tons at the Cernay-based company Valmet, Getzner Werkstoffe installed a vibration protection solution in 2015. The elastic Sylodyn® bearings protect the machine from vibrations to preserve the accuracy of its precision work while reducing maintenance needs at the same time. In order that the new precision grinding machine at the service centre of the technology provider Valmet in Cernay can be operated with long-term reliability, it was fitted with a vibration protection solution from Getzner in 2015. At 17 metres long and roughly five metres wide, the industrial grinding machine is used to renew the surface of metal rollers, such as those found in the paper and cardboard industry. The 170 metric ton unit rests on point bearings of Sylodyn® NE to protect it against shocks and vibrations. Developed and manufactured by Getzner itself, the material effectively reduces the transfer of vibrations, allowing the machine to deliver results with the utmost precision while reducing maintenance costs at the same time.

Tel: +43-5552-201-1862 Email: stephan.moosbrugger@getzner.com

Issue 21 PECM

Salmon to Return to River Don Following Sewage Works Upgrade he he River River Don Don is is cleaner cleaner now now than than at at any any time time since since the the Industrial Industrial Revolution, Revolution, thanks thanks in in part part to to aa ÂŁ78m ÂŁ78m scheme scheme to to improve improve the the Blackburn Blackburn Meadows Meadows Sewage Sewage Treatment Treatment Works Works in in Sheffield. Sheffield.

Much Much of of the the new new equipment equipment at at the the sewage sewage treatment treatment works works was was designed, designed, manufactured, manufactured, installed installed and and commissioned commissioned by by A&J A&J Fabtech Fabtech of of Dewsbury Dewsbury in in West West Yorkshire, Yorkshire, who who also also refurbished refurbished some some of of the the existing existing equipment. equipment. There There has has been been aa treatment treatment works works on on the the site site for for over over 130 130 years; years; today today itit serves serves nearly nearly 800,000 800,000 homes homes and and businesses businesses across across South South Yorkshire. Yorkshire.

PECM PECM Issue Issue 21 21

The The upgrade upgrade works works also also incorporate incorporate aa storm storm overflow overflow scheme scheme which which reduces reduces the the likelihood likelihood of of damaging damaging flooding flooding in in the the area, area, aa critical critical function function as as the the works works is is only only aa stone's stone's throw throw from from the the 280-store 280-store Meadow Meadow Hall Hall shopping shopping centre. centre.

The project to upgrade Blackburn Meadows started in 2012, with the initial objective being to reduce the levels of ammonia in the River Don so that a balanced and more natural ecosystem could develop. It has continued in stages and is now a state-of-the-art facility that ensures water quality capable of supporting a diverse plant and animal wildlife profile.

A&J A&J Fabtech Fabtech has has played played aa major major role role in in the the sewage sewage treatment treatment aspects aspects of of this this project, project, including including the the refurbishment refurbishment of of existing existing equipment equipment and and the the installation installation of of new new settlement settlement tanks. tanks. "The "The existing existing tanks tanks were were based based on on aa 1960s 1960s design, design, so so were were aa lot lot deeper deeper than than modern modern tanks tanks but but otherwise otherwise very very similar," similar," explains explains Shaun Shaun Brosnan, Brosnan, A&J A&J Fabtech's Fabtech's Contract Contract Manager Manager for for Blackburn Blackburn Meadows. Meadows. "It "It made made sense sense to to refurbish refurbish these, these, and and build build some some completely completely new new ones ones to to add add extra extra capacity." capacity."

The new tanks are fitted with three-quarter bridge scrapers for the activated sludge process (ASP). A&J Fabtech also supplied GRP launders, a drop box, weir plates, a weir cleaning system, dipping scum box, slip rings, loss of rotation sensors, torque limiting sensors, and a scum concentration collection system. Refurbishing the existing tanks included removal of their existing three-quarter bridges and installation of new ones, while

the Mckinney baffles were upgraded from 5m to 8.2m diameter to provide enhanced flow control in the effluent channel.

As with the new tanks, a weir cleaning system, dipping scum box, slip rings, loss of rotation sensors, torque limiting sensors and scum concentration collection system have also been provided.

The increased treatment capacity, especially in terms of secondary treatment processes, has been instrumental in reducing the ammonia levels in the final effluent that is discharged to the River Don. Under the European Freshwater Fish Directive, the treatment works is required to achieve a level of 3 mg/l or less of ammonia in order to comply. Since the refurbishment of Blackburn Meadows, there have been regular sightings of trout in the city centre reaches of the River Don.

“It’s the first time such fish have been so far upstream in over 100 years, and is one of the key indicators of the project’s success” says Shaun Brosnan. “There are plans to reintroduce salmon too, something that would have been completely inconceivable just a few years ago.”

www.ajfabtech.com

Measurement & Monitoring For instant gas analysis in the field - Agilent 490 Micro GC Designed Designed to to provide provide maximum maximum flflexibility exibility and and ease-of ease-of use, use, the the Agilent Agilent 490 490 Micro Micro gas gas chromatograph chromatograph off offers ers fast fast and and precise precise analysis analysis of of on-line on-line and and off off-line -line gas gas samples samples anywhere anywhere and and is is available available as as both both portable portable and and laboratory laboratory systems. systems. The The portable portable confi configuration guration can can be be used used for for measurements measurements at at natural natural gas gas pipelines pipelines and and metering metering stations, stations, fifield eld perimeter perimeter monitoring monitoring and and multiple multiple drilling drilling locations. locations. No No flflammable ammable gases gases are are used used so so the the analyser analyser can can be be used used in in environments environments where where operational operational safety safety is is critical. critical. Small, Small, lightweight lightweight and and equipped equipped with with rechargeable rechargeable batteries batteries and and built-in built-in gas gas cylinders, cylinders, you you can can expect expect eight eight hours hours of of productive productive fifield eld time. time. Sampling Sampling is is through through an an integral integral pump pump with with analysis analysis completed completed in in seconds. seconds. See See www.analytix.co.uk www.analytix.co.uk for for more more information. information. Enquiries Enquiries to to Analytix Analytix on on 0844 0844 800 800 or sales@analytix.co.uk sales@analytix.co.uk 4220 4220 or

New British made RayTemp 2 non-contact thermometer The The RayTemp RayTemp 22 is is the the fifirst rst in in aa new new series series of of non-contact non-contact infrared infrared thermometers thermometers designed designed and and manufactured manufactured here here in in the the UK UK by by ETI. ETI. ETI’s ETI’s Managing Managing Director Director Peter Peter Webb Webb commented commented “the “the development development of of infrared infrared thermometer thermometer technology technology is is an an exciting exciting breakthrough breakthrough for for ETI ETI and and we we now now have have the the capability capability to to manufacture manufacture high high accuracy accuracy non-contact non-contact infrared infrared thermometers thermometers here here in in our our UK UK factory, factory, itit has has been been aa long long time time coming coming but but itit is is now now aa reality”. reality”. Compact Compact and and lightweight, lightweight, the the RayTemp RayTemp 22 is is an an easy easy to to use use low low cost, cost, infrared infrared thermometer thermometer that that measures measures surface surface temperature temperature over over the the range range of of -49.9 -49.9 to to 349.9 349.9 °C °C with with an an assured assured accuracy accuracy of of ±1 ±1 °C °C over over the the range range of of 00 to to 100 100 °C. °C. Supplied Supplied with with aa FREE FREE traceable traceable certifi certificate cate of of calibration calibration the the RayTemp RayTemp 22 (order (order code code 228-020) 228-020) is is economically economically priced, priced, at at £30 £30 each each exclusive exclusive of of VAT VAT and and carriage carriage and and is is available available direct direct from from www.etiltd.com www.etiltd.com

Tel: Tel: 01903 01903 202151 202151

Email Email sales@etiltd.co.uk sales@etiltd.co.uk

Sensor adjustment made easy with latest HBM technology

Panasonic HG-C Laser distance sensor

As As sensors sensors in in aa force force shunt shunt must must be be calibrated calibrated together together with with their their system system after after assembly, assembly, the the new new Adjustment Adjustment Assistant Assistant from from HBM HBM –– market market leader leader in in the the ﬁﬁeld eld of of test test and and measurement measurement –– makes makes this this process process simple. simple.

Panasonic Panasonic oﬀ oﬀers ers the the laser laser distance distance sensor sensor HG-C HG-C with with aa repeatability repeatability of of 10µm 10µm and and aa response response time time of of 1.5ms 1.5ms at at an an unbeatable unbeatable price. price. The The distance distance sensor sensor HG-C HG-C opens opens up up many many new new possibilities possibilities for for industrial industrial automation. automation. For For example, example, the the sensor sensor is is optimally optimally suited suited for for positioning positioning robot robot arms, arms, measuring measuring the the position position of of hoops, hoops, checking checking for for the the presence presence of of very very small small objects objects or or checking checking for for the the overlapping overlapping of of even even the the thinnest thinnest types types of of material. material.

Designed Designed to to quickly quickly and and reliably reliably calibrate calibrate sensors sensors together together with with the the PMX PMX industrial industrial ampliﬁ ampliﬁer er system system from from HBM, HBM, the the new new Adjustment Adjustment Assistant Assistant guides guides users users through through the the process process with with simple simple menu menu navigation navigation and and step step by by step step instructions, instructions, enabling enabling the the adjustment adjustment process process to to be be undertaken undertaken in in seconds. seconds. The The new new Adjustment Adjustment Assistant, Assistant, which which can can be be seamlessly seamlessly integrated integrated into into the the PMX PMX web web server server to to display display the the measurement measurement data data in in the the browser, browser, can can also also be be used used to to easily easily control control calibration calibration of of up up to to four four sensors sensors at at aa time. time.

The The sensor sensor has has both both digital digital switching switching and and analogue analogue outputs, outputs, enabling enabling integration integration into into existing existing applications. applications. The The sensor sensor can can be be used used in in place place of of normal normal switching switching photoelectric photoelectric sensors, sensors, or or can can be be used used as as aa measuring measuring device device in in proﬁ proﬁling ling and and measuring measuring the the contours contours of of components. components.

Measuring Measuring the the acting acting forces forces correctly correctly is is key key to to industrial industrial process process control control as as itit is is the the only only way way to to increase increase product product quality quality and and reduce reduce overall overall production production costs. costs. The The new new Adjustment Adjustment Assistant Assistant from from HBM HBM is is an an intuitive intuitive programme programme designed designed to to conveniently conveniently guide guide users users quickly quickly and and easily easily through through the the calibration calibration process. process.

You You only only need need the the function function keys keys to to conﬁ conﬁgure gure the the sensor sensor and and immediately immediately the the measured measured distance distance will will be be displayed displayed in in millimetres millimetres on on the the built-in built-in four-digit four-digit display. display. Additional Additional digital digital inputs inputs are are used used to to trigger trigger the the sensor, sensor, to to control control the the laser laser power, power, and and to to perform perform zero zero adjustment. adjustment.

