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Global Success Through Innovation Issue 29 2017 ÂŁ3.95 www.pecm.co.uk
Pumps - 08
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Pumps are required throughout the process industry to move liquids from point A to point B.
Process engineers prepare to meet their supply chain Advanced Engineering 2017 has become the hub for the variety of sectors that rely on advanced engineering.
Early diagnosis of cancer can greatly improve survival rates, with health centres utilising the latest technology to ensure identification of the condition is achieved sooner.
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Editors Choice Advanced Engineering Preview Boilers & Maintenance Control & Automation Drives, Motors & Gears Electrical & Electronics Facilities Management Fasteners & Fixings Fluid Handling Health & Safety Labelling Systems Lifting & Handling Equipment Measurement & Monitoring News & Events Process Technologies Product News Pumps Software & Systems Storage, Handling & Distribution Switches & Sensors Training and Recuitment Valves & Flow Control
15 38 46 48 65 68 87 92 93 95 102 104 109 117 119 122 129 134 138 139 140 143
Control &
Engineering Inside Issue 29
INTERVIEW QUESTION AND ANSWER ON ‘FLUID MIXING AND MIXERS’ Mixing is at the heart of most production systems and is of vital importance in the chemical process industry, pharmaceutical industry, food industry and other allied industries SCADA UPGRADE REFINES BIODIESEL PRODUCTION Italy’s leading producer of refined biodiesel has optimised its production process by investing in Movicon SCADA, available in the UK through Products4Automation.
OVER 100 NEW KLARIUS COMPONENTS BOOST AFTERMARKET EMISSIONS CHOICE Klarius Products has further increased customer choice by expanding its range with over 100 new exhausts, catalytic converters (CATs), diesel particulate filters (DPFs) and accessories. RARE RADIAL STEAM TURBINE REJUVENATED Overhauling a steam turbine as part of a planned maintenance schedule is a regular task for many large-scale industrial enterprises that depend on these units to generate electrical power.
Issue 29 PECM
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industry news iet and thorpe park resort set national engineering challenge A national engineering challenge, which sets to inspire the next generation of engineers and technicians, has launched in schools across the UK. Teams of pupils will go against the clock to research, design and build a prototype solution to a real-life engineering problem, set by the Institution of Engineering and Technology (IET) and THORPE PARK Resort. The Faraday Challenge Days, run by the IET, aim to encourage more young people to study and consider exciting and rewarding careers in science, technology, engineering and maths (STEM) by using creativity, innovation and problem-solving skills in a fast-paced, modern engineering challenge. 169 events* are taking place across the UK to host the 2017-18 IET Faraday Challenge Days. Up to six teams of local school students aged 12-13 years will compete at each event to find the best solution to a secret engineering-related challenge set by THORPE PARK Resort. Holly Margerison-Smith, IET Faraday Education Manager, said: “Students who take part in the Faraday Challenge Days this year will experience working as an engineer through hands-on and practical engagement with real-life challenges relating to THORPE PARK Resort. The Challenge Days will give them an insight into the life of a real engineer, the variety a career in engineering can offer and just how exciting and creative engineering is.
Winners of neW photography competition tackle traditional outdated image of engineering In a bid to challenge misconceptions of engineering and demonstrate the ingenuity, breadth and vibrancy of the profession, the Institution of Engineering and Technology (IET) has today announced the winners of its International Engineering Photography Competition. The IET International Engineering Photography Competition was launched earlier in the year and was open to any photograph of an engineering-related subject that captures the dynamic, creative and progressive face of engineering and engineers today. The IET received over 500 photos from children, young people and adults across the world, who submitted photos to five categories: Digital; Environment and Energy; Structures and Transport; Robotics, and Design and Production. Winners include:
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Pranav Chaganty, aged 12, winner of the Environment and Energy category
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Elliot Tratt, aged 17, winner of the Robotics category
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Andrew Clark, aged 17, winner of the Structure and Transport category
Primary t
Daniel Lam Pui Yin, aged 5, winner of the Design and Production and Structure and Transport categories
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Freya Probert, aged 7, winner of the Digital category
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Luca Partridge, aged 7, winner of the Environment and Energy category
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Amelia England, aged 6, winner of the Robotics category
Adult t
Naf Selmani, winner of the Structure and Transport category
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Santiago Villamediana Sanchez, winner of the Design and Production and Robotics categories
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Stephen Morris, winner of the Environment and Energy category
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Vadim Melnicuk, winner of the Digital category
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Elena Probert, aged 13, winner of the Design and Production category
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Daniel Loveless, aged 14, winner of the Digital category
IET President Nick Winser said: “Engineering is an exciting and fast-changing sector – shaping the world around us and improving the quality of our everyday lives. It is a diverse, creative and exciting profession, and yet the traditional image of engineering focuses on hard hats and dirty overalls – which the IET is committed to change. “We launched our photography competition to help banish the outdated perception that engineers just fix and mend things. We received some brilliant images and I’d like to congratulate our winners.”
county durham’s killhope Wheel Wins top engineering aWard
Previous winners of Engineering Heritage Awards include Alan Turing’s Bombe at Bletchley Park, the E-Type Jaguar and the fastest ever Concorde. This will be the 110th Engineering Heritage Award.
The 19th century waterwheel joins ranks of the E-Type Jaguar and Concorde after being presented with an Institution of Mechanical Engineers’ Engineering Heritage Award on 6 October 2017.
The Killhope Wheel was honoured for being the oldest and largest surviving William Armstrong waterwheel in the world, designed and manufactured by the famous Tyneside engineer at his Elswick Works. The wheel, manufactured around 1860, is over 10 metres in diameter and was brought to Killhope in 1877.
County Durham’s Killhope Wheel was presented with an Institution of Mechanical Engineers’ Engineering Heritage Award at a special ceremony on 29 September 2017.
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PECM Issue 29
industry news nuclear safeguards bill Dr Jenifer Baxter, Head of Energy and Environment at the Institution of Mechanical Engineers, said in response to the introduction of the Nuclear Safeguards Bill in Parliament:
trading arrangements for civil nuclear.
“We welcome the creation of a UK Nuclear Safeguards Bill which is urgently required following the UK’s decision to leave the European Union and Euratom treaties.
“The Office for Nuclear Regulation are the obvious choice for delivering this new function. They already provide excellent licensing and regulation of our civil nuclear activities and have an established relationship with the International Atomic Energy Agency who will approve our new safeguards regime.
“The new bill will ensure the UK has internationally recognised nuclear safeguards in place, allowing many of our activities outside Euratom to be arranged, such as new nuclear co-operation agreements, research activities and future
“Once these high-level functions are in place, the detail of Euratom Directives and possible Associations with Euratom can be worked through to ensure that the UK remains a global leader in delivering civil nuclear activities, including the
eef comments on supporting returners to Work after time off for caring responsibilitiesv EEF has submitted comments on the Government Equalities Office (GEO) call for evidence on supporting returners to work after time off for caring responsibilities.
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New gender pay gap reporting regulations and the manufacturing gender pay gap
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Shared parental leave and pay
EEF has commented on:
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Use of flexible working among manufacturers
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Enhanced maternity pay and packages in the manufacturing industry
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The low numbers of women in manufacturing and engineering
online neWs programme ‘engineering the next generation’ launches The Institution of Engineering and Technology (IET) and ITN Productions have launched a news and current affairs-style programme ‘Engineering the Next Generation,’ which explores the challenges, careers and future of modern engineering in the UK. With the government announcing the £229 million of industrial strategy investment, ‘Engineering the Next Generation’ brings to life the opportunities and challenges the sector in the UK faces, the changes in policy and long term impact on the UK economy. ‘Engineering the Next Generation’ showcases the work being done to attract our future generations to engineering and the diverse range of jobs available in this sector, many which are unknown to career seekers. The programme also looks into how work experience and apprenticeships play a vital role in attracting the younger generation into a rewarding and life-long career in engineering.
development of standards, regulation, goods and services as well as international research collaborations. “In April 2017 the Institution in its report ‘Leaving Euratom: A Framework for the Future’ recommended the Government develop a new Safeguards Office for the UK and we are pleased to see that with the introduction of this new Bill the beginnings of this happening.” For interview requests and queries contact the Institution of Mechanical Engineers’ Press Office on +44 (0)7912 408 096 or email media@imeche.org.
customers and innovation in the driving seat for the future of sustainable energy, states neW iet president The new President of the Institution of Engineering and Technology (IET) will use his year-long term of office to champion how innovation and customers will become ‘change-makers’ in the decarbonisation of the energy system with renewables, smart homes, energy storage and electric vehicles playing a fundamental role. Nick Winser, Chair of the Energy Systems Catapult, became the 147th President of the IET on 1 October 2017 and held his first official engagement, the President’s Address, on Thursday 5 October 2017. During his speech, he highlighted the exciting role these changes will bring for engineers in order to meet industry needs for fast innovation across new products and services, infrastructure investment and integration of a complex and fast-moving energy system. Nick said: “With the widespread deployment of renewable energy technologies, massive commercial availability of electric cars and smart homes, energy customers will become change-makers and their voice is now more prominent than ever in shaping the energy market, products and services available. “During my term as IET President, I will champion engineers and technologists as our greatest innovators and the diversity of skills needed within the profession to drive forward this change, in order to meet the needs of society. Issue 29 PECM
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Issue 29 PECM
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centrifugal pumps in a nutshell
W
HY USE CENTRIFUGAL PUMPS?
Pumps are required throughout the process industry to move liquids from point A to point B. This may involve moving liquid from a lower pressure to a higher pressure, lifting the liquid from a lower elevation to a higher level, or a combination of both of these requirements. Liquids normally want to move from a higher pressure to a lower pressure and from a higher level to a lower level. To get liquid to move against its normal tendencies requires the addition of energy. That’s where pumps come in. Pumps are devices that transform mechanical energy into useful fluid energy. Centrifugal pumps are one of the simplest of all the pump designs. They have one moving part, called the rotor. The rotor has an impeller attached to it that accelerates liquid from its suction eye,
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PECM Issue 29
or inlet to a maximum speed at its outer diameter.
states that energy is always conserved in a fluid stream.)
The liquid is then gradually decelerated to a much lower velocity in the stationary casing, called a volute casing. As the liquid slows down, due to the increasing cross sectional area of the casing, pressure is developed, until full pressure is developed at the pump’s discharge. This simplicity of design and operation is what makes centrifugal pumps one of the most reliable of pump designs, assuming they are applied properly.
The greater the impeller diameter or rpm the greater the exit velocity and therefore the higher pressure developed at the pump’s discharge.
This process of converting velocity to pressure is similar to holding your hand outside of a moving automobile. As the high velocity air hits you, it slows down and pushes your hand back due to the pressure developed. Similarly, if you could insert your hand into the pump casing at the impeller exit and “catch” the liquid, you would feel the pressure produced by dynamic action of the impeller. When any high velocity stream slows down pressure is created. (This effect is called Bernoulli’s Principle, which simply
Another benefit of centrifugal pumps is that they can cover a wide range of hydraulic requirements, meaning they can be used in a wide range of flow and pressure applications. They can easily provide flows from less than 10 gallons per minute to well over 10,000 gallons per minute (gpm). Centrifugal pump impellers can easily be staged, that is arranged so that one impeller’s output is directed to a subsequent impeller, so that over 4500 pounds per square inch (psi) of pressure can be generated. One key disadvantage of centrifugal pumps is that their efficiencies are usually less than positive displacement pumps. While positive displacement pumps can deliver efficiencies greater than 90 percent range, centrifugal pump efficiencies can range from less than 30%
to over 80% depending on the type and size. Here are few samples of centrifugal pump efficiencies:
3.