Tel: Tel: 0208 0208 515 515 6000 6000 www.hbm.com www.hbm.com

Email: Email: Gaynor.bromley@eu.panasonic.com Gaynor.bromley@eu.panasonic.com www.panasonic-electric-works.co.uk www.panasonic-electric-works.co.uk

72 PECM PECM Issue Issue 21 21

Email: Email: info@hbm.com info@hbm.com

Measurement & Monitoring

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LumaSenseâ&#x20AC;&#x2122;s new Ratio Pyrometer with Automatic Transition between 1-color and 2-color Measurement The IGAR 6 Advanced employs a unique switchover technology that transitions between modes, creating a very long temperature measurement range.

umaSense Technologies oďŹ&#x192;cially introduced the IMPACÂŽ IGAR 6 Advanced, a digital, compact pyrometer with 1-color, 2-color, and Smart operating modes for noncontact temperature measurement in ranges between 100 to 2000 Â°C. This product is unique not only because of the wide temperature range, but because of the seamless â&#x20AC;&#x2DC;switchoverâ&#x20AC;&#x2122; technology,â&#x20AC;? This technology, known as Smart Mode, allows the pyrometer to measure temperature in 1- color mode at low temperatures (100 to 250 Â°C) and then transition to 2-color mode to provide the advantages of measurements in ratio mode at higher temperatures (280 to 2000 Â°C). The automatic, smooth transition from

1-color to 2-color measurement occurs between 250 and 280 Â°C. In addition, the pyrometer can operate in 1-color mode (100 to 2000 Â°C) and 2-color mode (250 to 2000 Â°C). The large temperature range, compact size, and new Smart Mode make the IGAR 6 Advanced pyrometer ideally suited for many diďŹ&#x20AC;erent industrial manufacturing applications such as induction heating, hardening, tempering/annealing, brazing, sintering, vacuum processes, coating, and laser heat treatment. Presented at various events in Europe and USA, show visitors previewed the instrument last month and raved about the large temperature range, the diďŹ&#x20AC;erent operating modes, and other features such as the automatic

emissivity determination and optional line optics. These additional features make this instrument unique and create opportunities to measure processes not considered previously and those not measured with appropriate accuracy. Contact: LumaSense Technologies GmbH, Frankfurt/M. Germany www.Lumasenseinc.com info@lumaseneinc.com

Issue 21 PECM

Latest range of strain gauges from HBM rise to the challenge HBM –– aa market market

leader leader in in the the fi field eld of of test test and and measurement measurement – – is is pleased pleased to to announce announce it it has has expanded expanded its its range range of of optical optical strain strain transducers, transducers, which which have have been been specifi specifically cally developed developed to to meet meet the the demanding demanding requirements requirements of of harsh harsh applications. applications. Suitable Suitable for for use use in in challenging challenging environments, environments, such such as as structure structure monitoring monitoring of of pipelines pipelines and and bridges bridges and and for for measuring measuring high high strains, strains, the the latest latest range range of of sensors sensors from from HBM HBM off offer er aa wider wider strain strain measurement measurement range range for for these these types types of of applications, applications, alongside alongside greater greater stability stability and and lower lower installation installation costs, costs, compared compared to to electrical electrical strain strain gauges. gauges. Featuring Featuring aa rugged rugged and and fl flexible exible design, design, the the latest latest innovative innovative range range of of strain strain gauges gauges from from HBM HBM features features steel-reinforced steel-reinforced fi fiber ber cables cables and and special special strain strain relief relief and and

74 PECM PECM Issue Issue 21 21

can can be be used used for for strains strains of of at at least least ±2000 ±2000 µm/m µm/m in in aa temperature temperature range range from from -40°C -40°C to to +80°C. +80°C.

The OR-W & OR-L weldable optical strain gauge are installed using a simple spot welding process that requires hardly any preparation The The OR-W OR-W & & OR-L OR-L weldable weldable optical optical strain strain gauge gauge are are installed installed using using aa simple simple spot spot welding welding process process that that requires requires hardly hardly any any preparation. preparation. Only Only aa little little practice practice is is needed needed for for the the user. user. Watch Watch our our short short video video on on the the easy easy installation installation thanks thanks to to spot spot welding welding method method HBM HBM has has been been aa leader leader in in Strain Strain Gauges Gauges for for over over 60 60

years. years. Its Its extensive extensive range range allows allows for for an an exceptionally exceptionally wide wide range range of of diﬀ diﬀering ering strain strain measurement measurement applications, applications, from from experimental experimental stress stress analysis, analysis, durability durability testing testing through through to to transducer transducer manufacturing. manufacturing. Additionally, Additionally, HBM HBM provides provides all all the the necessary necessary accessories accessories and and components components for for the the installation installation of of Strain Strain

Gauges, Gauges, for for maximum maximum convenience. convenience. HBM HBM also also supports supports its its customers customers with with training training and and contract contract installation installation to to ensure ensure optimum optimum operational operational usage. usage. For For more more information, information, please please contact contact HBM HBM on on +44 +44 (0) (0) 208 208 515 515 6000 6000 or or visit visit www.hbm.com www.hbm.com

HBM Strain Gauges Fast Ordering. Quick Delivery.

HBM has been offering strain gauges for both stress analysis and transducer design for over 65 years! With over 260 types of strain gauges available in our online shop, ordering your strain gauges has never been this fast and easy. In addition: ■

Optical fiber Bragg (FBG) sensors are available for high-precision measurements even under difficult and harsh environments!

■

If you are an OEM manufacturer, HBM specializes in custom strain gauges and sensors, from the design phase all the way to the finished product.

Visit the HBM website today to download a FREE eBook on everything you need to know about strain gauges, as well as an online tool that will help you find the equivalent HBM strain gauge to your current strain gauge.

For more information visit: www.hbm.com/sg-pecm

HBM United Kingdom Ltd

■

Tel. 0208 515 6000

■

info@uk.hbm.com

■

www.hbm.com

NEW online purchasing website Labfacility have just launched a NEW online purchasing website featuring our full range of Temperature Sensors, Thermocouple Connectors, Thermocouple Cables and associated Temperature Instrumentation – Please visit www.labfacility.com for immediate despatch from stock worldwide. Temperature Temperature Sensors Sensors Labfacility Labfacility are are the the UK’s UK’s leading leading manufacturer manufacturer of of Thermocouple Thermocouple and and PRT PRT sensors, sensors, made made in in our our South South Yorkshire Yorkshire site. site. Standard Standard confi configurations gurations are are off offered ered in in all all of of the the widely widely used used calibrations, calibrations, type type J,K,T,E,N,R,S J,K,T,E,N,R,S and and B.. B.. Depending Depending on on the the choice choice of of sensor sensor type type and and sheath sheath materials, materials, temperature temperature ratings ratings of of up up to to 1750oC 1750oC are are available available with with single single or or duplex duplex elements. elements. The The comprehensive comprehensive stock stock of of mineral mineral insulated insulated thermocouples thermocouples features features 0.5mm 0.5mm sheath sheath diameter diameter versions versions in in addition addition to to 1.0mm, 1.0mm, 1.5mm, 1.5mm, 3.0mm 3.0mm and and 6.0mm. 6.0mm. The The 0.5mm 0.5mm diameter diameter thermocouples thermocouples combine combine low low thermal thermal mass mass and and fast fast response response to to temperature temperature changes changes with with durable durable construction; construction; they they are are highly highly fl flexible exible and and their their use use minimizes minimizes process process intrusion. intrusion. Mineral Mineral insulated insulated PRT PRT sensors sensors are are available available in in aa range range of of diameters diameters and and confi configurations gurations to to meet meet the the need need for for high high accuracy, accuracy, high high stability, stability, sheath sheath fl flexibility exibility and and robust robust construction. construction. Resistance Resistance Thermometer Thermometer Sensing Sensing Resistors Resistors Labfacility Labfacility off offers ers aa range range of of high high quality quality Pt100 Pt100 and and Pt1000 Pt1000 sensing sensing resistors resistors in in wire-wound wire-wound and and thin-fi thin-film lm types. types. The The range range includes includes surface surface mount mount versions versions and and glass glass encapsulated encapsulated types types for for those those applications applications requiring requiring the the highest highest stability stability and and hermetic hermetic sealing. sealing. All All Pt100 Pt100 sensors sensors comply comply with with IEC751 IEC751 and, and, depending depending on on construction, construction, are are available available

Labfacility is the UK’s leading manufacturer of Temperature Sensors , Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables . The Company has been trading for 45 years, is ISO 9001 accredited, employs 70 staff over two UK sites - West Sussex and South Yorkshire and exports to over 85 countries. In addition to the stocked items , Labfacility also offers bespoke Temperature Sensors.

in in Class Class A, A, B B and and 1/3, 1/3, 1/5 1/5 and and 1/10 1/10 DIN DIN tolerances. tolerances. Dimensions Dimensions range range from from sub-miniature sub-miniature to to 50mm 50mm length length to to suit suit any any application application and and optional optional extended extended terminations terminations are are available available to to order. order. Probe Probe Installation Installation Fittings Fittings Labfacility Labfacility also also manufactures manufactures aa wide wide range range of of components components and and fi fittings ttings for for sensor sensor installation installation and and manufacture manufacture at at our our West West Sussex Sussex site. site. These These include include pot pot seals seals for for mineral mineral insulated insulated thermocouples, thermocouples, bayonet bayonet caps caps and and adaptors adaptors and and closed closed end end protection protection tubes. tubes. Additional Additional components components include include compression compression glands, glands, melt melt bolts, bolts, thermowells thermowells and and aa wide wide range range of of terminal terminal heads. heads. Buy Buy online online www.labfacility.com www.labfacility.com quoting quoting code code PECM5 PECM5 for for aa 5% 5% discount discount on on all all products products for for the the month month of of March March 2016! 2016! Labfacility Labfacility Ltd Ltd Bognor Bognor Regis Regis Tel: Tel: +44(0)1243 +44(0)1243 871280 871280 Sheffi Sheffield eld Tel: Tel: +44(0)1909 +44(0)1909 569446 569446 info@labfacility.com info@labfacility.com

TRUSTPILOT TRUSTPILOT REVIEWS REVIEWS please please see see our our latest latest customer customer reviews reviews on on our our website!s website!s

Measurement & Monitoring

Mydax Celebrates 30th Anniversary 1986-2016 Mydax Mydax is is proud proud to to announce announce that that we we are are celebrating celebrating our our 30th 30th year year in in business. business. Starting Starting in in February February 1986 1986 with with our our patented patented refrigeration refrigeration circuit circuit utilizing utilizing embedded embedded computer computer control, control, our our slogan slogan of of â&#x20AC;&#x153;Advanced â&#x20AC;&#x153;Advanced Temperature Temperature Control Control Technologyâ&#x20AC;? Technologyâ&#x20AC;? still still holds holds true true today. today. With With the the ability ability to to provide provide extreme extreme temperature temperature stabilities stabilities of of Âą0.05Â°C Âą0.05Â°C for for critical critical applications, applications, even even with with high high cooling cooling power power requirements requirements up up to to 70kW, 70kW, Mydax Mydax is is bringing bringing laboratory laboratory precision precision to to the the industrial industrial market. market. Mydax Mydax also also oďŹ&#x20AC; oďŹ&#x20AC;ers ers the the CryoDax CryoDax series series of of chiller chiller systems systems for for the the most most demanding demanding requirements requirements with with ďŹ&#x201A;ďŹ&#x201A;uid uid temperature temperature ranges ranges of of -70Â°C -70Â°C to to +150Â°C +150Â°C with with cooling cooling capacities capacities from from 3kW 3kW up up to to 30kW 30kW or or more more at at -40Â°C -40Â°C available. available. Please Please call call or or visit visit Mydax Mydax online online for for more more information. information. 00-1-530-888-6662 00-1-530-888-6662 â&#x20AC;˘â&#x20AC;˘ sales@mydax.com sales@mydax.com info@mydax.com info@mydax.com â&#x20AC;˘â&#x20AC;˘ www.mydax.com www.mydax.com Mydax Mydax Inc. Inc. 12260 12260 Shale Shale Ridge Ridge Ln, Ln, Auburn, Auburn, Ca. Ca. 95602 95602 USA USA

Vibration Monitoring Services Limited Vibration and Thermal Imaging Surveys Specialists in providing cost effective and professional Vibration Monitoring and Thermal Imaging Surveys

Surveys in: â&#x20AC;˘â&#x20AC;˘ Machine Vibration

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78 PECM PECM Issue Issue 21 21

â&#x20AC;˘â&#x20AC;˘ Building Vibration

Tel: Tel: 01795 01795 877177 877177 or or 07840 07840 791587 791587 Email: Email: enquiries@vmservicesltd.co.uk enquiries@vmservicesltd.co.uk www.vibrationmonitoringservices.co.uk www.vibrationmonitoringservices.co.uk

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Measurement & Monitoring

Creating Environments

Temperature & Climatic Chambers Test & Evaluation Systems

Tel: 01628 850611 www.unitemp.co.uk

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INSTRUMENTS THAT BECOME PART OF YOU. HYDROTECHNIK UK UK LIMITED LIMITED

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80 PECM PECM Issue Issue 21 21

MEASURING INSTRUMENT

Mahr

MarSurf PS10 MOBILE

Celebrating

YEARS IN UK

YOUR PARTNER IN MODERN METROLOGY We are happy to present to you the New Mobile Roughness Measuring Unit

This device is the perfect entry into the world of Surface Metrology from Mahr and will convince you with its comprehensible and intuitive operation. The 4.3”TFT touch screen display can be rotated in any direction. MarSurf PS10 can be used flexibly with the removable drive unit. The new feature is the integrated but removable calibration standard. PRODUCT FEATURES PRODUCT FEATURES MarShaft Scope Robot MarForm MFK Range ◼ Small and lightweight; ideal as mobile surface ◼ Individual sampling lengths and shortened cutoff can roughness measuring instruments be selected ◼ Direct access to your customized functions ◼ Phase-correct profile filter (Gaussian filter) acc. To DIN ◼ 31 parameters: offer the same range of functions as EN ISO 16610-21 (before DIN EN ISO 11562), special filter acc. to DIN EN ISO 13565-1, ls-filter acc. to DIN EN a laboratory instrument ◼ Data is saved in the device, e.g. TXT, X3P, CSV and ISO 3274 (disengageable) PDF file ◼ Evaluation of most common parameters conforming APPLICATIONS to standards and in accordance to ISO/JIS as well as ◼ On-Site Surface roughness measurment parameter lists ◼ Measuring during the production process ◼ Select standards (DIN-ISO/JIS/ASME/MOTIF) ◼ Universal use on processing machinery ◼ Automatic cutoff selection (patented) to ensure ◼ For incoming goods inspection correct measuring results

19 Drakes Mews, Crownhill, Milton Keynes, MK8 0ER, United Kingdom

Email: info@mahruk.com Website: www.mahruk.com Tel: 01908 563700

New level radar for chemical pilot plants

The The new new VEGAPULS VEGAPULS 64, 64, the the world’s world’s fifirst rst radar radar level level sensor sensor for for liquids liquids with with 80 80 GHz, GHz, now now has has an an antenna antenna system system integrated integrated directly directly into into the the flflush ush process process fifitting. tting.

The unrivalled focusing of the new 80 GHz VEGAPULS 64 allows for more flexibility in the chemical industry

n n recent recent years, years, non-contact non-contact radar radar level level measurement measurement technology technology has has been been used used in in ever ever more more application application areas areas in in the the chemical chemical industry. industry. The The big big advantage advantage of of radar radar technology technology is is its its immunity immunity to to process process conditions conditions such such as as temperature, temperature, pressure, pressure, vacuum vacuum and and density. density. The The main main limitation limitation in in the the past past has has been been the the vessel vessel size size it it can can work work on. on. With With the the new new VEGAPULS VEGAPULS 64, 64, using using aa much much higher higher frequency, frequency, it it means means the the level level and and volume volume can can now now be be measured measured in in applications applications where where the the process process and/ and/

or or structural structural conditions conditions were were previously previously not not suitable suitable for for radar. radar. Because Because of of the the current current trend trend in in the the chemical chemical industry industry is is towards towards smaller, smaller, specialized specialized more more proﬁ proﬁtable table batches. batches. The The resulting resulting equipment equipment and and containers containers generally generally have have smaller smaller dimensions dimensions and and reduced reduced volumes. volumes. However, However, engineers engineers and and technicians, technicians, especially especially those those in in research research centres centres and and pilot pilot plants, plants, ran ran up up against against limits limits again again and and again again when when they they tried tried to to use use radar radar level level measurement measurement technology technology

in in these these very very small small production production setups. setups. Factors Factors like like available available connections connections versus versus size size and and design design of of the the antennas, antennas, large large amounts amounts of of internal internal structures structures and and the the sensor sensor dead dead bands, bands, where where the the reliability reliability and and accuracy accuracy is is reduced reduced at at the the tank tank top top and and bottom, bottom, all all caused caused issues. issues. This This often often led led to to the the use use of of weighing weighing systems systems or or pressure pressure transmitters transmitters instead, instead, which which have have their their own own problems problems with with changing changing density density and and very very small small pressures pressures ranges. ranges. The The new new VEGAPULS VEGAPULS 64, 64, the the world’s world’s fi first rst radar radar level level sensor sensor for for liquids liquids with with 80 80 GHz, GHz, now now has has an an antenna antenna system system integrated integrated directly directly into into the the fl flush ush process process fi fitting. tting. Since Since no no antenna antenna protrudes protrudes into into the the vessel, vessel, it it is is possible possible to to measure measure right right up up to to the the process process fi fitting tting itself. itself. This This gives gives greater greater fl flexibility, exibility, because because practically practically all all of of the the container container volume volume can can be be measured measured and and utilized. utilized. Thanks Thanks to to the the more more tightly tightly focused focused measuring measuring beam beam – – with with an an antenna antenna diameter diameter of of 80 80 mm mm the the transmission transmission signal signal has has an an angle angle of of just just 3° 3° – – using using the the instrument instrument in in tanks tanks with with aa lot lot of of internals internals such such as as heating heating coils coils and and agitators agitators has has become become much much easier. easier. It It also also off offers ers aa signifi significant cant advantage advantage for for use use in in very very small small vessels, vessels, with with antenna antenna process process fi fittings ttings from from only only ¾”. ¾”. Another Another advantage advantage is is its its capability capability in in longer, longer, narrower narrower process process connections, connections, this this new new radar radar can can be be mounted mounted in in longer longer nozzles nozzles that that have have proved proved too too challenging challenging for for many many non-contact non-contact devices devices in in the the past. past. It It is is even even working working through through process process isolation isolation valves valves and and it it can can be be mounted mounted much much closer closer to to the the vessel vessel edge, edge, an an important important factor factor for for larger larger vessels vessels in in the the chemical chemical sector. sector. When When process process conditions conditions are are tough tough inside inside the the vessel, vessel, especially especially when when there there is is build build up, up, condensation, condensation, foam foam or or aa turbulent turbulent liquid liquid surface surface in in the the vessel, vessel, the the very very large large dynamic dynamic range range of of VEGAPULS VEGAPULS 64 64 delivers delivers aa much much higher higher measurement measurement certainty. certainty. Find Find out out more more information information on on this this amazing amazing new new technology technology and and its its abilities abilities by by going going to to www.vega.com/radar www.vega.com/radar

82 PECM PECM Issue Issue 21 21

A perfect view â&#x20AC;&#x201C; even with condensation! The future is 80 GHz: a new generation of radar level sensors

For the latest generation of radars, condensate on the sensor is not an issue. Totally unaffected by condensation or buildup on the antenna, VEGAPULS 64 accurately detects the liquid level. With the smallest antenna of its kind and exceptional focusing, it delivers outstanding performance every time. Simply world-class! www.vega.com/radar

providing NEW portable temperature calibrators with greater accuracy and additional features New 4000 Range covering -45Â°C to 1200Â°C Portable Dry Blocks, Liquid Baths and Multifunction Heat Sources Three versions from a Basic Heat Source to an ADVANCED Model with inbuilt three channel thermometer, data logging and automatic temperature cycling New Rugged Lightweight Outer Cases

Call now to request a FREE on-site demonstration - 01704 543830

Isothermal Isothermal Technology Technology Limited Limited Pine Pine Grove, Grove, Southport, Southport, Merseyside Merseyside PR9 PR9 9AG 9AG England England Telephone: Telephone: +44 +44 (0)1704 (0)1704 543830 543830 Fax: Fax: +44 +44 (0)1704 (0)1704 544799 544799 Email: Email: info@isotech.co.uk info@isotech.co.uk

www.isotech.co.uk www.isotech.co.uk

The Universal Digester, Flexible Options Provide Long-Life Tank Solutions

ith the advent of the

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Additional advantages of the double

new AMP6 TOTEX cost

the entire filled height of the tank. Good

seam build system include rapid on-site

requirements taking

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precedence in assessing

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new tank and Anaerobic Digester

the fermentation process. Flexible options

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Digester the ideal, individually tailored AD

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container solution, for the current market

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requirement for long lasting industrial

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and Water Utility Anaerobic Digestion

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When combined with an external gas

Martin Grant, Lipp's UK Sales and

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Marketing manager states that, "Part of the

Lipp offer a range of different Digester

an excellent, long-lasting tank solution

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models and specifications; the Universal

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Digester is an additional development

5,000 m3. Built using Lipp's automated

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for large industrial and municipal plants.

double seam system, the flexible

working with suppliers that have a long

Maximum life is the central focus for this

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track record and have successful client

container, with a stainless steel tank, using

adaptability have been proven over

product examples that demonstrate that

Lipp's VERINOXâ&#x201E;˘ composite stainless steel

hundreds of projects worldwide.

longevity in the field. Lipp's numerous

service life are just right for the new UK Water Utility market requirements.

material, combined with a welded stainless

International tank installations over several

steel diaphragm roof ensuring the highest

decades clearly show that capability".

quality for the inner part of the container. As a post-digester, the Universal Digester

www.lipp-system.de

is also an ideal solution for farming applications. The Universal Digester, just like Lipp's fully integrated KomBio Digester, enjoys the advantages of external heating, which, thanks to the good thermal conductivity of the steel wall, and the clear interior

Issue 21 PECM

Smaller, Faster, Hotter: Optimisation of Bearings for Challenging Applications Adding Adding new new design design features features or or applying applying

making making itit more more robust robust and and resistant resistant to to oiloil-

extend lubricant lubricant life, life, sometimes sometimes up up to to five five extend

special special techniques techniques and and coatings coatings to to

off off events. events. In In the the case case of of lubricant lubricant failure/ failure/

times longer longer than than conventional conventional steel steel ball ball times

bearing bearing components components can can optimise optimise the the

starvation, starvation, the the silver-plating silver-plating acts acts like like aa

bearings. bearings.

performance performance of of bearings bearings for for challenging challenging

solid, solid, dry dry lubricant, lubricant, allowing allowing the the bearing bearing to to

applications, applications, providing providing unique unique bearing bearing

continue continue running running for for aa short short period period of of time time

Examples of of applications applications for for ceramic ceramic Examples

solutions solutions to to clients’ clients’problems, problems, says says Nick Nick

or or in in an an emergency emergency situation. situation. Application Application

hybrid bearings bearings include include high-speed high-speed hybrid

Dowding, Dowding, Business Business Development Development Manager Manager

examples examples include include aerospace aerospace starter starter

vacuum pumps, pumps, medical/surgical medical/surgical hand hand vacuum

at at The The Barden Barden Corporation Corporation (UK) (UK) Ltd. Ltd.

generator generator bearings bearings and and bearings bearings for for air air

tools and and aerospace aerospace fans fans and and generators. generators. tools

conditioning conditioning units units on on trains. trains. • •

Adding Adding value value and and improving improving bearing bearing performance performance by by incorporating incorporating new new design design features features such such as as special special flanges, flanges, shafts shafts and and housings. housings.

• •

Materials

Ceramic hybrid bearings

In In materials materials technology, technology, the the most most

For For high-speed high-speed applications, applications, replacing replacing the the

appropriate appropriate bearing bearing materials materials can can

steel steel balls balls with with ceramic ceramic (silicon (silicon nitride) nitride)

be be selected selected to to maximise maximise bearing bearing

Optimising Optimising bearing bearing performance performance by by

balls balls can can radically radically improve improve bearing bearing

performance. performance. Special Special ring ring materials materials

replacing replacing traditional traditional bearing bearing materials materials

performance performance in in several several ways. ways. First, First, because because

are are used used successfully successfully in in aerospace aerospace and and

with with special special materials materials for for high high speed, speed,

ceramic ceramic balls balls are are much much lighter lighter than than steel steel

non-aerospace non-aerospace applications, applications, combining combining

high high temperature temperature or or harsh harsh operating operating

balls, balls, reducing reducing centrifugal centrifugal forces forces and and

superior superior corrosion corrosion and and wear wear resistance resistance

environments. environments.

improving improving dynamic dynamic conditions conditions whilst whilst their their

with with the the ability ability to to withstand withstand higher higher

The The use use of of surface surface coatings coatings such such as as

surface surface finish finish is is almost almost perfectly perfectly smooth, smooth,

dynamic dynamic loads loads than than conventional conventional bearing bearing

sub-micron sub-micron sputtered sputtered coatings coatings to to

they they exhibit exhibit vibration vibration levels levels two two to to seven seven

steels. steels. When When used used in in conjunction conjunction with with

further further optimise optimise bearing bearing performance performance

times times lower lower than than conventional conventional steel steel

ceramic ceramic balls, balls, significant significant gains gains in in bearing bearing

and and to to make make bearing bearing behaviour behaviour

ball ball bearings. bearings. At At higher higher speeds, speeds, internal internal

life life and and performance performance can can be be achieved. achieved.

more more predictable/consistent predictable/consistent in in harsh harsh

loading loading in in the the bearing bearing is is also also reduced. reduced.

environments. environments. Secondly, Secondly, ceramic ceramic hybrid hybrid bearings bearings also also There There are are many many different different design design features features

run run at at significantly significantly lower lower operating operating

and and techniques techniques that that can can be be applied applied to to

temperatures, temperatures, which which in in conjunction conjunction with with

aa bearing bearing to to optimise optimise and and improve improve its its

the the lower lower mass mass allows allows running running speeds speeds to to

performance performance in in order order to to meet meet particularly particularly

increase increase by by as as much much as as 40-50%. 40-50%. Lower Lower

challenging challenging (i.e. (i.e. high high speed, speed, high high

operating operating temperatures temperatures and and reduced reduced

temperature, temperature, harsh harsh operating operating conditions) conditions)

heat heat build build up up inside inside the the bearing bearing helps helps

applications. applications. These These techniques techniques include include applied applied coatings, coatings, altering altering the the geometry geometry of of aa specific specific bearing bearing component component or or replacing replacing conventional conventional bearing bearing materials materials with with high high performance performance alternatives. alternatives.