Shaft seal, which allows rotation of the rotor while preventing product leakage around the shaft
4.
Shaft and bearings, which maintain the position of the rotor with respect to the pump casing
10,000 gpm centrifugal pump—75 to 89% 500 gpm centrifugal pump—60 to 75%
RELIABILITY AND EFFICIENCY
100 gpm magnetic drive pump—40%
The key to exemplary centrifugal pump reliability and high overall system efficiency is selecting the right pump for the required application. This means that the pump’s best efficiency flow (BEP) and head should always closely match process’ hydraulic requirements. A poor hydraulic match will lead to high energy bills and maintenance costs.
100 gpm canned motor pump—35% Basic Centrifugal Pump Construction All centrifugal pumps have the following common elements. 1.
2.
Impeller, which adds energy to the liquid by accelerating it Pump casing and volute, which contains the liquid being pumped and decelerates the liquid expelled by the impeller
Centrifugal pumps like to operate close to their best efficiency point (BEP) where: t
Hydraulic efficiency is greatest
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Vibration and pressure pulsations are lowest
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Shaft deflection is minimized due to the improved pressure distribution of internal pressure around the impeller. This has a major positive effect on mechanical seal life. At the best efficiency point, the pressures around the impeller are nearly balanced so that radial forces on the impeller and shaft are minimized.
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Overall mechanical reliability is highest
BEP is the flow point where centrifugal pump designers would like to see their pumps to be operated. Conscientious pump operators should always strive to comply with the designer’s intent by operating all centrifugal pumps near their best efficiency point.
Contributing editor Chikezie Nwaoha (AMIMechE) interviews Robert Perez (He has more than 30 years of rotating equipment experience in the petrochemical industry and has numerous machinery reliability articles to his credit. Mr. Perez holds a BSME degree from Texas A&M University at College Station, a MSME degree from the University of Texas at Austin, and a Texas PE license). The author of a new book entitled, “Operator’s Guide to Centrifugal Pumps” and co-creator of the PumpCalcs.com website on Centrifugal Pumps in a Nutshell.
Q: HOW HAS CENTRIFUGAL PUMP TECHNOLOGY EVOLVED OVER THE PAST DECADE?
A: In the past decade I’ve seen several major trends. The first is a trend to lower and lower fugitive emission requirement for mechanical seals. This has been a real challenge to machinery engineers. Luckily mechanical seal manufacturers have come to rescue with design improvements, such as reduced face loading designs and dry gas seals. Another solution to this problem has been mag-drive and canned motor pumps, which address the issue in a different fashion. The hydraulic range of sealless pumps has expanded significantly in the last decade. The second trend has been the offering of low-cost pump monitoring solutions, which include wireless systems that can monitor pump vibration and temperatures remotely.
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The prices of these systems continue to drop while their capabilities are expanding. Some of these systems are now viable options for monitoring critical process pumps.
inches, is often used to define shaft flexibility. An upper limit of 60 for English units (2 in metric units) is recommended for L3/D4 to limit shaft deflection.
Q: HOW IS THE CENTRIFUGAL PUMP
In the 80’s, multistage and double suction overhung designs were outlawed in the API 610 Standard. These overhung designs were found to be highly unreliable and even dangerous in flammable services.
TECHNOLOGY OF TODAY MORE EFFECTIVE/ EFFICIENT THAN THE TECHNOLOGY OF PREVIOUS GENERATIONS?
A: In the 70’s and 80’s, 3600 rpm (or 3000 rpm in 50 Hz countries) pumps became the norm in process pump applications due to pricing pressures. This led to more vibration problems that were caused by rotordynamic and hydraulic stability issues. Thanks to a lot of smart people most of the common problems were solved by the end of the 80’s. Many of hydraulic stability issues were solved by limiting suction specific speeds (Nss) to less than 11,000 in English units (9460 in metric units, i.e. m3/h) and limiting operation to the 80% to 110% of the best efficiency flow. Aftermarket companies also began to offer “hydraulic rerates” for poorly applied pumps. (Rerating a pump means redesigning the pump internals and fitting them to an existing pump casing.) A lot of the rotordynamic issues were resolved by 1) limiting shaft flexibility, 2) improving balancing best practices, and 3) discouraging the use of certain overhung rotor designs. For overhung impellers, the term L3/D4, where L is the overhung length and D is the shaft diameter are both given in
Another huge improvement in the 80’s was the development and acceptance of the mechanical cartridge seal. This dramatically improved seal reliability by reducing early failures and allowing seal testing before their installation.
Q: WHEN SELECTING CENTRIFUGAL PUMP, WHAT ARE SOME KEY CONSIDERATIONS AN END-USER SHOULD MAKE TO ENSURE SUCCESS? A: Here are 10 tips to help you select efficient and reliable centrifugal pumps: Only select pumps with suction specific speeds (Nss) less than 11,000—an Nss of less than 9000 is even better. Never select a pump that will have to operate below 70% to 80% of its best efficiency point. Remember that 1800 rpm and slower pumps are usually more reliable that 3600 rpm pumps. Hydraulic efficiency peaks at specific speeds (Ns) between 2000 and 3000 and drops dramatically below 500. If efficiency
is important, try to select pumps in the Ns range. Use double suction impellers sparingly. They are less stable at off-design conditions than single suction impellers. Never select pumps with a maximum diameter impeller. You may need to increase the impeller diameter in the future for more flow or head. Always provide expected normal, minimum, and maximum pumping rates and temperatures in the bid specifications. This will allow bidders to make pump and seal recommendations that will meet the true process needs. Use hydraulic stability, not temperature rise as criteria for setting the minimum acceptable pump flow.
Q: HOW DOES A CENTRIFUGAL PUMP
DIFFER FROM OTHER TYPES OF PUMPS?
A: Centrifugal pumps are designed to operate in a narrow operating range, i.e. near the best efficiency point (BEP). This means that if they are not properly applied, they will be highly inefficient and unreliable. Once the proper pump is selected and installed, the proper controls are required to ensure the pump stays in its ideal flow zone. If the pump control system is not able to maintain a safe flow, then a safeguard such as a low flow spillback controller or fixed spillback flow orifice is highly recommended.
Q: WHAT ARE SOME BEST PRACTICES YOU CAN OFFER END-USERS IN THE AREAS OF SPECIFICATION, INSTALLATION AND MAINTENANCE OF CENTRIFUGAL PUMP
Incorporate a healthy NPSH (net positive suction head) margin or ratio, i.e. NPSHa/ NPSHr, into your selection. This ratio should be anywhere from 1.1 to 2.0 depending on the liquid, criticality, and suction energy level. A larger NSPH margin is always better.
TECHNOLOGY TO ENSURE LONG-TERM
Consider liquid volatility when making your pump selection. Be more conservative in your pump selection when the liquid has a single boiling point (more volatile); as opposed to a liquid with a wide boiling point range (less volatile).
Monitor your pumps regularly. Monitor flows, pressures, vibration, and either replace the lubricating oil regularly or have the oil tested in a lab for contamination and wear metals. When it‘s time to repair the pump, this data will help define the pump repair workscope and reduce repair costs.
PERFORMANCE?
A: Always purchase and install heavy duty pump baseplates that are grouted in and minimized piping loads on the pump.
Develop detailed repair standards that contain balance standards and acceptable limits for critical fits and runouts. These standards will pay for themselves in reliability improvements.
Q: WHAT ARE SOME PITFALLS YOU SEE END-USERS COMMONLY ENCOUNTER IN CENTRIFUGAL PUMP APPLICATIONS? HOW CAN END-USERS BEST AVOID AND/ OR RESPOND TO SUCH APPLICATION PITFALLS?
A: Pump control issues are common. If the process controls permit pump operation outside the ideal flow range, some type of flow protection should be implemented. A pump does not like to be started up with inadequate liquid level or without sufficient backpressure. This means that pump operators must always ensure that the proper suction liquid level and discharge backpressure conditions are met before starting up a pump. Detailed start-up procedures will help provide low stress pump start-ups. Operating centrifugal pumps in parallel with other pumps can lead to flow problems if their head-flow curves do not match. Always check with a pump professional to see if it’s acceptable to operate pumps in parallel. Most processing plants view centrifugal pumps as commodities and sometimes as throw away items. Issue 29 PECM
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This makes it difficult to make design improvements that cost any significant amount of money. I recommend that you work to get a sponsor from upper management to champion pump reliability efforts. This will ensure more visibility and clout to get critical upgrades approved and implemented.
Q: HOW DOES THE INDUSTRY INTEND TO EXPOSE THE APPLICATIONS THAT DID NOT MEET EXPECTATIONS? AND WHAT IS THE PROCEDURE FOR ACHIEVING THAT?
A: Mean time between failures (MTBF) is a commonly used metric for assessing reliability. MTBF is generally defined by the following equation: where M is the total pump count, T is the reporting time, and R is the total number of repairs during the reporting time. For example, if you have 200 pumps and 20 failures in a 3 month period, then the MTBF is 200x3/20=30 months between repairs. A MTBF of 6 years is considered above average for API pumps and a value of 3.5 years is considered average for ANSI pumps. I have found that plotting monthly MTBF values versus time for critical process units is an easy way to indentify a developing reliability problem.
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If the MTBF of your pump population falls below these benchmarks, you must determine what type of failures you are experiencing and what their root causes are. This requires your engineers, technicians and mechanics to be trained to conduct root cause failures analyses (RCFA’s). The purpose of an RCFA is to identify the initiating cause of your failures. Once the root causes are identified and eliminated, the plants MTBF should rise to or above the levels mentioned above. Keep in mind that this process is a team effort and requires buy-in by maintenance, plant engineering, and operations departments.
Q: WHAT IS ON THE PROSPECT IN TERMS OF CENTRIFUGAL PUMP TECHNOLOGY? HOW WILL THE CENTRIFUGAL PUMP TECHNOLOGY OF TOMORROW BE MORE EFFECTIVE/EFFICIENT THAN THE CENTRIFUGAL PUMP TECHNOLOGY OF TODAY?
A: To get the most out of our process equipment, they need to be designed with efficiency and integration in mind. For pumps, this requires highly efficient pumps, i.e. “smart pumps,” that can “think” and react to changes in the process in order to minimize power costs and maximize reliably. An example of this would be a
variable speed pump that has an integrated flow meter, pressure transmitters, spillback controller, vibration sensors, temperature sensors, emission sensors, and PLC. The PLC would constantly be assessing current pump operating conditions and determine if changes are required. The PLC is always looking for the lowest power demand condition that satisfies the process and doesn’t harm pump components. Ideally the pump “brain” would learn from the past and eventually become an expert at optimizing pump operation. This “smart pump” would also trend its performance and mechanical condition and alert plant personnel whenever a fault is detected.
Issue 29 PECM
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Robert Perez is mechanical engineer with more than 35 years of rotating equipment experience in the petrochemical industry. He has worked in petroleum refineries, chemical facilities, and gas processing plants. He earned a BSME degree from Texas A&M University at College Station, an MSME degree from the University of Texas at Austin, and holds a Texas PE license. Mr. Perez has written numerous machinery reliability articles for magazines and conferences proceedings and has authored 4 books and coauthored 4 books related to machinery reliability. He resides in San Antonio, Texas.
Q: WHAT ARE THE PLANS FOR THE FUTURE, FROM THE INDUSTRY STAND POINT? A: Process plants continually have to do more with less. This requires more efficient equipment designs, more efficient process designs, better process controls, and fewer people. I see training, controls, and monitoring as the keys to a safer and more profitable future. To get the most out of our people, we must provide the best training available and provide state of the art monitoring that allows them to keep an eye on their machines.
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It goes without saying that nothing happens without effective process controls. Controls are required to optimize process yields. Optimizing requires balancing production yields with energy and maintenance costs. Future control technology will incorporate all these factors in their designs in order to get the most out of processes.
Q: FROM YOUR VIEWPOINT, WHAT ARE THE HIGH-LEVEL BEST PRACTICES YOU TYPICALLY PROPOSE? A: Every processing facility should have: Detailed pump selection and installation best practices for all classes of pumps
and drivers to ensure the right pumps are selected and properly installed. Written procedures for all normal and abnormal pump start-ups and shutdowns to ensure pumps are properly operated under all process conditions. Written procedures for all pump repairs to minimize early failures and maximize run intervals. Also, the new trend in pump maintenance is the establishment of maintenance agreements with OEM’s or third parties. I have seen these agreements work well for mechanical seals. There is no reason that similar agreements cannot be made for total pump maintenance.
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Another rise in the Landfill Tax means that it now costs £86.10 to dispose of one ton of waste in one of the UK’s burdened landfill sites. Annual tax hikes, and other Government efforts to boost industrial recycling and materials reuse, have been designed to persuade companies to tighten up the way they manage their waste. Waste creation remains one of industry’s top environmental impacts, and the pressure is on to handle industrial by-products more sustainably than in the past. That’s the message award-winning national independent waste managers CSG will be promoting when the company makes an appearance at this year’s Advanced Engineering Exhibition on November 1-2 (Stand G26). Tel: 0800 048 0622 Email: technicalsales@csg.co.uk Web: www.csg.co.uk
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PECM Issue 29
Corrotherm International Corrotherm International is an experienced and knowledgeable stockist and supplier of high-performance nickel alloys for a range of industrial applications. The company offers a wide range of technically superior INCONEL, INCOLOY and MONEL alloys, produced to the highest specifications by trusted manufacturers. The product lines available include INCONEL alloy 625, a widely used material renowned for its exceptional corrosion resistance, high strength and excellent fabricability, which is versatile enough to be applied across a spectrum of industries. There is also the popular INCOLOY alloy 825, which plays a significant role in chemical processing, as well as the oil and gas industry. The sales team at Corrotherm are on hand to answer questions about the materials available and help you select the right product to meet your requirements. www.corrotherm.co.uk
ductless ventilation in fume cupboards Technical Sales Manager Geoff Edwards, briefly discusses the importance of industrial fans in ductless recirculating fume extraction systems. Science laboratories within educational establishments such as universities and schools should be committed to ensuring that the users of ductless and ducted fume cupboards handling hazardous substances, are suitably protected from the inherent hazards associated with procedures undertaken as part of their duties. These units also have a duty to reduce both their carbon emissions and reduce overall energy consumption. This works alongside the Governments targets to reduce overall consumption and to improve energy efficiency initiatives. The large number of fume cupboards within universities, contribute significantly to both energy bills and CO2 output, and in order to lower this impact, energy saving principles must be applied to all new and existing fume cupboards. Ductless fume hoods, Ductless containment hoods or self-contained laboratory enclosures as they’re known are used within manufacturing, medical, chemical, laboratory and pharmaceutical and are negative pressure systems designed to protect the operator from hazardous fumes. The most significant difference between Ductless and conventional ducted systems is the exhaust method; in ducted systems the removed air is exhausted to the outdoors whereas ductless systems are designed to recirculate filtered air back into the immediate environment. The latter means that heated air is not expelled from the laboratory but also that noxious fumes are not expelled into the atmosphere.
DUCTLESS EXTRACTION: HOW DOES THE PROCESS WORK? 1.
Hazardous particles, vapour or fumes are pulled into the filtration system by the unit’s powerful fan.
2.
Air is processed through a pre-filter to capture some of the particles
3.
Air is purified by passing through a main filter. Options include HEPA, ASHRAE, Activated Carbon and speciality blended filtration media.
4.
Filtered air is distributed back into the immediate environment through a recirculating air pattern using no external ducting or venting
BENEFITS OF SELF CONTAINED HOODS The principle is simple, air is drawn in through the front opening of the fume cabinet, circulated through a filter, and then expelled back into the lab via a fan. Ducted systems are a necessity and preferred in many instances, such as chemical and hazardous fume applications, but there are many considerable advantages to using new ductless fume hoods:
ENVIRONMENTALLY FRIENDLY Ductless units recycle the air while cleaning the chemical mixture, so no fumes or hazardous particles are passed into the atmosphere, protecting the environment and exposed of correctly.
ENERGY EFFICIENCY There is no potential to waste energy and increase costs that are associated with traditional ducted systems where heated or cooled air is expelled outside which then needs to be replaced by more air conditioned air.
MINIMAL MAINTENANCE Ductless systems are essentially a plug and play system with low set up costs and minimal installation. They can be moved easily to new locations as they require no venting. The only maintenance would be in removing, replacing and disposing of the saturated filter media and wiping down the unit regularly.
INDUSTRIAL FANS FOR DUCTLESS FUME EXTRACTION SYSTEMS Recirculating fume cupboards are mainly used in educational purposes where the design of the building does not allow for fitting of external ducting, the fan can
often be fitted underneath the worktop or above the workstation. The fan and filter system is the integral part of the extraction hood, many also have built in air flow alarms or monitors which highlight when airflow is low or filter media is clogged. These procedures continue to ensure the safety of operators, students and staff. Speed controllers are also available which allow the user to set the centrifugal fan motor speed as desired to achieve the required airflow. Centrifugal fans such as single or three phase direct drive units with ATEX certification are common due to the hazardous substances in question.
EC BACKWARD CURVED CENTRIFUGAL FANS Our collection of EC impellers can be used effectively within re circulation hoods to deliver high air volume with low noise. These units take up less space than their forward curved counterparts and are available in a large range of sizes. Our collection of Ecofit RRE and modular versions of our e-wheel are also available on request. For more information visit our Backward Curved Centrifugal Fans page.
EC FORWARD CURVED CENTRIFUGAL FANS Axair stock a wide range of EC forward curved centrifugal fans in single or double inlet configurations. Suitable for higher volume airflow, high pressure and larger recirculating cabinets with a low noise output. As we have mentioned, there are many fume extraction projects that require traditional ducted systems that would require corrosion resistant centrifugal fans that are situated at the end of the vented system to enable the fume to be expelled outside. For more information on this product range visit our our website, our corrosion resistant fans are also available in ATEX certified units. www.axair-fans.co.uk
Issue 29 PECM
17
blueacre technology leaning is a large part of many industrial processes. Whether it is to remove rust from steel components or carbonised polymer material from molds, cleaning is a consumable and manpower intensive operation that has not evolved much over the previous decades.
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A new method for cleaning has been developed that utilises laser light to vaporize surface contaniments, providing a cost efficient, non-consumable alternative to chemicals or abrasive material. Laser cleaning is the process by which coatings, debris or impurities (e.g. rust, carbon, silicon and rubber) are removed from the surface of a material by using laser irradiation. At the core of laser cleaning is a non-contact process, which is fast becoming the go to solution is industries ranging from automotive to aerospace and pharmaceutical to agri-food. Blueacre Technology’s laser cleaning process is based on very powerful, short laser pulses that interact with the surface of the material to selectively remove the contamination layer, be it rust, carbon, organic material or paint. As the laser interacts with the surface in two ways. Firstly, it is absorbed by the contaminant material, causing it to
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PECM Issue 29
vaporise and sublimate from the surface. Secondly, it sets up a localised shock wave on the surface, which shakes contaminate material free. This dual action process, allows laser cleaning to be used on a range of materials with high efficiency. Conventional cleaning techniques are either chemical based or utilise abrasive media to blast the contamination away. Both these methods require a high degree of preparation, such as masking, and require continuous replenishment of the cleaning material. In the case of chemical based cleaning, post processing steps are required to ensure no chemicals remain and with bead blasting, significant workload is required to clean away the abrasive media. On the other hand, laser cleaning has no consumable cost with the laser itself requiring single phase operation. It is highly accurate and easy to use and will clean only where the laser is pointed. The contamination is vaporised and can be collected with simple extraction systems. The laser cleaning system developed by Blueacre Technology is an environmentally friendly means to remove contaminations and coatings. No solvents, detergents or abrasives are used and so there is no added waste.
Laser cleaning is an economically proven technology, where investment costs can be recouped in 1-2 years. Laser cleaning can be integrated into 24/7 fully automated production environments requiring on operator interaction. This reduces stopped lines, improves cleaning consistency and leads to increased profitability. www.blueacretechnology.com
blueacre laser technology: providing the most effective, environmentally friendly cleaning solution
Low Power Laser Cleaner
High Power Laser Cleaner
20W – 200W
200W – 1000W
Rust Removal
Automotive
Architectural
Metal Polishing
Laser Cleaning Definition Laser cleaning is the process by which contaminants, debris or impurities (e.g. rust, carbon, silicon and rubber) are removed from the surface of a material by using laser irradiation. Blueacre Technology laser cleaning technology is the perfect tool for cleaning your products to their original condition, other advantages include;
As the laser is tuned to remove surface containments it is non-destructive to the base material
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Removes coatings, oxides, oils & more in all in one step.
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Base material is not damaged
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Higher levels of 'clean' can be reached
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Versatile system suitable for Automated and handheld applications
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Lower sensitivity to corrosion after cleaning
Laser cleaning removes the need for expensive consumables and due to high efficiency electrical running costs are kept to a minimum t
No chemical waste
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Low noise, no dust
t
Stable process
Laser cleaning has the lowest operating costs of all industrial cleaning methods t
Minimum training required
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Can be operated remotely
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Can be used for micro-scale or large-scale cleaning of a number of materials.
www.blueacretechnology.com | info@blueacretechnology.com | + 353 (0) 42 9386922
editors choice
mobileWorxs
MobileWorxs recently announced the launch of the xTablet T1150 - rugged tablet for the mobile workforce. The features available make the xTablet T1150 one of the most robust Windows tablets on the market today. The thin and lightweight highly rugged tablet is an innovative, multi-tasking tool for manufacturing warehousing, distribution, shipping, and other industries where mobile flexibility is required. The xTablet T1150 boasts a 10-inch scratch-resistant, high definition LCD display.