Ring materials can be optimised for specific applications. The four predominant ring materials used by Barden are AISI 440C (corrosionresistant steel), SAE 52100, AISI M50 and Cronidur 30®. For high temperature applications (up to 345°C) AISI M50 tool steel or a special tempered version of Cronidur 30® are suitable and are widely used in high temperature aerospace accessory applications such as bleed valve systems on aircraft.

Silver-plating of metal cages In In some some high high speed, speed, high high temperature temperature applications, applications, steel steel cages cages can can be be coated coated with with silver silver to to improve improve lubrication lubrication performance performance and and reliability. reliability. Silver Silver plating plating improves improves the the lubricity lubricity of of the the bearing, bearing,

PECM PECM Issue Issue 21 21

Cronidur Cronidur 30® 30® is is aa martensitic martensitic throughthroughhardened, hardened, high high nitrogen, nitrogen, corrosioncorrosionresistant resistant steel steel that that can can also also be be induction induction case case hardened. hardened. This This material material enhances enhances corrosion-resistance corrosion-resistance and and improves improves the the fatigue fatigue life life and and wear wear resistance. resistance.

Full complement bearings Full complement bearings capitalise on the space normally occupied by the ball retainer. This allows for more balls, which in turn provides an increase in load capacity, either predominantly radial, in the case of filling notch designs, or axial and in the case of angular contact designs. The use of preloaded angular contact pairs can also allow bi-directional axial loads to be applied. Applications here range from high temperature valves for aerospace applications, to missile fin supports and emergency touch down bearings.

Sub-micron coatings

and tribological characteristics of bearing surfaces. The success of such techniques relies on the avoidance of distinct layers by generating a graduated or diffused interface between different materials. Similarly, keying layers such as nickel or copper are frequently used to improve the adhesion of soft films to hard or passivated substrates. Sub-micron coatings can be applied to the internal and external surfaces of bearing rings and rolling elements if required. For example, molybdenum disulphide (MOS2) or tungsten disulphide (WS2) can be sputter coated to the surface of bearing components in order to make bearing

The role of surface engineering in rolling

behaviour more predictable in harsh

bearing technology is also becoming

environments.

increasingly important as bearings get progressively smaller, but are still required

Special polymers

to run faster, at higher temperatures,

In some high speed applications, the

carry higher loads and operate reliably for longer periods.

can be applied to bearings that combat

with oil to increase the life of the bearing.

friction, prevent corrosion and reduce

The special polymer material retains the

wear, even under the harshest operating

oil in a controlled manner when vacuum

conditions. The resulting benefits

impregnated. Application examples

are higher power density, improved

include bearings for high speed aircraft

performance, more predictable/consistent

gyros.

longer service intervals. Multi-layer submicron (sputtered) coatings, for example, can be employed to enhance the physical

of manufacturing means that the integration of bearing systems into mating components is becoming more common. The resulting assemblies are neater, more compact, faster to put together and offer the additional benefits of reducing space and mass, whilst resolving the issues of tolerance stack-up. For more information, please contact the Barden Marketing Department on +44 (0)1752 725531, visit the website at www.bardenbearings.co.uk or email: caroline.evans@schaeffler.com

in special polymer materials. These components are vacuum-impregnated

environments), lower running costs and

Pressure to reduce costs in all areas

ball separators or cages can be supplied

Advanced coatings and surface treatments

bearing behaviour (particularly in harsh

Adding value through new design features

Other special polymers can be provided for high speed harsh environments where the bearings require high resistance to chemicals or thermal attack.

Special design features can be incorporated into the bearing to improve its performance. These features include flanges, shafts and housings, which make fitting easier, faster and more accurate, which in turn, reduce assembly time and overall operating costs.

Process Technologies Heraeus Infra-Red Heating System Helps in The Manufacture of Auto Glass

A A fast fast response response medium medium wave wave (FRMW) (FRMW) infra-red infra-red heating heating system system from from Heraeus Heraeus Noblelight Noblelight is is helping helping Dura Dura Automotive Automotive Systems Systems of of Castle Castle Bromwich Bromwich to to ensure ensure the the reliable reliable and and precise precise adhesion adhesion of of molded molded thermoplastic thermoplastic sealings sealings to to custom-designed, custom-designed, automotive automotive glass glass windows. windows. The The system system is is located located in in aa robotic robotic cell cell and and integrates integrates exactly exactly with with the the robot robot cycle. cycle.

Tel: Tel: 0208 0208 339 339 7370 7370 Fax: Fax: 0208 0208 339 339 7371 7371

Unit Unit 55 Russell Russell House, House, Molesey Molesey Road Road Walton-on-Thames, Walton-on-Thames, Surrey Surrey KT12 KT12 3PE 3PE

Email: Email: sales@blackfast.com sales@blackfast.com

Dura Dura contacted contacted Bauromat Bauromat (UK) (UK) Ltd Ltd aa recognised recognised leader leader in in robot robot manufacturing manufacturing cells. cells. Consequently, Consequently, aa cell cell featuring featuring two two Kuka Kuka robots robots was was installed installed to to carry carry out out the the delicate delicate operation operation of of applying applying aa prime prime adhesive adhesive coating coating to to the the quarter quarter glass glass to to allow allow aa molded molded seal seal to to be be affi affixed xed in in aa subsequent subsequent operation. operation. However However to to ensure ensure ideal ideal adhesion adhesion of of the the molded molded seal seal to to the the prime prime coating coating it it was was necessary necessary to to heat heat the the coating coating to to aa specifi specified ed temperature temperature to to achieve achieve the the required required cure cure and and “tackiness” “tackiness” before before the the glass glass is is precisely precisely over-molded over-molded in in aa further further operation. operation. Infra-red Infra-red was was considered considered to to provide provide the the best best solution solution to to this this problem. problem. Unlike Unlike aa warm warm air air oven, oven, an an infra-red infra-red system system takes takes up up very very little little space, space, can can be be precisely precisely controlled controlled to to synchronise synchronise with with the the robot robot operations operations and and is is very very energy-effi energy-efficient cient

Web: Web: www.blackfast.com www.blackfast.com

www.heraeus-infraredsolutions.co.uk www.heraeus-infraredsolutions.co.uk

Save energy & save money! Air Air Dryer Dryer Technology Technology is is an an independent independent specialist specialist company company providing providing service service and and after after sales sales support support on on all all types types and and makes makes of of compressed compressed air/gas air/gas dryer, dryer, fi filtration ltration and and condensate condensate management management systems. systems. The The main main activity activity is is providing providing technical technical support support and and comprehensive comprehensive packages packages for for on-site on-site servicing servicing of of compressed compressed air/gas air/gas treatment treatment equipment equipment and and desiccant desiccant air air drying drying plant. plant. Air Air Dryer Dryer Technology Technology also also provides provides consultancy consultancy and and equipment equipment upgrades upgrades to to increase increase effi efficiency ciency and and reduce reduce energy energy costs. costs. Retrofi Retrofitting tting aa dryer dryer control control system system provides provides signifi significant cant benefi benefits ts by by operating operating to to actual actual site site conditions, conditions, rather rather than than original original design design specifi specification. cation. It It will will also also restore restore customer customer confi confidence dence in in equipment equipment operation operation and and performance. performance. Installing Installing aa dewpoint dewpoint control control system system to to aa compressed compressed air air desiccant desiccant dryer dryer will will save save energy, energy, considerably considerably reduce reduce operating operating costs, costs, and and provide provide effi efficient cient dewpoint dewpoint control. control. Features Features and and benefi benefits ts include; include; •• •• •• •• •• •• •• ••

Controls Controls Compressed Compressed Air Air Monitor Monitor Dewpoint Dewpoint Extends Extends Service Service Time Time Extend Extend Cycle Cycle Time Time Constant Constant Dryer Dryer Knowledge Knowledge Retroﬁ Retroﬁtt Design Design Record Record Performance Performance Data Data Installation Installation Service/Technical Service/Technical Support Support

Tel: Tel: 0161 0161 788 788 7900 7900

88 PECM PECM Issue Issue 21 21

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

www.airdryertechnology.com www.airdryertechnology.com

Process Technologies

• Oil-water separators • Service kits • Condensate solutions

Quality

that goes on and on

To sustain the quality that you have come to expect from Sepura, our products can now only be obtained through our selected distributors.

Remember, if it doesn’t say SEPURA on the label its not SEPURA

SILEXA™ filtration media inside

To find your nearest distributor please visit our website

www.sepura-technologies.com

+44 (0)1543 379212

e: sales@sepura-technologies.com

Issue 21 PECM

KECOL

STILL NO.1 FOR VISCOUS PUMPING SOLUTIONS With over 25 years experience in pumping viscous materials, Kecol is the number one choice of many of the World’s leading pharmaceutical, cosmetic and food manufacturers. Kecol equipment is used to transfer flowable & non-flowable materials from drums, IBC’s, mixing vessels and process vessels of various shapes, sizes and designs, without heating the material. Kecol’s extensive range of equipment is designed to transfer products from triple concentrate Tomato Paste through to Petroleum Jelly and Mascara, quickly, cleanly and efficiently from standard 200 litre drums, tapered or conical drums fitted with an aseptic bag, tote bins and IBC’s. Our vast experience has shown there are never two applications the same and that’s why we also offer bespoke systems designed and manufactured to suit your specific vessels and production requirements.

System for IBC’s

Trolley Mounted Vertical or Horizontal pumps

System for 4 x pallet mounted drums

NOW ATEX APPROVED

Tel: 01746 764311

VISIT US ON STAND E41

Fax: 01746 763375 Email: sales@kecol.co.uk Here are just a few of the products we pump: • Petroleum Jelly • Magnesium Hydroxide • Mascara • Lanolin • Lip Gloss • Veterinary Creams • Eye Ointments •Paraffin Wax • Face Scrub • Teething Gels • Medical Adhesives • Toothpaste • Wax • Sun Lotions • Aluminium Hydroxide • Hand /Face Creams • Shaving Cream • Glycerine • Honey • Cake Batter • Butter • Mayonnaise • Peanut Butter • Fruit Concentrate • Margarine • Jam • Tomato Puree • Chopped Tomato • Pie Fillings • Syrups • Biscuit Creams • Caramel Products • Fruit Pastes •Cooking Fats • Fondants • Sweet Mince Meat • High Viscosity Grease • Mastic • Wood Filler • Silicon • Paint • Ink • Polymers • Epoxy Pastes • Sealants • Glue • Resin

www.kecol.co.uk

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

WE KEEP YOUR INDUSTRY RUNNING. TEMPERATURE SOLUTIONS FROM THE EXPERTS S

Complete consultative support and turnkey solutions to ensure your temperature control plant is as reliable and efficient as possible.

0800 774 7415

info@icscoolenergy.com TTH HEE TTEEM MPPEER RAT ATU UR REE CO CON NTTR RO OLL SSPPEC ECIIA ALLIISSTTS. S. SSA ALLEESS.. H HIIR REE.. SSEER RV VIIC CEE..