The rugged tablet runs enterprise-ready Windows 10 Professional and partners with an Intel Atom Quad Core X5-Z8550 processor, 4GB of memory and 64GB of storage. Other integration options and accessories of the rugged tablet include a high performance 2D barcode scanner, 3D camera fingerprint reader, 4G LTE and hot swappable battery, Link www.mobileworxs.com/ products/rugged-tablets/ xtablet-t1150/ Email sales@mobileworxs.com
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PECM Issue 29
Newland Magnetics Europe SAS located in France are part of Ningbo Newland Magnet Industry Co. Ltd a Chinese manufacturere of NdFeB magntes and magnetic assemblies with ISO9001:2015 and IATF16949:2016 accreditation. Newland Magnetics Europe was formed to provide technical/design and sales support for our European customers also logistic solutions including consignment or stock holding within our European warehouse. Using simulation software our engineers assist with design/ prototyping of your magnetic assemblies ensuring they meet required specifications and performance. With extensive market/application knowledge within Automotive, Medical, Electronics, Aerospace and Green Energy sectors. Products include electric and hybrid motors, sensors, liner motors and magnetic couplings. www.newlandmagnetics.eu Call us: +33 (6) 21 96 41 12 Email: info@newlandmagnetics.eu
application Jet engine maintenance The Problem: Aviation jet engine maintenance requires engineers to stand at many heights and positions to provide MRO. Many steel and aluminium structures have fixed height and widths and cannot be made wider or narrower without major rework. They have to be custom made for each project and are cumbersome and difficult to transport. Typically, they become redundant when the project comes to an end or if work at a different height is needed and can take up valuable hangar space. The Solution: LOBO Systems’ safe and secure platform product. The unique and patented clamp allows the system to be assembled without the use of tools into any size or shape. Therefore, a solution can be provided to all jet engine types. Aviation MRO engineers can reconfigure the system, adapting it from one project to another with ease, without the need for any tools from flat pack or from a LOBO Towerstore. By fitting a wheel kit, the system can be transported throughout the hangar. The system can be assembled, disassembled and reassembled quickly, is easy to flat pack and is transportable.
The Benefits: The unique versatility of the LOBO System brings cost and waste reduction and enhanced efficiency & performance, together with a safer working environment. Its transportability means it can be used anywhere in the world and erected by anyone. This means aviation mechanics can erect the system to their exact requirements whenever and wherever needed, thus saving on labour costs. The LOBO System creates a safe working environment, which increases productivity, reduces cost and maximises the return on investment.
LOBO Systems Ltd, Centurion Way Business Park, Alfreton Road, Derby DE21 4AY sales@lobosystems.com www.lobosystems.com + 44 (0)1332 365666
intervieW Questions and ansWers on pipeline expansion Joints
xpansion joints are flexible connectors used to reduce vibration, dampen sound, and compensate for movement in piping systems handling pressurized fluids.
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They are used in HVAC and power generation systems, sewage and water treatment plants, pulp and paper mills, and in chemical processing, primary metals production and petroleum refining plants. Pipe movement (face-to-face, angular, compression, lateral, elongation and vibration) can be caused by a number of factors, including system pressure or vacuum, temperature gradients, equipment vibration, system weight and structural settlement. Expansion joints are typically located at the suction or discharge side of pumps, and at directional changes and long runs of piping. They offer a number of advantages compared with pipe loops and bends, which are less expensive, but have hidden costs in terms of space requirements, installation labor and pipe supports.
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PECM Issue 29
1.
HOW HAS EXPANSION JOINT TECHNOLOGY EVOLVED OVER THE PAST DECADE? HOW IS THE TECHNOLOGY OF TODAY MORE EFFECTIVE/EFFICIENT THAN THAT OF PREVIOUS GENERATIONS?
Many of our customers are moving beyond operational excellence to focus on safety and sustainability as important business objectives. Manufacturers of expansion joints are working on developing nextgeneration products and services to help customers achieve these goals. 2.
WHAT ARE THE MAJOR EXPANSION JOINT TECHNOLOGIES AVAILABLE TODAY?
The two primary types of expansion joints are elastomer and metal. Elastomer expansion joints are usually fabricated from natural or synthetic rubber and reinforced with fabric. In some cases, metal body rings are added for reinforcement. Elastomer expansion joints accommodate greater pipe movement than metal units, offer a wider range of spring rates and have higher abrasion resistance. They also provide acoustical impedance and visible signs of fatigue, alerting users to potential failure.
Metal expansion joints are usually constructed in a bellows-like configuration from relatively thin-gauge material designed to absorb mechanical and thermal movements. They can withstand temperatures of up to 1,800°F (982°C) and pressures up to 1,000 psi, both of which are beyond the capabilities of elastomer joints. 3.
WHEN SELECTING EXPANSION JOINTS, WHAT ARE SOME KEY CONSIDERATIONS TO ENSURE SUCCESS?
It is important to understand how process conditions will affect expansion joints. In selecting the proper expansion joint for a particular application, the following factors should be taken into account: t
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THEY AVOID OR RESPOND TO SUCH PITFALLS?
4.
WHAT ARE SOME OF THE VARIOUS EXPANSION JOINT ACCESSORIES, AND DO THEY AFFECT FLUID CONVEYANCE?
Retainer rings should be used for all elastomer expansion joints to distribute bolting pressure evenly and prevent flange damage during tightening. The rings are installed directly against the back of the expansion joint flanges and bolted through to the mating pipe flanges. This helps to ensure that a seal is created between these flanges. Control units are recommended for most applications to prevent damage due to excessive pipe movement. These units consist of two or more control rod assemblies to minimize potential damage from excessive axial movement. They also prevent over-elongation and excessive compression if compression nuts are used. Flow liners extend service life by protecting elastomer expansion joints from abrasive materials, particularly in high-velocity applications. These liners prevent fast-flowing fluids or highly abrasive slurries from prematurely degrading the expansion joint tubes. 5.
WHAT ARE SOME BEST PRACTICES YOU CAN OFFER IN THE AREAS OF SPECIFICATION, INSTALLATION AND MAINTENANCE OF EXPANSION JOINTS TO ENSURE LONG-TERM PERFORMANCE?
The service life of an elastomer expansion joint is subject primarily to service conditions and pipe misalignment. With proper storage and installation, this type of expansion joint can be expected to last approximately five years under moderate service conditions and minimal misalignment.
The biggest pitfall is subjecting expansion joints to conditions beyond their specified capabilities. Expansion joints are designed to operate within certain ranges of temperature, pressure and movement. When operating conditions exceed these parameters, premature failures occur. It is therefore recommended to work with your supplier to assure the correct expansion joint is specified for a particular application. 7.
HOW DOES THE INDUSTRY INTEND TO ADDRESS APPLICATIONS THAT DID NOT MEET EXPECTATIONS?
WHAT IS THE PROCEDURE FOR ACHIEVING THAT? Many industries such as power generation and chemical processing have associations and user groups that meet regularly to review members’ concerns. These meetings cover technical issues and provide an opportunity for members with similar problems to compare their experiences and pursue corrective action. 8.
WHAT IS THE PROSPECT FOR NEW EXPANSION JOINTS TECHNOLOGIES? HOW WILL THE TECHNOLOGY OF TOMORROW BE MORE EFFECTIVE/EFFICIENT THAN THE TECHNOLOGY OF TODAY?
The best innovations are customer-driven through continuous feedback via sales and applications engineers. This type of innovation, which sometimes involves direct collaboration between the manufacturer and customer, focuses on the latter’s need to improve not only operational performance, but also sustainability and plant safety.
WHAT ARE THE PLANS FOR THE
An area of particular focus is providing customers technical support Training seminars for installation and maintenance personnel address topics such as expansion joint removal, visual inspection, proper bolting, lifting and lugging, trouble-shooting, dimensional verification and others. It is also important to instruct customers in preventative maintenance through routine, on-site inspection of all the expansion joints in their facilities. This enables timely replacement of worn joints to avoid catastrophic failures. Also provided are failure analysis reports, offering insights into the root causes of expansion joint failures. These reports help improve the mechanical integrity of plant equipment, and can be used to create and maintain a data file for future reference. 10.
FROM YOUR VIEWPOINT, WHAT ARE THE HIGH-LEVEL BEST PRACTICES YOU TYPICALLY PROPOSE?
It is critically important to work with an expansion joint manufacturer that offers a complete package of products and technical support. A full-service supplier that can recommend the correct expansion joint for a given application will help improve plant safety, the mechanical integrity of the system in which it is installed, and ultimately the user’s competitive position in the marketplace.
neW compact process analyses family – economical online monitoring of industrial Waste Water and more
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etrohm Process Analytics presents the new family of economical online process analysers: the 2026 Titrolyzer and 2029 Process Photometer. These powerful, compact process analysers are integrated solutions for 24/7 online analysis of critical chemical parameters in industrial processes and wastewater streams. Each single-method system is available in several application-specific configurations for monitoring up to 2 process streams.
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Three basic configurations for titrimetric/ISE, pH, or photometric measurements The 202X Process Analyser family comes in three basic configurations, covering several market needs. The 2026 Titrolyzer is suitable for titrimetric, ion selective, or pH measurements. The 2029 Process Photometer performs photometric absorption measurements in the visible light
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PECM Issue 29
range. A 7� full-color touchscreen shows trend graphs and allows easy access to your data. These process analysers are especially suitable for analysis in the chemical, petrochemical, semiconductor, food and beverage, potable water, and environmental branches. Customized for your application Metrohm Process Analytics can offer process analysers which are configured for each specific application challenge. Sample dilution, extra reagents, or even another sample stream can be added with the addition of peristaltic pumps in the modular wet part. Robust design (IP66) Strict separation of wet part and electronics ensures safe operation in harsh environments. The electronics part is housed within non-corrosive polyester-coated stainless steel. With an Ingress Protection
rating 66, the analyser is guaranteed to be dust and water-tight. Virtually unlimited sample conditioning options Metrohm Process Analytics provides virtually any sample preconditioning system, such as cooling or heating, pressure reduction, degassing, filtration, and more. Diverse data communication Information including results, remote control and status info, can be communicated through discrete I/O (i.e. analog outputs digital in/outputs), MODbus TCP/ IP (Ethernet), or RTU (RS485) communication. Remote control is possible through VNC (Ethernet). Results can also export to USB. For more information visit www.metrohm.co.uk or contact process@metrohm.co.uk
TERMITRAB Complete
Benchmark Surge Protection for the Process Industry The The protection protection of of signal signal lines lines is is often often forgotten forgotten
about about concept concept with with many many industrial industrial sectors, sectors, not not so so with with the the process process Oil Oil and and Gas Gas and and Petrochemical Petrochemical industries. industries. Installations Installations such such as as refineries, refineries, oil oil and and gas gas pipelines, pipelines, gas gas processing processing facilities, facilities, Oil Oil or or Gas Gas storage storage facilities facilities are are all all massively massively important important infrastructure infrastructure assets assets that that rely rely heavily heavily on on the the reliable reliable operation operation of of electrical electrical and and electronic electronic equipment equipment including including safety safety and and emergency emergency shutdown shutdown systems, systems, and and anything anything that that threatens threatens the the smooth smooth operation operation of of these these systems systems is is mitigated mitigated against. against. One One such such eventuality eventuality is is the the risk risk of of lightning lightning strike strike and and the the potential potential for for direct direct or or indirect indirect damage damage that that lightning lightning strikes strikes pose. pose. Oil Oil & & Gas Gas Installations Installations are are particularly particularly susceptible susceptible given given their their large large surface surface area, area, location, location, design design and and the the use use of of multiple multiple field field mounted mounted modern modern measuring measuring and and control control equipment. equipment. The The cost cost involved involved in in planning, planning, designing designing and and installing installing surge surge protection protection measures measures are are out out of of all all proportion proportion when when compared compared with with the the maintenance maintenance costs costs that that result result from from damage damage to to sensitive sensitive control control systems, systems, not not to to mention mention potential potential revenue revenue loss loss due due to to operational operational downtime. downtime. Earlier Earlier this this year year Phoenix Phoenix Contact Contact unveiled unveiled aa completely completely new new family family of of Surge Surge Protection Protection Devices, Devices, TERMITRAB TERMITRAB COMPLETE COMPLETE (TTC). (TTC). This This is is the the world’s world’s narrowest narrowest range range of of surge surge protective protective devices devices for for Measurement, Measurement, Control Control and and Regulation, Regulation, or or in in other other words words surge surge protection protection devices devices for for signal signal lines. lines. So So what what are are the the main main requirements requirements for for the the process process sector? sector? One One of of the the main main trends trends is is for for aa higher higher packing packing density density in in the the control control cabinet cabinet and and itit is is not not uncommon uncommon for for several several thousand thousand signals signals terminating terminating in in high-density high-density marshalling marshalling cabinets cabinets with with the the consequence consequence that that ever ever narrower narrower components components are are required. required. With With the the TERMITRAB TERMITRAB Complete Complete the the narrowest narrowest devices devices are are just just 3.5 3.5 mm mm wide, wide, by by far far the the slimmest slimmest on on the the market. market. The The devices devices are are
equipped equipped with with six six terminal terminal points points to to which which two two signal signal lines lines each each and and aa common common reference reference potential potential can can be be connected. connected. This This allows allows protection protection against against surge surge voltages voltages of of 572 572 signal signal conductors conductors in in just just one one metre metre of of cabinet cabinet space. space. The The use use of of decoupling decoupling resistors resistors has has also also had had the the effect effect of of significantly significantly reducing reducing power power dissipation, dissipation, another another key key requirement requirement of of high high density density signal signal packing. packing. Having Having the the relevant relevant approvals approvals are are of of vital vital importance importance to to the the Oil Oil and and Gas Gas industry industry and and process process industry industry in in general general and and hazardous hazardous area area approvals approvals especially especially so. so. TERMITRAB TERMITRAB complete complete also also offers offers the the ideal ideal solution solution for for protecting protecting signals signals in in intrinsically intrinsically safe safe circuits circuits with with Ex Ex ii type type of of protection. protection. The The properties properties of of the the intrinsically intrinsically safe safe circuit circuit are are not not affected affected by by the the installation installation of of the the surge surge protection protection module, module, and and devices devices can can be be installed installed in in Ex Ex Zone Zone 1, 1, Ex Ex Zone Zone 22 or or in in the the non-Ex non-Ex area area and and the the signals signals can can be be forwarded forwarded through through to to Ex Ex Zone Zone 0. 0. The The products products are are approved approved according according to to ATEX ATEX and and IECEx IECEx Where Where Phoenix Phoenix Contact Contact is is leading leading the the way way is is by by providing providing surge surge protection protection devices devices that that offer offer more more than than just just surge surge protection. protection. The The TERMITRAB TERMITRAB Complete Complete range range offer offer more more than than just just surge surge protection, protection, they they can can also also be be used used as as fully fully fledged fledged terminal terminal blocks blocks in in cable cable distribution distribution cabinets cabinets and and marshalling marshalling cabinets cabinets thus thus reducing reducing the the number number of of required required components components to to connect connect field field instruments instruments to to the the control control system. system. The The TERMITRAB TERMITRAB Complete Complete has has been been designed designed with with “operability” “operability” in in mind, mind, and and includes includes versions versions with with additional additional functions functions to to provide provide support support during during maintenance maintenance and and scheduled scheduled shut shut downs. downs. Integrated Integrated knife knife disconnection disconnection allows allows separation separation of of signals signals from from the the controller controller side side and and field field side side which which allows allows loop loop resistance resistance testing testing directly directly on on the the terminals terminals of of the the SPD. SPD. The The lightning lightning protection protection standards standards recommend recommend regular regular inspection inspection of of protective protective devices. devices. This This is is only only possible possible through through visual visual
To To know know in in detail detail how how the the TERMITRAB TERMITRAB range range can can give give you you the the best best surge surge protection, protection, email email marketing@phoenixcontact.co.uk marketing@phoenixcontact.co.uk or or visit visit the the webiste. webiste. www.phoenixcontact.co.uk/TERMITRAB www.phoenixcontact.co.uk/TERMITRAB
examination examination and and this this family family of of products products has has built built in in overload overload detection detection and and feature feature aa mechanical mechanical status status indicator indicator that that displays displays an an overload overload of of the the surge surge protection protection directly directly on on the the device. device. Since Since itit is is purely purely mechanical, mechanical, no no additional additional power power is is needed needed for for this this indication. indication. With With the the pluggable pluggable options, options, where where the the surge surge protection protection components components are are housed housed within within aa detachable detachable plug, plug, there there is is also also the the ability ability to to remove remove the the plug plug and and test test its its integrity. integrity. Removal Removal of of the the plug plug has has no no effect effect on on the the system system availability availability while while itit is is being being tested, tested, and and testing testing is is straightforward straightforward using using the the Phoenix Phoenix Contact Contact Checkmaster Checkmaster II. II. There There is is also also the the possibility possibility to to monitor monitor the the status status of of up up to to 40 40 surge surge arresters arresters using using the the remote remote signalling signalling modules modules which which can can be be installed installed at at each each end end of of aa row row of of SPD’s. SPD’s. Any Any resulting resulting error error status status can can be be forwarded forwarded to to subsequent subsequent systems systems via via aa floating floating contact contact— —consequently consequently monitoring monitoring can can be be easily easily integrated integrated into into aa control control system. system. So So in in summary, summary, the the TERMITRAB TERMITRAB Complete Complete range range has has the the following following features. features. Narrow Narrow overall overall width width with with versions versions starting starting from from 3.5mm 3.5mm Tailored Tailored portfolio portfolio –there –there is is aa version version for for almost almost any any MCR MCR application application whether whether itit is is protection protection current current loops, loops, analog, analog, digital digital or or temperature temperature signals signals Easy Easy testing, testing, thanks thanks to to pluggable pluggable version version of of surge surge protective protective devices devices Built Built in in overload overload detection detection and and Status Status indicator indicator Optional Optional remote remote signalling signalling set set enabling enabling communication communication up up to to higher higher level level system. system. Worldwide Worldwide use use in in potentially potentially explosive explosive areas, areas, thanks thanks to to ATEX ATEX and and IECEx IECEx approvals approvals
Surge protection in thin slices The 3.5 mm solution for MCR applications TERMITRAB complete is the world’s narrowest surge protection for MCR technology. The new product range provides you with a complete system kit, featuring a status indicator and optional remote signaling. The narrowest protective devices are only 3.5 mm wide.
For additional information call +49 52 35 3-00 or visit phoenixcontact.com
TT 03-16.000.L1 © PHOENIX CONTACT 2017
editors choice
H2scan H2scan was founded in 2002, and has its headquarters, sales, production and marketing staff in Valencia, California. The Company provides the most accurate, tolerant and affordable hydrogen leak detection and process gas monitoring solutions for industrial markets. H2scan enables the accurate monitoring and control functions for a wide range of applications, including control systems, safety monitoring and alarm systems. H2scan also provides portable, handheld configurations for easy leak detection and monitoring. H2scan supplies their hydrogen process analyzer and hydrogen leak detectors to utility, petrochemical, refinery, and gas line companies, nuclear power plants, fuel cell, petroleum and other industrial organizations through 10 long term supply agreements. H2scan helps its customers meet safety, regulatory and process control requirements while doing critical hydrogen monitoring. For more information, please visit www.h2scan.com
Mapvision
Metrohm
Mapvision Quality Gate is the fastest 100% in-line inspection system for welded and die cast car body and chassis components. It can measure hundreds of 3D features in less than 30 seconds.
Metrohm Process Analytics presents a new family of economical online process analysers: the 2026 Titrolyzer and 2029 Process Photometer. These powerful, compact process analysers are integrated solutions for 24/7 online analysis of critical chemical parameters in industrial processes and wastewater streams. Each single-method system is available in several applicationspecific configurations for monitoring up to 2 process streams.
The Mapvision technology is based on closerange multi-camera photogrammetry combined with image recognition. A fully digital measurement process, there are no moving parts or robots. This makes it faster and more accurate than any other in-line measurement system. Mapvision Ltd Ruosilantie 10 FI-00390 Helsinki, Finland www.mapvision.fi/en UK Sales: Mr. Jarno Pääjärvi jarno.paajarvi@mapvision.fi Tel +358 50 439 0916
The 202X Process Analyzer family comes in three basic configurations, covering several market needs. The 2026 Titrolyzer is suitable for titrimetric, ion selective, or pH measurements. The 2029 Process Photometer performs photometric absorption measurements in the visible light range. A 7” full-colour touchscreen shows trend graphs and allows easy access to your data. For more information visit www.metrohm.co.uk or email us at info@metrohm.co.uk
Great disc filters, greater service… Helapet’s Filter Devices division specialise in the manufacture of bespoke or off-the-shelf inline disc filters used for precise filtration and clarification of particulates in air/gas or liquids. Each filter is manufactured in-house to our ISO 13485 accredited standard by a highly skilled cleanroom team in ISO Class 7 rated cleanroom facilities, equipped with the latest machinery providing a quick yet accurate output. Incorporating a variety of filter media and membrane options including PTFE, HEPA, PES, WPE and Nylon, with our extensive range of inlet/outlet connectors, each inline disc filter is produced to your exact specifications. Inline disc filters are used in a multitude of essential industry applications including instrument protection, sterile venting, particulate filtration and ink clarification. Helapet produce filters that are low linting, clean and chemically compatible negating the use of adhesives or binders. Ultrasonic welding techniques and over-moulding maintains integrity, allowing our filters to withstand intense heat and pressure without the risk of bypass or compromising flow rates. For specific applications we offer our customers a chance to custom design and build their own disc filter. Our end-to-end consultation service ensures that each unique filter is manufactured to the exact specifications of the client before the final design is completed. Using professional Computer Aided Design (CAD) software our team will work with you to get the filter design approved and ready for production, supported by manufactured samples. Hear what our customers have had to say: “We have been impressed by the quality of the filters provided by Helapet. Deliveries and lead times have been very good. An additional benefit has been the level of support on a technical basis, advising of the materials to be used and the professionalism of the sales and engineering staff.” Medical device manufacturer, UK Email us at filters@helapet.co.uk and send us details of your filtration requirements, or visit www.filterdevices.co.uk to learn more.
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PECM Issue 29
editors choice
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Issue 29 PECM
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rittal’s solutions for centralised or de-centralised automation We live in a world of rapid change, driven by the growth of ‘smart technology’. Automation components are becoming more compact, both for centralised and decentralised applications, while still delivering considerable computing power. Sensors and actuators are also getting more ‘intelligent’. Packing components into an enclosure is a science and an art. The engineer must plan the interior configuration to reduce wasted space and optimise the size of the enclosure, yet avoid issues such as over-heating or problems of future access to any of the components. Rittal offers customers a range of solutions for the safe packing of sophisticated electronics systems, both centralised and decentralised.
s well as a huge range of enclosures in different sizes, materials and paint specs, employing the company’s sophisticated Eplan software allows engineers to populate the panel in a CAD format, optimising the use of space while enabling changes to be made quickly and easily before applying them in a workshop.