W WW WW.I W.ICSCO CSCOO OLLEEN NEER RGY.COM GY.COM

Product News Archco-Rigidon Tank Lining for Cristal Hertel (UK) Ltd of Middlesbrough, part of the Hertel leading international services company, are long-term users of Winn & Coales (Denso) Ltd’s Archco-Rigidon 403D glass flake vinyl ester coatings. One of the companies that Hertel has regularly been contracted to line internal surfaces of pipework, tanks and vessels is Cristal of Immingham (formerly known as Cristal Pigments). The latest project was to line a large tank that contains an agitator for one of Cristal’s processes. Following blast cleaning at Hertel’s premises of the internal surfaces of the tank to the Sa 2½ near white metal standard, the first coat of Archco-Rigidon 403D was applied to approximately 1000 microns. A second coat was applied to 1000 microns to achieve an overall thickness of 2000 microns. A final 250 microns coat of Archco-Rigidon Blue Wax Topcoat was then applied. Final thickness readings were taken and full holiday detection was carried out to ensure the work was in line with the specification requirements. Whilst the lining work was being applied by Hertel, Cristal representatives carried out inspections of the process to confirm that the work met the specification requirements.

Increase Reliability and Efficiency of your Weighing Process Even small inefficiencies can add up to big costs. Why settle for inefficient operations when you can improve overall productivity with innovative POWERCELL® technology from METTLER TOLEDO. Modern weigh modules with POWERCELL® technology help predict and diagnose issues before they even happen to avoid downtime and production problems - keeping your equipment running until repair is possible. METTLER TOLEDO’s accuracy white paper and batch-control checklist can help increase yield, reduce risks and enhance the efficiency of your weighing process. Stand-alone batch controller advantages also include:

Cristal mixer tank lined with Winn & Coales’ Archco-Rigidon 403 by Hertel (UK)

Tel: 020 8670 7511 Fax: 020 8761 2456 Email: denso.net www.denso.net

Digi International Introduces Cellular Gateway Solution for No or Low Power Locations Digi International® (NASDAQ: DGII, www.digi.com), a leading global provider of machine-to-machine (M2M) and Internet of Things (IoT) connectivity products and services, today introduced Digi Connect Sensor, a battery-powered, enterprise-ready, cellular gateway solution for wireless connectivity at locations with either no power or low power. In offering a plug-and-play solution, Connect Sensor allows for remote sensor monitoring to be deployed in environments previously considered too harsh, remote or not economically viable. With versatility and flexibility to accommodate off-the-shelf sensors, such as flow, level, pressure and environmental conditions, the newly announced cellular gateway solution will help make sensor use ubiquitous.

•

Minimum raw material wastage and risk through track and trace

•

Legislative compliance

•

Consistent results

•

Lower costs

www.mt.com/uk-SWB605-WP www.mt.com/uk-batch-checklist

Accurate, Simple Batch Control Systems Minimise material wastage, ensure legislative compliance and increase batch quality and proﬁtability by reducing under and overﬁlling. METTLER TOLEDO’s online video “Expert Guidance on Batching Control Systems” demonstrates how to eliminate unnecessary cost during production and improve productivity.

New Vibration Core Products Catalogue from ACE Fabreeka UK

Discover how the new checklist for Designing Batching Control Systems helps you improve your process explaining what should be considered with a new batching control system. You will also gain batching knowledge to maximise productivity and minimise costs in your operation.

ACE and Fabreeka have come together to become the new ACE Fabreeka UK. Both of these well recognised, market leading brands are available from one highly experienced team focused on the UK motion and vibration control market.

The rugged industrial batch controller IND780 can distribute to multiple controllers via ethernet connection from a single batch tool, easily managing changes to the batch process. Built in reports provide critical batch history information to help track and trace every step of your results.

The Digi Connect Sensor has immediate availability. Please visit http://www.digi.com/connectsensor for additional details.

A new 104-page Fabreeka Vibration Control core products catalogue is now available, giving designers, architects and structural engineers a comprehensive, technical overview of products to solve vibration and isolation problems. In addition to a very extensive range of products, ACE Fabreeka UK will also be able to oﬀer access to added value design and customer support services when more than just a product is necessary and a total vibration control solution is required. To get your copy of this new catalogue contact ACE Fabreeka UK on 01942 727440 or email: info@ace-fabreeka.co.uk

The error-free recipe guides assist operators through the process reducing material wastage and optimising consistency, speed and accuracy. To discover more watch the online batching video and download the free checklist.

www.mt.com/uk-ind-batching-webinar

Issue 21 PECM

Pumps Eliminate 52% of bearing failures

Lubrication Lubrication

Corrosion Corrosion

11%

Other Other

Overloading Overloading

4% Particle Particle Contamination Contamination

48% Misalignment Misalignment

13% Disassembly Disassembly

15%

A A major major study study into into equipment equipment reliability reliability has has shown shown 52% 52% of of all all bearing bearing failures failures are are due due to to particle particle contamination contamination and and corrosion corrosion caused caused by by water water contamination. contamination. 66 bearing bearing protection protection range range can can reduce reduce bearing bearing oil oil contamination contamination The The LabTecta LabTecta®®66 from from 83% 83% to to 0.0003% 0.0003% significantly significantly reducing reducing bearing bearing failure. failure. Visit Visit www.LabTecta.com www.LabTecta.com for for aa 3-minute 3-minute video video showing showing statistics statistics and and technology technology www.aesseal.com www.aesseal.com

Eliminate 52% of Bearing Failures LabTecta is a bearing protection seal that can eliminate bearing oil contamination, the major cause of 52% of bearing failures.

hen hen equipment equipment rotates rotates the the bearing bearing housing housing heats heats up up and and the the oil/air oil/air mixture mixture inside inside expands expands and and this this is is forced forced through through the the seal. seal. The The real real problem problem arises arises when when the the equipment equipment cools cools because because the the oil/air oil/air mixture mixture cools cools and and contracts contracts sucking sucking air air from from the the external external atmosphere atmosphere through through the the bearing bearing seal seal back back into into the the housing. housing. LabTecta LabTecta incorporates incorporates dynamic dynamic lift lift technology technology that that uses uses the the centrifugal centrifugal force force of of rotating rotating equipment equipment to to open open aa temporary temporary micro micro gap gap allowing allowing expansion expansion of of the the oil oil air air mixture mixture in in the the bearing bearing housing, housing, which which consequently consequently allows allows the the equipment equipment to to breathe. breathe. When When the the equipment equipment stops stops rotating rotating the the micro micro gap gap immediately immediately closes closes forming forming aa perfect perfect

94 PECM PECM Issue Issue 21 21

Figure Figure 1: 1: Water Water contamination contamination on on aa continuous continuous digester digester prior prior to to aa LabTecta LabTecta being being installed. installed.

seal, seal, preventing preventing dust dust and and moisture moisture being being sucked sucked back back into into the the bearing bearing housing housing and and eliminating eliminating bearing bearing oil oil contamination. contamination. Rated Rated to to IP66 IP66 of of the the ingress ingress protection protection code, code, LabTecta LabTecta is is capable capable of of reducing reducing water water contamination contamination of of the the bearing bearing oil oil from from as as high high as as 83% 83% to to just just 0.0003% 0.0003% compared compared to to lip lip seals, seals, even even when when exposed exposed to to high high pressure pressure water water jets. jets. The The range range is is ATEX ATEX certifi certified ed for for use use in in explosive explosive environments environments and and aa number number of of special special designs designs make make it it suitable suitable for for aa wide wide and and varied varied range range of of applications applications helping helping to to signifi significantly cantly reduce reduce downtime downtime due due to to bearing bearing failure. failure. www.aesseal.com www.aesseal.com

Figure Figure 2: 2: LabTecta LabTecta Bearing Bearing Protection Protection Seal Seal

A PREVIEW OF THE

VERDERFLEX VANTAGE 5000 tube burst sensing system. This makes its performance highly reliable as compared to standard basic cased pumping systems.

PRECISE DOSING The Verderflex Vantage 5000 has a higher turn down ratio for precise dosing control leading to optimised chemical usage and lowered water treatment & processing costs. With precision dosing at high discharge pressures, the Verderflex Vantage 5000 solves many pumping problems. With its gentle and low shear peristaltic pumping action, it is ideal for

The next generation peristaltic case pump with intuitive touchscreen technology. By Lekha Bodhe

he new Verderflex Vantage 5000 is a highly advanced Next Generation peristaltic pump system with touch screen technology and intuitive operating system. Easy to operate, Verderflex Vantage 5000 offers an extremely userfriendly operations menu structure with highly visible, colour coded on-screen status alerts and alarms indicators. The advanced system in Verderflex Vantage 5000 is one of the rare pump systems in the market that not only has enough internal memory that saves up to 30 dosing and batching programmes, but also allows users to back-up job-files through its USB data-port. In addition to a rotor that increases tube life and service intervals, the Verderflex Vantage 5000 has a smart

Quick facts Precision dosing

Wide range of remote control options

pumping fragile biotech cultures and particle size sensitive water industry flocculants. As a genuine dry priming pump, Verderflex Vantage 5000 readily pumps off-gassing liquids like Hypochlorites, eliminating vapour locking dosing failures without additional degassing valves and other ancillary equipment. As with all peristaltic pumps, only the tubing is in contact with the pumped fluid, making the Verderflex Vantage 5000 ideal for metering corrosive reagents or particle heavy slurries such as lime.

6600 ml/min / 104 GPH

INNOVATIVE TECHNOLOGY

7 bar / 100 PSI

Besides this, Verderflex Vantage 5000 employs new technology featuring Analogue Remote Control action, Real time event clock for timer triggered operations, options with SCADA versions with optical isolation and Digital Control Protocols like RS 485, IEEE 802.11 Wi-Fi, Profibus and Modbus. This means the smart system is compatible with almost all high-tech pumping applications in various industries like water treatment, food, pharmaceuticals, breweries and chemical dosing with highly reliable and efficient performance.

Up to double the flow compared to

other leading brands High flow per revolution enhances

tube life Advanced touch screen technology Intuitive, icon based menues

Verderflex T: 01924 221020 E: info@verderflex.com www.verderflex.com/en/vantage5000/

Improved Asset Performance in Refineries Through Innovative Services

he he high high density density of of

Looking Looking at at the the broadest broadest picture picture to to begin begin

be be focussed focussed on on preventing preventing breakdowns, breakdowns,

rotating rotating equipment equipment used used

with with -- we we know know that that daily daily production production costs costs

which which means means monitoring monitoring and and ensuring ensuring aa

in in refineries refineries means means that that

within within refineries refineries can can run run to to enormous enormous

high high quality quality of of repairs. repairs.

effective effective asset asset management management

sums sums and and these these can can only only be be met met through through

of of pumps, pumps, turbines, turbines, compressors, compressors, motors motors

the the efficient efficient production production of of all all the the byby-

In In industries industries where where high high value value or or high high

and and generators, generators, can can play play aa vital vital role role in in

products products that that are are created created by by the the processes processes

volume volume commodities commodities are are produced, produced,

maintaining maintaining plant plant up-time up-time and and achieving achieving

within within the the facility. facility. Hence, Hence, keeping keeping all all of of the the

the the failure failure of of aa seemingly seemingly insignificant insignificant

OEE OEE targets, targets, in in addition addition to to ensuring ensuring high high

production production equipment equipment and and components components

component component can can have have enormous enormous knock-on knock-on

safety safety levels levels and and profitability. profitability. Since Since every every

running running at at optimum optimum performance performance levels levels is is

effects effects that that can can bring bring some some or or even even all all

refinery refinery operates operates with with aa variety variety of of steadily steadily

crucial crucial in in delivering delivering aa positive positive bottom bottom line. line.

production production to to aa halt. halt. In In some some instances instances

ageing ageing plant plant and and equipment, equipment, drawing drawing on on

itit may may be be economic economic to to develop develop stand-by stand-by

the the knowledge knowledge and and experience experience of of aa global global

Understanding the costs

engineering engineering company company -- especially especially one one

Rotating Rotating components components within within any any

that that performs performs both both routine routine servicing servicing and and

production production process process will will eventually eventually wear wear

emergency emergency repairs repairs for for rotating rotating equipment equipment

and and require require service service or or replacement; replacement; the the

around around the the world world -- can can help help ensure ensure aa

type type of of maintenance maintenance program program that that is is

site site is is executing executing the the most most cost cost effective effective

used used to to effect effect any any work work can can make make the the

maintenance maintenance program. program.

difference difference between between aa good good investment investment

Harald GroĂ&#x;mann, Service Center Manager for Sulzer's Neuss Service Center in Germany looks at the maintenance challenges facing petrochemical refineries and how to improve asset performance and reliability.

and and unnecessary unnecessary expenditure. expenditure. The The costs costs associated associated with with aa breakdown breakdown rather rather than than aa service service for for example example include include the the price price of of the the new new parts parts as as well well as as the the additional additional labor labor that that is is required required to to install install it. it. In In most most cases, cases, this this will will be be insignificant insignificant compared compared to to the the costs costs associated associated with with lost lost production production and and process process re-starts, re-starts, hence, hence, any any policy policy must must

PECM PECM Issue Issue 21 21

equipment equipment that that can can be be brought brought on on line line to to return return production production levels levels to to normal normal much much quicker. quicker. However, However, there there will will still still be be aa period period of of lost lost productivity productivity and and when when the the process process is is restarted restarted there there may may be be aa significant significant quantity quantity of of final final product product that that cannot cannot be be used used due due to to the the reduced reduced quality. quality. Clearly Clearly the the overall overall costs costs depend depend on on the the piece piece of of equipment equipment and and the the process process in in which which itit operates, operates, but but being being able able to to quantify quantify these these costs costs enables enables the the maintenance maintenance team team to to start start the the process process of of prioritizing prioritizing the the assets assets within within the the facility. facility.