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RITTAL “THERM” SPEEDS-UP CLIMATE CALCULATIONS Component size is typically determined by the space needed for terminals, connectors, and clamps, as well as their accessibility for commissioning, servicing, and maintenance. As components get smaller, enclosure packing density is increasing. Furthermore, new functionality such as power management, networking etc, means that additional components are being put in all the time.
Paul Metcalfe, Rittal’s Industrial & Outdoor Enclosures Product Manager comments: “Reducing the size of individual components has not had a noticeable effect on the available space within enclosures, mainly because this is largely determined by the arrangement of the DIN rails, cable ducts and other components. Components are frequently installed in groups and space can only be marginally optimised by individual components. “We would caution that where space is taken up by smaller components, users should review climate control because higher packing densities increases the overall risk of hotspots. The good news is this doesn’t have to be a laborious task because Rittal’s “Therm” application performs the calculation of climate control in its entirety, providing users with appropriate and correctly dimensioned solutions.”
Photo: fri110281200Rittal-Centralisedor-DecentralisedAutomation Source: Rittal Limited
COMPONENTS IN DISTRIBUTED SYSTEMS Major distributed systems are commonly found in the petro-chemical industry and conveyor systems. They employ less technically advanced enclosures to house control equipment in a separate room, however, the cost of cabling to connect to the machinery can be high. Rittal’s range of enclosures includes models with high IP ratings in sheet steel, stainless steel or plastic, designed to protect the equipment housed in it. This means that, rather than putting the control gear in a separate room, all the control gear can be next to the machine itself. This offers cost savings around the amount of cabling needed and this type of locally-employed enclosure distribution is often more efficient because of the specialist protection it provides the equipment against dust and oil. In other, highly-sensitised environments such as the food industry where hygiene standards must be met, users now have a choice of both the materials used and the enclosure design, in order to prevent contaminants being deposited and simplify cleaning.
Are you COOL about the internal temperature of your enclosures? ENCLOSURES
POWER DISTRIBUTION
CLIMATE CONTROL
COMPACT MACHINES AND DECENTRALISATION In decentralisation, the focus is around making machines as compact and centralised as possible to make it easy to commission them. Machines can be assembled as complete transportable units, however, the control technology for the machines needs to be in the right place. This can be done either by machine-integrated standard enclosures or through appropriate integration in the body of the machine. Paul advises: “We have products, accessories and expert advisors who can advise around protection category, heat dissipation, EMC (electro-magnetic compatibility) and the corresponding installation regulations/ requirements, which all have to be taken into account.” Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.
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Editors Choice
Process Monitoring made easy With the Onset HOBO UX120-006M 4-Channel Analogue Data Logger from Tempcon Instrumentation. The high-performance LCD display data logger for process control applications. •
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Accepts a wide range of sensors, incl. 4-20mA, AC Current, AC Voltage, Air Velocity, Carbon Dioxide, Compressed Air Flow, DC Current, DC Voltage, Differential Pressure, Gauge Pressure, Kilowatts (kW), Temperature and Volatile Organic Compounds. LCD displays near real-time measurement data Minimum/maximum/average and standard deviation logging options On-screen alarms.
Only £117.62 Ex VAT For a full solution including sensors, or just some friendly advice – contact the Tempcon technical sales team. Call +44 (0)1243 558270, or email: info@tempcon.co.uk www.tempcon.co.uk/ux120
TRINAMIC Motion Control GmbH & Co KG TRINAMIC Motion Control announces the TMCM-1633-CANopen, a new compact 300W BLDC servo controller module with sinusoidal commutation compatible with the industry standard CANopen protocol. The TMCM-1633-CANopen is a cost-efficient module embedding advanced motor control and motion control functions, as well as PLC features. The new drive (92mm x 50mm) is equipped with a CAN interface, CANopen (CiA-402) protocol stack and Trinamic’s free TMCL-IDE. The module provides a flexible, cost-effective solution to decentralized coordinated control of BLDC or BLAC motors of up to 10A RMS continuous current at 48V supply voltage. Featuring field-oriented control using a/b/n incremental encoder signals, the BLDC servo controller allows for precise and dynamic positioning and trapezoidal ramping. The firmware supports hall sensor inputs for faster initialization. TRINAMIC Motion Control, Waterloohain 5 22769 Hamburg, Germany Site: www.trinamic.com Email: tmc_info@trinamic.com
Altra We are a leading global designer and manufacturer of quality power transmission and motion control products utilized on a wide variety of industrial drivetrain applications. Altra clutches and brakes, couplings, gearing and PT component product lines are marketed under 23 well known manufacturing brands. Each of these businesses is committed to the guiding principles of operational excellence, continuous improvement and customer satisfaction. Highly-engineered Altra solutions are sold in over 70 countries and utilized in a variety of major industrial markets, including food processing, material handling, packaging machinery, mining, energy, automotive, primary metals, turf and garden and many others. Contact: 300 Granite Street, Suite 201 Braintree, MA 02184 Phone: 781-917-0600 Fax: 781-843-0709 Email: info@altramotion.com
INDUSTRIAL FLOORING FROM RESPOL
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Respol are family owned industrial flooring specialists with over 30 years of experience. Their epoxy and polyurethane flooring systems are strong, durable and easy to maintain – able to withstand anything you throw at them. No matter the requirements of your industry: low-slip, anti-static, chemical resistant, suitable for heavy traffic, fast overnight curing or just easy to clean – they have a solution.
accidents while still looking great along with oil retaining ramps around machines and bund walls if required.
If an oily environment is your main concern then their seamless flooring solutions are ideal. Combined with hardwearing aggregate, lowslip flooring helps prevent
Keep both feet on the ground with dependable and guaranteed industrial flooring - call 01952 740400 or visit www.respol.co.uk
For further safeguarding, you can add health and safety markings such as pedestrian crossings, walking men, ear defender logos etc. as Respol offer health and safety markings and demarcation lining as a standard part of their service.
optimas increases productivity for cancer diagnostic eQuipment manufacturer arly diagnosis of cancer can greatly improve survival rates, with health centres utilising the latest technology to ensure identification of the condition is achieved sooner. Cancer diagnosis machines are at the forefront of this technology, which emphasizes the importance of smooth manufacturing operations when producing such equipment. When one leading manufacturer was experiencing downtime due to fastener issues, they contacted Optimas to help improve productivity.
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The manufacturer was suffering between 15-30 minutes of downtime on a daily basis, with the entire production line coming to a halt in such circumstances. The fasteners were identified as the cause of the stoppages: certain components that were installed via airgun presented multiple issues. Firstly, fasteners were becoming jammed during installation into the machine's sheet metal. Furthermore, fasteners were becoming stripped of their coating, and in more severe cases, the applied torque was forcing the airgun out of the operator's hands, causing health and safety concerns. Optimas was contacted by the manufacturer due to a proven track record of developing and supplying fastener solutions globally to OEM manufacturers
of medical equipment. The business operates a vast component portfolio, backed by a highly efficient logistics network that blends global capability with local points of contact. Often consulted at the initial design stage of projects, Optimas was a logical choice to tackle the challenges presented by this particular component. Working closely with the manufacturer's engineering teams and the part supplier, Optimas fastener experts started to assess what aspect of the fastener was causing issues. Dialogue between the teams at this stage was key, and resulted in the identification of the cause. A section of the thread featured a nylon coating, which is often referred to as a 'patch'. The patch offered increased integrity, ensuring that the fastener could not back out from its aperture over a prolonged service life. However, Optimas engineers were able to identify that the coating was too thick, which was causing the jamming issues during the installation of the component. Having identified the root cause, Optimas engineers worked in conjunction with the supplier's engineering team to deliver a solution. Leaning on experience from originating custom parts for a wide range of demanding applications, Optimas and the supplier were able to
design and source a component where the nylon coating was reduced by 50%. The new component was introduced to the production line, and trailed in the manufacturing process. The benefits were clear. Jamming, stripping and associated injuries were entirely eliminated, minimizing potential risk to workers and greatly increasing the efficiency of production. By the introduction of this component alone, the manufacturer was able to increase productivity by 27%. The component was such a success, that it has now been accepted as an industry standard. Known as the 'light patch' the new component delivered the engineering performance required but with the benefit of easy installation. Identifying highly specialized solutions can reap huge efficiency rewards – whether dealing in large systems or individual components. By approaching the problematic fastener methodically, utilizing the existing engineering teams at both the supplier and manufacturer, Optimas was able to deliver tangible productivity benefits across an entire production process. It is proof that focusing on the small details can deliver big rewards. www.optimas.com Issue 29 PECM
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process engineers prepare to meet their supply chain
he process industry is broad in what it can offer, yet it makes an essential contribution to the engineering and manufacturing markets evey working day. Manufacturing employs 2.7 million people and contributes 45% of the UK’s total exports, according to the EEF, and what better way for these millions of people to connect then at the UK’s largest meeting place for advanced engineers.
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Advanced Engineering 2017 has become the hub for the variety of sectors that rely on advanced engineering. The Show, the largest free-to-attend open conference of its kind, takes place on 1-2 November, at the NEC, Birmingham; with the keynote speakers and thought-provoking industry topics announced. The Show is the place where the UK supply chain meets face-to-face with engineering management, spanning: process, control
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and plant industries; R & D; design; test; production & procurement from OEMs, integrators and top tier industry players. Registration numbers for visitors this year are nearly 50% more than at the same time last year; they will be coming from a range of engineering specialisms, including; measurements & monitoring, process control, drives and controls, sensors and systems, automation, fluid handling, food processing, machining and many more from a range of sectors. Alison Willis, industrial divisional director at Easyfairs, organisers of the Show, said: “We’re very excited about this year’s exhibition. With the industrial manufacturing and process engineering market growing strongly, Advanced Engineering 2017 is the place to find new suppliers and customers, and meet with existing contacts, to make this growth continue.
“We will bring together the latest advances in engineering, and just importantly the experts on topics that are consistently discussed within the specialist media.” Whether you are a visitor or an exhibitor, Advanced Engineering will not only provide you with a business forum and supply chain showcase for your own sector, but will also introduce you to new opportunities in industries using related technologies and services. Co-locating as part of the Show are five zones: t
Aero Engineering
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Composites Engineering
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Automotive Engineering
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Performance Metals Engineering
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Connected Manufacturing - NEW FOR 2017
One of the hubs which is being expanded this year is Enabling Innovation hosted by Magna International, a leading global automotive supplier. This is a dedicated area for up to 50 carefully selected SMEs and micro businesses which are at the early stages of their development, perhaps prototyping. And new to the show this year is the Connected Manufacturing zone, which will catalyse the business and technology opportunities that exist between innovators, customers and suppliers - including those within big data, automation and more. This marks a significant step in the revolution of Industry 4.0. The keynote speakers for Advanced Engineering 2017 open-conference have been announced and will include representatives from major OEMs and niche SMEs.
Topics will include how specific engineering problems have been overcome, as well as more strategic issues such as the fourth industrial revolution, Brexit, additive manufacturing and advances in aluminium engineering. Here’s a few of the issues that will be covered: t
Nissan - Meeting the needs of high volume production;
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Formaplex - Thermoplastic composites for automotive applications;
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EEF - Leading factories of the future. How the fourth industrial revolution (4IR) is shaping a new leadership and skills dimension; and
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GKN and Meggitt Modular Modifiable Manufacturing (M4) - Various aspects of manufacturing within aerospace engineering.
The Show is in its ninth year and has established itself as the leading event in the advanced engineering calendar. For more information on Advanced Engineering, or to secure your free ticket for the show, visit: www.advancedengineeringuk.com. Find regular updates on Twitter via #AEUK17.
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Boeing, ALFED and Nissan speakers for the UK's largest advanced engineering show Advanced Engineering 2017 today announced a raft of speakers and conference topics, including talks from Boeing, Nissan, ALFED and Composites UK. Topics will include how specific engineering problems have been overcome, as well as more strategic issues such as the fourth industrial revolution, Brexit, additive manufacturing and advances in aluminium engineering. The five co-locating zones within the show will have various discussions and keynote speakers during the two-day conference; below is a brief insight into the issues that visitors can expect to be covered by each specialism.
AEROSPACE ENGINEERING t
Denzil J. Lawrence, Boeing Commercial Airplanes - Innovation and technology effectiveness in the supply chain;
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Professor Meiling Zhu, Exeter University - Self powered wireless sensing in Aerospace - piezoelectric and miniature turbine;
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Simon Young, West of England Aerospace Forum (WEAF) - Want the Best? Look to the South West!;
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Alex Martin, Vapormatt - The Science of Control: Wetblasting redefined.
COMPOSITES ENGINEERING t
Faye Smith, Composites UK Supporting growth and demand in the industry;
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Chris Hare, NetComposites – Making Bad Composites for Good Reasons;
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Ben Morgan, AMRC - Automation and industry 4.0 for SMEs;
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Clive Chitiz, Plataine - Your Digital Assistant: AI and IIOT in the Service of Advanced Manufacturing Optimisation.
PERFORMANCE METALS ENGINEERING t
Jan Lukaszewski and Ian Oliver, ALFED - The Future's Light - Advances in Aluminium Engineering;
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Dr Uday Phadke, Cartezia - The chasm II funding challenge;
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Hywel Jarman, EEF, the manufacturers’ organisation UK Manufacturing and Brexit - an overview of latest insight and intelligence;
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Dr Steven Moseley, Hilti AG, European Hard Materials Group and European Powder Metallurgy Association (EPMA) - Developments in Hard Materials - Introducing the world of modern hard materials.
AUTOMOTIVE ENGINEERING
CONNECTED MANUFACTURING
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Dr Uday Phadke, Cartezia - The scale-up challenge for innovative engineering companies;
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Mike Wilson, BARA - Industry 4.0, smart factories and Autonomous (Mobile) Robots;
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Far Composites - City car carbon fibre structures;
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Andy Reilly, Granta Design - Materials information management for automotive product design and development;
Martin Strutt, EEF - Leading factories of the future. How the fourth industrial revolution (4IR) is shaping a new leadership and skills dimension;
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Tony Dye, Epicam - Phase-change in Air - A New Source of Zero Carbon Energy For A New Generation Of Allpurpose Engines; Jon Fenton, Fetu - Roticulation - A new mechanical paradigm enables new possibilities.
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Paul Hingley, SIEMENS - Digitisation Keynote;
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Grant Coffin, Rockwell Automation - Time To Value: implementing I4.0 solutions in the real world.
The show is newly ‘Continuing Professional Development (CPD)’ accredited for this year, by the CPD Certification Service. Recognised by
employers, and which complements the policies of professional institutes and academic bodies, it also acknowledges the effective professional development visitors of the conference can gain. Attending the conference will help visitors broaden their knowledge around the various advanced engineering sectors and the interesting and technical topics that will be discussed. Advanced Engineering 2017 is the place where the UK supply chain meets faceto-face with engineering management, spanning: process, control and plant industries; R & D; design; test; production & procurement from OEMs, integrators and top tier industry players within multiple industries. It takes place on 1&2 November at the NEC, Birmingham. Alison Willis, industrial divisional director at Easyfairs, the organisers of the exhibition, said: “We’re very excited about the speakers at this year’s exhibition; with presentations from Boeing, Nissan NetComposites and Magna International we’re set to have an interesting two days! “The conference will provide insights into topics affecting the array of industries our show covers. We have something for everyone and expert industry keynotes will allow for interesting discussions and Q&As, especially around the hot-topic of industry 4.0.” New for this year: a dedicated zone for industry 4.0, Connected Manufacturing; and an expanded zone for start-ups sponsored by Magna International. Now in its ninth year, the show is set for record breaking visitor numbers, bringing together over 700 exhibiting firms - all looking to source, specify and invest in the most up-to-date products and explore the latest industry innovations. For more information on Advanced Engineering, or to secure your free ticket for the show, visit: www.advancedengineeringuk.com. Find regular updates on Twitter via #AEUK17.
ADVANCED ENGINEERING2017
1 & 2 November 2017, NEC, Birmingham The UK’s largest annual gathering of advanced engineering professionals Advanced Engineering is the industry event where high-technology manufacturing sectors converge under one roof to meet and do business. Join us where the familiar and the unfamiliar collide to provide new opportunities across the engineering supply chain. Register to attend today!
AERO ENGINEERING COMPOSITES ENGINEERING AUTOMOTIVE ENGINEERING PERFORMANCE METALS ENGINEERING NEW FOR 2017
Register for FREE entry today mm www.advancedengineeringuk.com
advanced engineering show preview
• Intuitive drag & drop GUI for fast test creation • Touch-screen enabled • Extensive suite of calculations for materials testing • 4 models available: 5, 10, 25 and 50 kN • Optional extensometry and full range of test fixtures
connect 2 cleanrooms pioneering offsite cleanroom construction at advanced engineering 2017 Visitors can discover how Connect 2 Cleanrooms’ cleanroom systems (STAND B50) is using the latest construction methods to reduce failure rates and improve consistency for clients, adding value and efficiency to a process. By using the latest advances in Building Information Modelling (BIM) and off-site construction techniques, Connect 2 Cleanrooms’ methodology can potentially deliver a 3050% timescale reduction to a cleanroom project. Offsite construction delivers a consistent cleanroom environment, with 100% personalisation. It also has the added benefit of a ‘clean’ on site assembly, as every component is pre-engineered.
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A challenge for offsite construction is adapting the cleanroom to fit within existing buildings and structural layouts. Connect 2 Cleanrooms use BIM techniques such as point cloud 3D scanning; ensuring connecting interfaces between the cleanroom and building are managed to precise tolerances. Each cleanroom is designed specifically around organisations’ production environments, to protect processes from airborne contamination. Visitors to Advanced Engineering can discover its scalable cleanroom design options, such as hardwall, softwall and panel system wall construction. www.connect2cleanrooms.com
advanced engineering show preview
curtiss-Wright surface technologies Curtiss-Wright Surface Technologies (CWST) provides high quality surface treatments which will improve the life and performance of critical components through its global network of over 70 operating divisions and specialist onsite teams. Our surface treatments have been successfully used by OEM’s in major industries such as aerospace, automotive, oil & gas and power generation for many years. We are only too aware of the logistical challenges and costs faced by our customers and so we can offer a “One Stop Shop” solution providing a wide range of surface treatments including Controlled Shot and Laser Shock Peening, bespoke and trade Coating Applications, Thermal Spray Coatings and Parylene Coatings for metal, alloy, plastic and electronic components as well as Analytical Services.
We offer our customers a single source solution and point of contact for all their surface treatments, supporting their requirements through our global network of over 70 worldwide facilities and on-site field teams, improving and reducing turnaround times and costs. We are specialists in protecting components from common failures and reducing maintenance costs for key industries such as aerospace, oil and gas, automotive, medical and general industrial markets. Building on the unique heritage of Glenn Curtiss and the Wright brothers, CurtissWright Surface Technologies has a long tradition of providing innovative solutions and building solid and trusted customer relationships.
Full quality and customer approvals including NADCAP, ISO 9001:2008 and AS9100 Rev C. To find out more please visit www.cwst.co.uk
Leaders in surface engineering Increasing the performance and life of critical components l Shot peening l Peen forming l Thermal spray l Engineered coatings l Analytical services l Approvals: AS9100 Rev C l NADCAP l ISO 9001:2008 l FAA
www.cwst.co.uk/aerospace | eurosales@cwst.com | +44 (0) 1635 279621 CWST will be exhibiting at Advance Engineering in Birmingham on 1st & 2nd November 17, Stand L83 Issue 29 PECM
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intervieW Question and ansWer on ‘fluid mixing and mixers’ ixing is at the heart of most production systems and is of vital importance in the chemical process industry, pharmaceutical industry, food industry and other allied industries. Mixing is critical because the quality of the final product and its attributes depend on the quality of the mix. Good mixing is imperative for improved product quality, providing high yields, lowering operating costs and thereby enhancing profitability.
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Fluid mixing can be broadly classified into the following application classes blending of miscible liquids, blending of immiscible liquids, liquid gas mixing, liquid solid mixing, fluid motion. Though mixing of solids to some extent resemble the mixing of low-viscosity liquids, there are significant differences between the two processes. The wide variety and ever increasing complexity of mixing processes encountered in industrial applications requires careful selection, design and scale up to ensure effective and efficient mixing. Fluid mixing technology has vastly improved over the past decade. In addition to the laboratory and pilot scale trials, design engineers have access to tools such as Computational Fluid Mixing (CFM), Digital Particle Image Velocimetry (DPIV), Laser Doppler Anemometry (LDA), Laser Induced Fluorescence (LIF), for better understanding of mixing systems. As a result, equipment manufacturers have been able to develop and improvise impeller designs customized for end user applications. Moreover, the improvements and the technological advances in the mechanical, electrical, and electronic components, instrumentation and process control, have accelerated the development of mixing equipment that maximize mixing performance at lower power consumption.
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The success of mixing equipment largely depends on a good working relationship between the equipment manufacturer and the end user. While it is the responsibility of the equipment manufacturer to build, install and commission mixing equipment best suited to end user’s applications, it is equally important that the end user should clearly define the process materials, conditions and any special requirements. .A mixing equipment is no longer a generic production tool, but a critical and decisive business tool. This is because profitability and competitive advantage are dependent upon subtle improvements in product quality through gains in mixing performance and efficiency.
1) HOW DO FLUID MIXERS DIFFER FROM OTHER TYPES OF MIXERS/BLENDERS? Industrial applications involve mixing of solids to solids (free flowing solids and pasty materials), solids to liquids, solids to gas (reactions), liquids to liquids, and liquids to gas. Fluid mixing is generally associated with liquid – liquid mixing and liquid-gas mixing. Though mixing of solids to some extent resembles the mixing of low-viscosity liquids, there are significant differences between the two processes. These are as follows: Fluid mixing depends on the creation of flow currents, which transport unmixed material to the mixing zone adjacent to the impeller. In heavy pastes or masses of particulate solids there are no such currents are possible and mixing is accomplished by other means. Power required for mixing of dry solids and viscous pastes is higher than that consumed in blending of liquids.