Across a refinery site there can be thousands of assets, some more important than others, some more expensive than others.

www.sulzer.com

Reactive and Preventative Maintenance Historically, many refineries have taken a decision to employ a reactive maintenance policy whereby assets are replaced or repaired on a fix-as-fail basis which in the short term can deliver some cost savings, unless a more serious failure occurs. Reactive maintenance relies on the skills of the on-site maintenance team and the availability of spare parts. If either of these factors fails to meet expectations, there is a real possibility of substantial losses due to lost production. The purpose of preventative maintenance is to use all available information and techniques to build a maintenance program that will identify assets that require some form of service intervention and schedule the works to be completed as a preventative measure. In this way the work can be scheduled to cause minimal disruption and countermeasures can be used to reduce or even avoid lost production costs. In a number of cases some of the equipment may be overlooked in terms of regular maintenance and inspection schedules for a variety of reasons, but this can develop

Developing even the most rudimentary scheme for preventative maintenance can pay dividends in terms of reliability and productivity.

A preventative maintenance program that will reduce the costs associated with repairs caused by unexpected failures can be developed to include all the key assets within the refinery and may involve procedures such as thermography and

It is common for the refinery to have a well

vibration analysis. However, complete

developed relationship with a local service

service providers such as Sulzer can

and maintenance provider that can offer

also provide design improvements to a

skills and services that are not available

number of larger rotating components

within the facility itself. Sulzer has many

such as pumps, compressors, motors and

years' experience in providing skilled

generators that will deliver improved

engineers and engineering technology

reliability and efficiency.

to the refinery sector and so has built-up an in-depth knowledge of the demands within the industry. Developing the relationship between the technical engineering department within the refinery and the local service agent, that may also be on-site, is crucial for improving the processes within the facility both in terms of operation and maintenance. Local Sulzer locations for example have access to a worldwide network of engineering and repair specialists that are supported by modern design facilities, the latest manufacturing technology and skilled teams of site engineers.

into a false economy. Issue 21 PECM

Process specific solutions A A great great deal deal of of equipment equipment within within aa typical typical refinery refinery could could benefit benefit from from changes changes in in design design or or simply simply an an upgrade upgrade to to more more modern modern materials materials in in order order to to increase increase reliability. reliability. Improvements Improvements to to bearing bearing designs designs on on larger larger pieces pieces of of equipment equipment for for instance instance can can increase increase service service life life and and reduce reduce time time spent spent on on regular regular maintenance. maintenance. The The impeller impeller design design in in many many multi-stage multi-stage compressors compressors could could be be improved improved as as part part of of aa scheduled scheduled maintenance maintenance program program in in order order to to deliver deliver greater greater output output which which would would allow allow aa more more flexible flexible working working envelope envelope and and improve improve efficiency. efficiency. Sulzer Sulzer has has the the expertise expertise and and facilities facilities to to enable enable the the engineering engineering teams teams within within the the refinery refinery to to achieve achieve their their goals goals in in terms terms of of reliability reliability while while also also delivering delivering aa cost cost effective effective program. program.

application of of surface surface treatments treatments can can also also application

productivity, productivity, the the refinery's refinery's engineering engineering

be used used to to extend extend the the operational operational life life of of be

team team is is able able to to build build aa partnership partnership with with the the

the pumps. pumps. In In each each case, case, ifif Sulzer Sulzer is is dealing dealing the

local local service service provider provider and and continue continue making making

with the the component, component, itit is is examined examined and and with

improvements. improvements.

the most most appropriate appropriate actions actions are are proposed proposed the to the the client. client. to

For the majority of cases involving component failure, Sulzer can offer considerably reduced lead times for a completed repair when compared to the OEM. For example, an emergency repair to a steam turbine which had a cracked low pressure casing saw a team of Sulzer engineers on site within 24 hours. The overall shutdown period was just 9 weeks, which is remarkable when compared to the 14 months that had been offered by the OEM.

Improving long-term reliability With With so so many many production production processes processes involving involving aa multitude multitude of of pumps, pumps, compressors, compressors, turbines turbines and and motors, motors, itit is is essential essential to to have have aa well-developed well-developed asset asset management management system system in in order order to to reduce reduce the the amount amount of of reactive reactive maintenance maintenance within within the the refinery. refinery. As As these these assets assets mature mature so so an an increased increased amount amount of of intervention intervention will will be be required required and and itit is is the the responsibility responsibility of of the the site site engineering engineering team team to to ensure ensure that that the the most most cost cost effective effective solution solution is is implemented. implemented. The The global global network network of of Sulzer Sulzer engineers engineers has has considerable considerable experience experience in in maintaining maintaining

Even Even when when replacement replacement parts parts appear appear to to

and and managing managing mature mature equipment equipment by by

Innovative Innovative solutions solutions can can also also be be applied applied

be be unavailable, unavailable, Sulzer Sulzer has has the the necessary necessary

applying applying experience experience and and the the latest latest

to to the the huge huge number number of of pumps pumps installed installed

technology technology to to reverse reverse engineer engineer new new

technological technological innovations innovations to to extend extend the the

within within the the facility. facility. Remanufacturing Remanufacturing of of

components, components, manufacture manufacture them them from from the the

life life cycle cycle of of these these vital vital assets assets and and maximize maximize

impellers, impellers, balancing balancing and and bearing bearing overhauls overhauls

latest latest materials materials and and even even correcting correcting any any

productivity. productivity. All All of of this this knowledge knowledge and and

can can all all be be accomplished accomplished within within scheduled scheduled

design design flaws flaws in in the the original. original. By By using using skills skills

expertise expertise is is available available through through the the local local

maintenance maintenance intervals, intervals, while while the the

such such as as these these and and seeing seeing the the benefit benefit to to

service service center center that that in in many many cases cases may may already already be be very very close close at at hand. hand.

PECM PECM Issue Issue 21 21

Sensors, Software & Systems

New Prototyping Capability From the Comus Group of Companies

omus Europe recently acquired a Stratasys uPrint SE 3D printer providing the capability to produce prototype parts in natural ABS without costly tooling or machinery. With a maximum build size of 203 x 203 x 152 (8 x 8 x 6 in) and a minimum layer thickness 0.254mm (0.010in) the uPrint SE is capable of creating prototype parts from .stl files in a short time scale with limited finishing operations. These parts can be used for design development and customer approval greatly reducing development costs and time to market. There is also the possibility of using the machine to make tooling components such as moulds and assembly nests. The parts are built by laying down layers of ABS filament to build the completed part. A washable support material is laid down at the same time to support the

product during build. This material is then removed in a purpose built wash tank. The product can, if required, be hand ﬁnished by the customer to improve surface ﬁnish or add colour. Complex parts such as a ball in a lattice box and even assemblies with moving parts such as a chain can be produced as one piece with this process. Features • Prototyping without the costly tooling charges. • Uses natural ABS plastic to build the completed part. • Complex objects with moving parts can be built as one piece. • Moulds and assembly nests may be possible. • Making custom designs more available. For more information contact sales@comuseurope.co.uk Issue 21 PECM

City of Dayton Ohio Selects Process Sensors Corporation’s “Triple Play” Of Infrared Instruments to Satisfy Crucial Lime Kiln Application Requirements

he Infrared Infrared Division Division he of Process Process Sensors Sensors of Corporation located located Corporation in Franklin Franklin Lakes, Lakes, NJ NJ in once again again drew drew on on its its decades decades once of IR IR experience experience and and the the widest widest of range of of innovative, innovative, non-contact non-contact range sensing products products to to successfully successfully sensing supply the the solutions solutions needed needed by by supply the City City of of Dayton Dayton at at its its Regional Regional the Lime Reclamation Reclamation Facility. Facility. Lime The plant plant is is engaged engaged in in the the The production of of aa new new type type of of production “burnt lime”. lime”. The The lime lime is is used used “burnt for treatment treatment of of drinking drinking water. water. for To produce produce “burnt “burnt lime”, lime”, high high To quality limestone limestone is is calcined calcined in in aa quality continuous process process using using aa rotary rotary continuous kiln at at 1100°C, 1100°C, volatizing volatizing oﬀ oﬀ the the kiln carbon dioxide dioxide to to leave leave calcium calcium carbon oxide: CaCO CaCO33 + + Heat Heat   CaO CaO + + oxide: CO CO22. . Dayton’s Dayton’s use use of of “burnt “burnt lime” lime” reduces reduces land land contamination contamination by by spent spent residuals, residuals, reduces reduces the the amount amount of of mined mined lime lime and and reduces reduces the the carbon carbon footprint footprint by by using using the the resulting resulting carbon carbon dioxide dioxide in in their their process. process. Surplus Surplus is is then then sent sent to to aa sister sister water water treatment treatment plant plant for for water water stabilization. stabilization.

Reclamation Reclamation Facility Facility Supervisor, Supervisor, said said “The “The PSC PSC instrumentation instrumentation helps helps us us keep keep very very close close operational operational control control of of our our process, process, allowing allowing us us to to be be much much more more eﬃ eﬃcient.” cient.” A A PSC-400 PSC-400 Surveyor Surveyor Thermal Thermal Imaging Imaging Camera Camera System System suitable suitable for for outdoor outdoor applications applications and and equipped equipped with with aa NEMA NEMA 4 4 enclosure enclosure and and rugged rugged accessories, accessories, handles handles continuous continuous monitoring monitoring of of the the kiln kiln shell shell in in order order to to avoid avoid troublesome troublesome hot hot spots spots that that could could result result in in costly costly down down time time and and disruption disruption of of production. production. Process Process Sensors Sensors recommended recommended and and provided provided aa PSC-T40L PSC-T40L selfselfcontained, contained, 2-wire 2-wire pyrometer pyrometer with with integrated integrated USB USB interface interface and and built-in built-in peak peak picker picker for for the the mid-kiln mid-kiln temperature temperature measurement. measurement. The The IR IR sensor sensor views views into into aa minimum minimum 4 4 inch inch diameter diameter (I.D.) (I.D.) customer-supplied customer-supplied target target tube tube and and delivers delivers aa fast fast response, response, recording recording the the highest highest temperature temperature reading reading during during each each kiln kiln rotation. rotation.

The The new new process process being being used used in in Dayton, Dayton, recycles recycles the the waste waste stream stream the the lime lime softening softening water water plant plant produces. produces. Normally Normally plants plants buy buy mined mined lime, lime, treat treat the the water water and and lagoon lagoon the the waste waste residuals residuals to to be be left left there there forever forever or or applied applied on on farmers’ farmers’ ﬁ ﬁelds elds to to adjust adjust the the pH pH of of their their soil. soil. By By recycling, recycling, every every run run through through the the cycle, cycle, actually actually gains gains about about 0.2% 0.2% due due to to the the lime lime removed removed from from the the raw raw water water in in the the process. process.

A A Metis Metis M311 M311 2-color 2-color pyrometer pyrometer that that automatically automatically compensates compensates for for changes changes in in target target emissivity, emissivity, is is designed designed for for viewing viewing through through dust dust and and partial partial smoke, smoke, and and provides provides temperature temperature readings readings as as well well as as aa real-time real-time visible visible image image of of the the process. process. The The IR IR temperature temperature sensor sensor is is positioned positioned at at the the kiln kiln discharge discharge end end to to determine determine product product temperature temperature and and to to observe observe any any product product build build up up as as it it exits exits the the kiln. kiln.

The The City City needed needed constant constant observation observation of of their their process process temperatures temperatures and and equipment equipment at at three three crucial crucial points: points: the the kiln kiln shell, shell, mid-kiln, mid-kiln, and and the the discharge discharge end end of of the the kiln. kiln. A A versatile versatile selection selection of of IR IR sensing sensing products products and and the the guidance guidance of of PSC’s PSC’s experienced experienced engineers engineers provided provided the the right right solution solution needed needed by by the the City City of of Dayton. Dayton. Shannon Shannon Zell, Zell, Dayton’s Dayton’s Regional Regional Lime Lime

On-site On-site support support and and product product training training was was provided provided by by the the PSC PSC IR IR Division, Division, assisted assisted by by Mike Mike Luck Luck and and Scott Scott Elliot Elliot of of Glatte, Glatte, Inc., Inc., the the local local technical technical representatives. representatives.

100 PECM PECM Issue Issue 21 21

Kiln Kiln Shell Shell Monitoring Monitoring

Complete Complete speciﬁ speciﬁcations cations for for all all three three models models can can be be downloaded downloaded from: from: www.ProcessSensorsIR.com www.ProcessSensorsIR.com irtemp@processsensors.com irtemp@processsensors.com

Mid-Kiln Mid-Kiln Monitoring Monitoring

Discharge End End Discharge Monitoring Monitoring

Sensors, Software & Systems TE Connectivity, Pepperl+Fuchs and Software AG Present Solution for Cost-Effective Connection of Legacy Systems to the Cloud for Industry 4.0 Applications TE Connectivity (TE), a world leader in connectivity and sensors, is working with Pepperl+Fuchs and Software AG on solutions to optimize interlinked manufacturing processes. The three companies are also working on smart status monitoring and maintenance. The collaborative project, which has the umbrella title Overall Equipment Effectiveness (OEE), was demonstrated for the first time at this year’s CeBIT in March. The companies showed how machine uptime and productivity can be increased significantly with easy-to-retrofit hardware components and a business platform with special analysis tools. This means that even older systems can be connected to IT systems and modernized in line with Industry 4.0, without any major investment.

Tel: +49 6154 607 1740

www.te.com

Virtually saving money, time and lives. Audi’s use of Virtual Prototyping The automotive world is changing, from automated production lines to tighter safety and emissions legislation. But perhaps the most signiﬁcant change in the industry is the move towards Virtual Reality - automotive industry’s new best friend. Virtual Reality allows engineers to get inside a car before it is built, gaining a much better idea of how it will be used by their customers, and allowing manufacturers to ultimately save both money and time by building a better performing, safer car. During product development, computer-aided design (CAD), computer-automated design (CAutoD) and computer-aided engineering (CAE) software helps engineers quickly explore the performance of thousands of design alternatives without investing the time and money required to build physical prototypes. Since 2009, engineers at Audi have been using ESI’s IC.IDO solution at their Ingolstadt and Neckarsulm plants to run virtual simulation so they can anticipate and solve process related issues before the ﬁrst car comes on the production line.

www.esi-group.com

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

Your Ideas. Realised Issue 21 PECM

101

Man Man and and Machine Machine provides provides BlueCielo BlueCielo and and Autodesk Autodesk software, software, support, support, training training and and consultancy. consultancy.

BlueCielo Intelligent Asset Management for Plant Owners T

he he UK UK off offshore shore oil oil and and gas gas industry industry remains remains the the country’s country’s largest largest industrial industrial investor, investor, paying paying more more tax tax than than any any other other corporate corporate sector. sector. This This is is aa time time of of extraordinary extraordinary global global economic economic and and political political turbulence, turbulence, and and the the Oil Oil and and Gas Gas industry industry is is facing facing some some fundamental fundamental challenges. challenges. Historically, Historically, the the focus focus in in this this industry industry has has been been on on locating locating resources resources and and meeting meeting rising rising energy energy demands. demands. Today, Today, however, however, the the picture picture is is more more complex. complex. The The fall fall off off in in demand demand for for fuel, fuel, particularly particularly for for transportation transportation and and manufacturing, manufacturing, has has signifi significantly cantly hit hit demand, demand, and and evolving evolving regulatory regulatory pressures pressures are are squeezing squeezing already already tight tight margins. margins. As As we we move move into into an an era era where where technology technology provides provides the the competitive competitive edge edge and and companies companies look look to to add add value, value, rather rather than than volume, volume, businesses businesses in in the the sector sector need need forward forward thinking thinking advice advice and and practical practical strategies strategies from from professionals professionals who who understand understand their their businesses businesses and and their their challenges. challenges. As As aa rapidly rapidly growing growing and and developing developing global global population population creates creates more more and and more more demand demand for for energy, energy, design design and and engineering engineering teams teams in in the the oil oil & & gas gas industry industry are are under under immense immense pressure pressure to to deliver deliver projects projects quickly. quickly. They They must must be be more more responsive, responsive, more more effi efficient cient and and more more competitive competitive than than ever ever before. before.

102 PECM PECM Issue Issue 21 21

Finding Finding effi efficient cient and and cost cost eff effective ective ways ways to to manage manage the the lifecycle lifecycle of of projects projects is is key. key. Man Man and and Machine Machine provide provide applications applications and and services services that that underpin underpin equipment equipment creation, creation, operation operation and and maintenance maintenance as as well well as as providing providing 2D/3D 2D/3D solutions solutions for for plant plant factory factory creation, creation, simulation simulation and and visualisation. visualisation. This This alongside alongside the the Autodesk Autodesk portfolio portfolio of of oil oil & & gas gas engineering engineering software software can can help help you you speed speed up up design design cycles, cycles, collaborate collaborate and and communicate communicate more more eff effectively ectively and and better better understand understand real-world real-world project project performance. performance. Man Man and and Machine Machine also also off offers ers BlueCielo BlueCielo data data management management solutions. solutions. The The industry industry trends trends facing facing the the Plant Plant industry industry including including aging aging facilities facilities and and infrastructure, infrastructure, emerging emerging economies, economies, shorter shorter project project timelines timelines plus plus retiring retiring expertise, expertise, acquisition acquisition and and retention retention of of talent talent and and knowledge. knowledge. All All of of these these things things suggest suggest there there is is aa higher higher need need for for systems systems that that work work effi efficiently ciently and and eff effectively. ectively. One One of of the the main main things things that that can can help help is is having having up up to to date date software software to to not not only only manage manage your your systems systems but but keep keep them them up up to to date. date. Autodesk Autodesk off offer er Plant Plant 3D 3D software software which which enables enables piping piping designers designers to to more more quickly quickly lay lay out out steel steel structures, structures, model model equipment equipment and and route route piping piping design design using using AutoCAD AutoCAD commands. commands.

“We “We made made the the switch switch to to P3D P3D when when we we started started our our new new company. company. After After being being long long time time AutoPlant AutoPlant users, users, we we were were off off and and running running in in aa matter matter of of days. days. Our Our designers designers were were productive productive within within the the fi first rst week week of of use.” use.” James James Cope Cope – – Managing Managing Partner Partner at at D3 D3 Design Design Solutions Solutions LLC LLC BlueCielo BlueCielo is is aa CAD-independent CAD-independent versatile versatile Content Content Engineering Engineering and and Document Document Management Management solution solution that that allows allows customers customers to to optimise optimise business business processes processes throughout throughout the the organisation. organisation. It It off offers ers fl flexible exible revision revision management management and and workfl workflow ow support support for for projects projects and and documents documents in in aa safe, safe, secure secure “vaulted” “vaulted” environment. environment. The The solution solution supports supports internal internal and and external external web web based based collaboration collaboration and and allows allows database database choice choice from from Hypertrieve Hypertrieve to to Microsoft Microsoft SQL SQL and and Oracle. Oracle. The The key key capabilities capabilities of of the the system system include; include; CAD CAD application application integration, integration, audit audit trail, trail, reporting reporting and and content content viewing viewing without without the the need need for for non-CAD non-CAD users. users. Man Man and and Machine Machine provides provides BlueCielo BlueCielo and and Autodesk Autodesk software, software, support, support, training training and and consultancy. consultancy. Contact Contact us us on on 01844 01844 263700, 263700, email email marketing@manandmachine.co.uk marketing@manandmachine.co.uk or or visit visit www.manandmachine.co.uk www.manandmachine.co.uk

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Maintaining Archimedes Screw Pumps

he he enduring enduring simplicity simplicity of of the the Archimedes Archimedes screw screw pump pump continues continues to to make make itit one one of of the the most most efficient efficient

pumping pumping methods methods over over short short distances, distances, but but this this efficiency efficiency should should not not be be taken taken for for

Capable of moving large quantities of water over short distances, it is ideal for maintaining water levels and pumping water contaminated with debris that would seriously damage a centrifugal pump.

granted. granted. Often Often running running 24 24 hours hours per per day day

While While the the lower lower bearing bearing is is usually usually submersed submersed in in water water and and inaccessible, inaccessible, the the top top bearing, bearing, which which is is located located close close to to the the motor motor drive drive and and gearbox, gearbox, will will require require maintenance maintenance checks checks to to be be carried carried out. out. Automatic Automatic grease grease cartridges cartridges are are often often employed employed on on these these bearings bearings as as well well as as

these these workhorses workhorses of of the the water water industry industry can can

The The maintenance maintenance regime regime for for aa screw screw pump pump

on on the the gearbox gearbox so so aa simple simple inspection inspection of of

become become neglected, neglected, but but implementing implementing aa

is is considerably considerably less less complicated complicated than than

the the grease grease level level is is all all that that is is required, required, with with

comprehensive comprehensive maintenance maintenance regime regime will will

that that for for aa centrifugal centrifugal pump pump which, which, unlike unlike

replacement replacement of of the the cartridge cartridge as as necessary. necessary.

ensure ensure continued continued reliability reliability and and efficiency efficiency

Archimedes' Archimedes' design, design, can can become become blocked blocked

levels. levels.

or or overheat overheat ifif itit runs runs dry. dry.

Dave Dave Bennion, Bennion, Project Project Manager Manager at at

Modern Modern bottom bottom bearings, bearings, such such as as the the EcoEco-

trough trough will will start start to to wear wear in in time, time, as as will will the the

ECS ECS Engineering Engineering Services, Services, looks looks at at the the

friendly friendly bearing bearing from from Landustrie, Landustrie, which which

flights flights of of the the screw screw pump. pump. The The speed speed of of

importance importance of of maintaining maintaining these these vital vital

locates locates the the screw screw position position in in the the trough, trough,

this this erosion erosion is is dependent dependent on on the the amount amount

assets. assets. The The Archimedes Archimedes screw screw pump pump is is

are are now now sealed sealed for for life, life, removing removing the the need need

of of debris debris suspended suspended and and floating floating in in the the

renowned renowned for for reliability reliability and and efficiency, efficiency,

to to check check grease grease pumps pumps and and lubrication lubrication

water water as as well well as as levels levels of of various various chemicals chemicals

which which is is why why itit is is employed employed in in so so many many

lines lines regularly. regularly.

such such as as hydrogen hydrogen sulphide, sulphide, ammonia ammonia and and

With With many many of of these these pumps pumps working working 24 24 hours hours per per day, day, even even the the hardest hardest concrete concrete

applications, applications, especially especially in in the the water water

sulphuric sulphuric acid, acid, all all of of which which can can be be found found in in

treatment treatment industry industry and and drainage drainage

waste waste water water treatment treatment environments. environments.

environments. environments.

104

PECM PECM Issue Issue 21 21

Physical and chemical erosion of the

Once the trough has been

trough increases the gap between the

properly prepared, fresh concrete

outer edge of the screw pump flight and

is poured and a new trough starts

the trough itself, which allows more water

to take shape. The finished surface

to pass the flight rather than travel up the

is created by reinstalling the screw

trough.

which has temporary screeding bars attached to the flights and

This will clearly affect the overall efficiency

slowly rotating the screw to give

of the screw pump as more energy will be

the perfect clearance.

required to transport the same volume of water.Although this is a very gradual

While the flights on the screw

process there comes a point where the

were refurbished the bearings

increased energy costs and reduced

can also be replaced and in cases

performance necessitate a refurbishment

where the bottom bearing has a forced

of the screw and trough.

lubrication feed, this can be replaced with a new stainless steel, eco-friendly bearing

In essence this involves welding a new

which is sealed for life and requires no

section onto the flights of the screw

annual maintenance. Top bearings can be

pump to return the outside diameter to

assessed for wear and replaced as required

its original dimensions and then remaking

to ensure the refurbished installation will

the trough to provide the optimum flight

continue to operate for many years to

to trough clearance.

come.

Having removed the screw for refurbishment, the on-site team would expect to break out the original concrete trough using a pneumatic breaker that is fitted to a remote controlled, tracked vehicle.

ECS Engineering Services is able to offer an on-site inspection service, carried out by experienced engineers to assess the condition and expected lifetime of any screw pump installation. If any maintenance is required, ECS can

Due to the access difficulties involved

deliver a complete service offering,

with refurbishing the concrete trough it

including, if necessary, renewal of the

is important to carry out the work in the

screw itself with support from its long

safest manner possible.

established partner Landustrie.

This type of project is something that ECS Engineering Services is regularly involved with, providing a complete turnkey solution that minimises any disruption to the operation of the treatment works.

www.ecsengineeringservices.com

The UK’s largest meeting place for advanced engineering professionals

“Fantastic…I think this is the best year yet” Dave Dave Withey, Withey, Senior Senior Project Project Engineer, Engineer, Research, Research, Jaguar Jaguar Land Land Rover Rover

Managing Managing Director, Director,

and they are our decision makers”

Graham Graham Mulholland, Mulholland, Managing Managing Director, Director, epm: epm: technology technology group group

“It w min spo got Mark Mark

Training & Recruitment Safety in Numbers

Excel is a fabulously versatile tool, but it is not easy to make it clear to users how your spreadsheet reaches its results. Do you know how the results you use have been derived? One of the beneﬁts of developing strong spreadsheet skills is that you can lift the lid on the methods employed. Learn a bit of Visual Basic, and even macros need not stand in your way. Nicholson Solutions is a Learning and Performance Institute accredited learning provider, with a track record of developing spreadsheet solutions and analysing existing ones. www.nicholsonsolutions.co.uk

The World’s Most Used Project Management Method

RINCE2® (Projects in a Controlled Environment) is a structured project management method that have beencan full all the time, be applied regardless of project scale, r decision makers” 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. was fantastic to meet with likewhich are easily integrated with the nded people - especially in motor ® method. This PRINCE2 provides a orts and hybrid power…We’ve secure framework for any type of project, t some great leads to follow up” including business change, construction, IT, research and product Harbord, Harbord, Sales Sales && engineering, Marketing Marketing Manager, Manager, LCL LCL Electronics Electronics 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.

Issue 21 PECM

107

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A Full Hygienic Offer from Dixon As As aa result, result, Dixon Dixon Europe Europe are are pleased pleased to to be be launching launching aa new new product, product, the the Dixon Dixon Hygienic Hygienic Breakaway Breakaway Check Check Valve, Valve, which which isis proving proving to to be be‘the ‘the right right connection’ connection’,, potentially potentially saving saving companies companies thousands. thousands.

t’s not not every every year year aa company company can can t’s celebrate 100 100 years years of of business, business, celebrate so Dixon Dixon are are proud proud to to be be one one of of so those few. few. Founded Founded in in 1916 1916 Dixon Dixon those has grown grown to to become become aa world world leading leading has manufacturer of of hose hose fi fittings ttings and and related related manufacturer accessories for for all all industries. industries. accessories Over the the last last 30 30 years years Dixon Dixon has has Over significantly cantly extended extended its its range range of of Valves, Valves, signifi Fittings and and Couplings Couplings for for the the Hygienic Hygienic Fittings markets through through product product development development markets and acquisition. acquisition. and Dixon off offers ers aa full full range range of of stainless stainless steel steel Dixon hygienic fi fittings ttings and and valves valves for for use use in in the the hygienic food, dairy, dairy, beverage, beverage, brewery, brewery, cosmetic, cosmetic, food, chemical and and pharmaceutical pharmaceutical industries. industries. chemical Of particular particular note note is is Dixon’s Dixon’s range range of of high high Of quality process process valves valves which which include include ball, ball, quality butterfly, y, diaphragm, diaphragm, seat, seat, sample, sample, and and butterfl mix-proof valves valves which which can can be be actuated actuated to to mix-proof customer specifi specifications cations and and fi fitted tted with with aa customer range of of stocked stocked accessories accessories that that includes includes range limit switches, switches, solenoids solenoids and and positioners. positioners. limit Here in in the the UK, UK, Dixon Dixon off offers, ers, specialised specialised Here support and and bespoke bespoke engineered engineered solutions solutions support from concept, concept, to to design, design, through through to to from installation. Dixon’s Dixon’s onsite onsite manufacturing manufacturing installation. and engineering engineering department department means means that that and new designs, designs, animations animations and and 3D 3D modelling modelling new can rapidly rapidly be be produced produced to to support support can customer’s requirements. requirements. customer’s

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110 PECM PECM Issue Issue 21 21

As aa result, result, Dixon Dixon Europe Europe are are pleased pleased to to As be launching launching aa new new product, product, the the Dixon Dixon be Hygienic Breakaway Breakaway Check Check Valve, Valve, which which Hygienic is proving proving to to be be ‘the ‘the right right connection’, connection’, is potentially saving saving companies companies thousands. thousands. potentially

At aa recent recent trade trade show, show, an an engineer engineer from from At well-known UK UK dairy dairy company company explained explained aa well-known how aa milk milk tanker tanker had had driven driven away away from from how the loading loading bay bay before before disconnecting disconnecting the the delivery delivery hose hose costing costing thousands thousands in in the replacement piping piping and and install install cost. cost. replacement Dixon’s Hygienic Hygienic Breakaway Breakaway coupling coupling is is aa Dixon’s solution to to this this problem. problem. In In such such instance instance solution the coupling coupling will will break break in in two, two, separating separating the the tanker tanker from from the the loading loading bay. bay. The The 13kN 13kN the break load load bolts bolts are are the the only only items items that that break will need need replacing. replacing. will The new new Dixon Dixon Breakaway Breakaway Check Check Valve Valve is is The an innovative innovative solution solution that that is is designed designed to to an eliminate product product loss loss too. too. It It incorporates incorporates eliminate the Breakaway Breakaway Coupling Coupling and and aa Hygienic Hygienic the Check Valve. Valve. It It acts acts as as aa single single unit unit that that Check has aa diverted diverted breaking breaking point point which which will will has break at at aa determined determined break-load. break-load. Then Then break the check check valve valve will will close close protecting protecting the the the loading bay bay pipe pipe system system AND AND avoiding avoiding loading product spillage. spillage. product Designed with with hygienic hygienic processing processing in in Designed mind, you you can can be be assured assured that that the the mind, breakaway conforms conforms to to FDA FDA standards standards breakaway and is is CIP CIP capable; capable; but, but, without without the the and intricate workings workings and and associated associated cost cost of of intricate similar products products on on the the market. market. similar Also available available from from Dixon’s Dixon’s in-house in-house Also production capabilities capabilities are are full full hygienic hygienic production fabrications and and custom custom made made hose hose fabrications assemblies for for the the hygienic hygienic market. market. assemblies Our range range includes includes but but is is not not limited limited to to Our San hygienic hygienic Rubber, Rubber, Silicone, Silicone, Metallic, Metallic, San PTFE lined, lined, and and general general PVC PVC suction suction and and PTFE delivery hoses. hoses. This This means means that that whatever whatever delivery hygienic special special you you require require and and whatever whatever hygienic industry you you serve serve to, to, Dixon Dixon can can help. help. industry

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Global and local As an integral part of the world’s third-largest civil aircraft manufacturer, Bombardier Aerospace, Belfast looks to its involvement with the Royal Academy of Engineering’s research schemes to make an impact on its operations and on the local community in its long-established base in Northern Ireland. Bombardier’s experience of the Academy’s research schemes goes back more than a decade and the company is already developing ideas for further involvement. Gavin Campbell, Bombardier’s Director of Design Engineering and Technology Development, said, “The company is selective in picking partners for this kind of initiative. It’s the standing of the Academy that has attracted us. There’s a reputation for excellence, and the calibre of output that’s expected from the appointees is very high. It also provides us with an independent and valuable validation, not just of the candidate but also of the field of study that we’ve chosen.” The impact of research Bombardier Aerospace has had a substantial presence in UK

engineering over many years, principally through its acquisition in 1989 of Short Brothers, one of the great names of UK aviation and engineering. The company is the oldest aircraft manufacturer in the world, having secured the first-ever orders from the Wright brothers for six Wright flyers in early 1909. The company set up a base in Belfast, Northern Ireland in 1936. “The new appointment reflects not just the company’s research priorities in terms of subject matter, but also the way in which it likes to approach the organisation of research,” said Campbell. Previously, the group and the Academy had collaborated on the appointment of Professor Srinivasan Raghunathan at Queen’s University Belfast. Bombardier identities its priorities in terms of future products and processes and then looks to see which technologies can be de-risked to help achieve those priorities. “So we tend to look at the universities to be continuously trying to bring technologies

Bombardier Aerospace and Royal Academy of Engineering’s jointly funded Research Chairs (Past and Present): Professor Srinivasan Raghunathan, Professor of Aerodynamics at Queen’s University Belfast Professor Brian Falzon, Professor of Aerospace Composites, also at Queen’s University Belfast

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forward from basic research,” Campbell said. The relationship between Bombardier and academia is, however, evolving. “In the past, professorial supervised research would take place exclusively in the academic environment with large research facilities and highly specialised research equipment, and our work would be very much on the applied side,” Campbell said. “But more recently, we’ve helped develop a cross-sectoral centre for the research and development of advanced engineering and advanced materials technologies, along with Queen’s and the University of Ulster, and with investment from the Department for Business, Innovation and Skills and Invest Northern Ireland.” Professor Falzon’s role at Queen’s University Belfast is intended to be “the pivotal position in the relationship between the engineering community in the company and the engineering community in the university”, said Campbell. Measuring the impact As part of an international company, Bombardier Aerospace supports work in several UK and European universities. Campbell said, “The recent chair at Queen’s University, Belfast was the pinnacle of its involvement with academia in the UK. The direct support and involvement of the Academy is an important component in the development of this research”.

waiting for the research to flow; it’s about a relationship that works across a number of levels, and the prestige locally of being involved with the Academy is a very important part of that too.” Professor Brian Falzon said he was looking forward to promoting greater collaboration between the academic world and the requirements of industry.

But there is an international dimension too: two of the engineering professorships that Bombardier sponsors in Canadian institutions also cover the important aerospace technology of engineering composites. “We hope to develop an international network that will clearly benefit us but also benefit the professors and the universities”, said Campbell. The direct impact of the new post will be felt in three areas. “The first is the pull-through of new technologies and the validation of ideas into projects with clearer industrial application. We recognise that it can take many years to develop a product or a process, but we also recognise the need to keep the pipeline of ideas topped up with projects at all stages of maturity,” said Campbell. The second is to ensure that key skills within the company and the universities are enhanced. In tandem with this, there is an emphasis on the transfer of skills and knowledge. “There can be frontline support, maybe some personal mentoring and certainly advice on challenging problems from someone who is a leading expert in their field.”

Chief Technical Engineer David Riordan said that this kind of knowledge transfer had been a feature of the earlier joint professorship with the Academy “Professor Raghunathan brought extremely good links into the wider university and also into other industrial companies. We gained both from his specific knowledge and from his breadth of knowledge.” The third specific area that Bombardier Aerospace has for its involvement with the Academy is a local one. “We’re very much a company that tries to live by its corporate social responsibility, and we run an educational outreach programme,” Campbell said. “We see this as an important part of what Bombardier as a company puts back into society locally and nationally.” There is a strong Northern Ireland aspect to this. “When we were developing the proposal with the Academy we were obviously looking for academic excellence,” Campbell said. “But the geography is also important because it’s not just a matter of writing a cheque and

“This is an exciting role which facilitates the exploration and exploitation of new ideas and innovations with one of the world’s leading aerospace companies and with the support of the Academy. The requirement for reduced development and production timeframes, lower life cycle costs and increasingly stringent environmental targets, presents a number of intellectually challenging and complex problems. For example, the further development, utilisation and integration of computational tools for ‘high- delity’ virtual testing and design of advanced composite aerostructures has the potential to transform current design philosophies and methodologies,” he said.

“We recruit very actively from the universities, both at graduate level and increasingly at doctorate and postdoctorate levels,” Campbell said.

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