In fluid mixing, a “well-mixed” product usually means a truly homogenous liquid phase. In mixing pastes and powders the product often consists of two or more easily identifiable phases, each of which may contain individual particles of considerable size. From a “well-mixed” product of this kind, small random samples will differ markedly in composition. As a result, there are several differences in the design, construction and operation of fluid mixing equipment as compared to solid mixers. Fluid mixing equipment are termed as liquid agitators. Solid mixing equipment are commonly referred to as mixers and blenders. While fluid mixing technology has been extensively studied and understood, solid mixing is more complex. The understanding of solid mixing, and the design of solid mixers continues to be art rather than a science.
2) HOW HAS FLUID MIXING TECHNOLOGY EVOLVED OVER THE PAST DECADE? HOW IS THE FLUID MIXING TECHNOLOGY OF TODAY MORE EFFECTIVE/EFFICIENT THAN THE TECHNOLOGY OF PREVIOUS GENERATIONS?
The end user’s understanding of fluid mixing technology has improved over the past decade. The highly competitive industrial environment requires that mixing equipment manufacturers constantly improve and provide customized solutions which are productive, efficient and economical. Equipment manufactures, industry are constantly in search of newer technologies and are investing in product research and development. The following are some of the significant improvements in the field of fluid mixing technology and equipment.
(a) New and improved impellers designs customized for specific processes and applications. (b) Impeller designs that maximize mixing performance at lower power consumption. (c) A more systematic and guided approach towards mixing studies, through applications of tools as Computational Fluid Mixing (CFM), Digital Particle Image Velocimetry (DPIV), Laser Doppler Anemometry (LDA), Laser Induced Fluorescence (LIF). This has resulted in manufactures being able to respond faster to the customer needs, problems and avoid time-consuming trialand-error physical testing. (d) Improvements in design, construction of power transmission system, drive system for the mixing equipment. Use of energy efficient electrical motors, efficient speed reducers (gearbox), electronic variable speed devices for optimizing agitator speeds based on process operation, mixer sealing designs and materials.
(e) The use of flush bottom product discharge valves, which ensure that there are no dead pockets / unmixed zones, within the mixing vessels, improved polishing standards for mixing vessels and agitators, improvements in instrumentation and process control, and so on.
(b) The desired capacity, productivity levels from the mixer per batch, per week, per month. It is important to state if the mixer would be in operation on a single shift basis or all throughout out the day. This information is required while carrying out the process design as well as the mechanical design of the mixer.
3) WHEN SELECTING FLUID MIXERS,
(c) The pre-processing equipment, from which material is transferred to the mixer. The post processing equipment to which material is transferred after the mixing. The plant and equipment layout for the mixer, and the related equipment. This shall help in better understanding of the process and operational requirements.
WHAT ARE SOME KEY CONSIDERATIONS AN END-USER SHOULD MAKE TO ENSURE SUCCESS?
The success of mixing equipment largely depends on the equipment manufacturers’ understanding of the end user’s requirement. It is therefore essential that the end user should clearly define the process materials, conditions and special requirements to the mixer manufacturer. These include the following: (a) The properties of fluid, materials being mixed, process parameters, operating conditions, required objective of mixing.
(d) In case the same equipment is likely to be used for multiple products, processes and applications, then all of these should be brought to the attention of the mixer manufacturer. The design of the mixer would have to be carried out taking accordingly. (e) Special requirements such as need for cleaning the mixer after every batch,
surface finish requirements for wetted parts of mixer, requirement for heating or cooling the mixer contents, operation of mixer under vacuum and pressure conditions, preferred sealing materials and sealing technology for mixer, equipment maintenance related requirements and so on should be clearly specified. (f ) If the end user has a previous experience of a similar or identical process, it is imperative that the relevant information is provided, along with the areas that may require improvement. The end user needs to ensure that the equipment manufacturer has understood his requirements and is equipped with the technology and resources to deliver the desired performance.
4) WHAT ARE SOME PITFALLS YOU SEE END-USERS COMMONLY ENCOUNTER IN FLUID MIXING APPLICATIONS? HOW CAN END-USERS BEST AVOID AND/ OR RESPOND TO SUCH APPLICATION PITFALLS?
The awareness of the end-users about
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the different types of agitator designs available, and their applications need to be increased. Moreover, a better understanding is required on the concepts of flow and shear, produced by the impellers. More often than not, end users prefer to duplicate their operational systems, even for new requirements which may be different from the existing. The effects of improper selection are realized much later, during actual operations. I would like to bring to you attention a very recent example, where in the works manager from a chemical company called me and asked me to quote for a “power saver” agitator for a 12,000 litres vessel. When, I enquired about his process, I was told not to worry about the technical aspects, since they felt that the “power saver” impeller was their best option. They termed the “hydrofoil impeller” as the “power saver” impeller, and chose it because someone told them that they would reduce on power consumption during agitation. Very few users know that hydrofoil impellers are available in different designs, solidity ratios, each of which is best suited for a particular kind of application. Users therefore need
to consider selection of the agitator types, keeping in mind their process requirements, properties of process materials and other operating conditions. It is recommended that the selection of agitators be carried out in consultation of the agitator specialist. Besides selection of impellers, scale-up of agitation equipment offers several challenges in fluid mixing. While scaling up, design factors such as the physical configuration of mixing vessel (off-bottom distance, spacing between impellers and the ratio of impeller diameter to tank diameter), impeller diameter, speed, power consumption, and so on need to be considered. Application pitfalls can be avoided by ensuring that the equipment manufacturer knows everything about the process, including what could go wrong in case there is a deviation in the process conditions. In case of new processes, applications, it is recommended that laboratory, pilot scale trials be carried out to establish process objectives and equipment design and performance parameters.
5) HOW DOES THE INDUSTRY INTEND TO EXPOSE THE APPLICATIONS THAT DID NOT MEET EXPECTATIONS? AND WHAT IS THE PROCEDURE FOR ACHIEVING THAT?
Mixing is a critical operation which determines the quality and properties of the products in the chemical, pharmaceutical, food and other related industries. Improper mixing can result in high product rejection, which may only be realized much later in the manufacturing process. The cost of improper mixing can have significant impact on the product bottom-line. More often than not, improper mixing is a result of incorrect selection or design of the fluid mixing equipment, agitator. With the myriad of mixing equipment available, it is a matter of understanding and application which is required, to identify the most suitable equipment. There are several instances where the mixing performance falls short of the user expectation. Improvements can be brought about identifying the gap between the existing operation and the required performance, and experimenting with changes in the process (if permissible) or through design modifications, changes in operating parameters of the equipment. In most cases this knowledge remains limited to end users and equipment manufactures. The end user prefers to maintain secrecy about special processes and equipment. Likewise the equipment manufacturers likes to safeguard what they have learnt, and use this information in business interest. In some cases however, equipment manufacturers provide case studies which are available in public domain and may be informative. Considering the wide variety of industrial applications, not every application in mixing has been studied and many applications are difficult to model computationally. As a result, it is sometimes laboratory trails become necessary.
6) WHAT ARE THE HIGH-LEVEL BEST PRACTICES YOU TYPICALLY PROPOSE AND ADOPT?
Unique Mixers has been a pioneer in the field of industrial mixing for the last thirty years. We lay emphasis on understanding the process objectives and the special requirements of the customers. Once the process needs are known, we draw Issue 29 PECM
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Jayesh Tekchandaney is the Technical Director at Unique Mixers & Furnaces Pvt. Ltd. (www.uniquemixer.com) and the Projects Director at Unimix Equipments Pvt. Ltd. Unique Mixers is engaged in the design, manufacture and supply of industrial mixers for liquid, solid and viscous mixing applications. Unimix Equipments manufactures a wide range of industrial process equipment such as reaction vessels, pressure vessels, columns, heat exchangers, ball mills. Unimix Equipment also has a custom metal fabrication division manufacturing stacks, pipings, ducts, heavy structures. Jayesh is the author of the chapter titled “Mixers” in a John Wiley publication titled “Process Plant Equipment Operation, Reliability and Control” and a contributor to the “Dictionary of Industrial Terms”. He is an expert adviser in the field of Industrial Mixing, and has to his credit articles on mixing technology published on his technical blog www.mixing-expert.com.
up the mixer specifications based on the inputs received from the customer and our special knowledge of mixing equipment, systems. The specifications provide details on equipment geometry, impeller type, power transmission system for the agitator, internal surface finish requirement of the mixer, material charging and discharge systems, electrical operations, instrumentation and so on. The specifications are reviewed along with the end user and fine tuned to achieve the desired objectives. The equipment design is thus derived based on process objectives and is backed by sound mechanical design. For new applications, we offer technology support through our laboratory and pilot scale testing facilities, which is equipped with prototypes of mixing equipment. These trials enable us to better understand the process and recommend a customized solution to the end user requirements. The focus on
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continual development is driven by the end users increasing demand to maximize productivity and performance from the process equipment. Sound engineering is backed up by the good manufacturing practices and guidance during equipment installation and commissioning. 7) What are some best practices you can offer end-users in the areas of specification, installation and maintenance of fluid mixing equipment to ensure the desired mixing performance and long-term trouble free operation? A good working relationship between the equipment manufacturer and the end user is critical to satisfactory mixing performance. It is the responsibility of the equipment manufacturer to build and deliver mixing equipment that has been custom designed for the end user’s
applications, and is maintenance friendly. The manufacturer should guide and assist in the installation and commissioning to ensure trouble-free operation of the mixer. The following are our recommendations. Mixer Specifications are to be clearly defined in terms of: (a) Process objective (b) Process materials and their properties (c) Equipment capacities – gross volume and working volume (d) Materials of construction for wetted and non-wetted parts of the mixer (e) Surface finish requirements (f ) Operating pressure and temperature conditions
procedures recommended by the mixing equipment manufacturer should be followed. The following are some of the common checks that need to be carried our during equipment installation : (a) Ensure that all components as per the manufacturers packing list are received and available at the place of installation. (b) Inspect all components visually to check for any damage to components during transit from the manufacturer’s factory to the place of installation. Any abnormal observations should be immediately reported to the manufacturer and corrective action should be taken. (c) Prior to installation, inspect the equipment gearbox seals, agitator seals for oil leakage. (d) Ensure that the steady bearings are properly aligned and are well lubricated. (e) Ensure proper alignment of coupling between the gearbox shaft and the agitator shaft, in-tank couplings if any. (f ) Ensure that the mixer seal is correctly installed. (g) Impellers are to be positioned and assembled as per manufacturer’s guidelines.
(g) Cleaning requirements (h) Mixer duty cycle (Hours of operation per day) (i) Heat transfer media (if any) (j) Compatibility of sealing material with process, operating conditions (k) Any abnormal conditions that may occur during operation, information relevant to the process, operation.
INSTALLATION Proper installation is critical to the satisfactory long-term performance of the mixing equipment. Improper installation can lead to expensive process downtime and repairs. It is recommended that installation
It is best to carry out installation under the supervision of the manufacturer’s qualified technician, to ensure that all the components are available and inspected prior to installation, and are satisfactorily installed at site. A trial run of the equipment in the presence of the manufacturer’s technician would give confidence to both the manufacturer and the end user about the satisfactory performance of the mixing equipment.
MAINTENANCE A good preventive maintenance program is necessary to ensure trouble free operation of the mixer, increase equipment life and minimize downtime. The following are our recommendations: As a first rule, follow the manufacturers’ guideline on equipment maintenance, to safeguard equipment guaranties. Equipment records, maintenance drawings, repairs and maintenance history should be well documented and easily accessible to
the operational and maintenance team. Critical equipment spares to avoid down time should be clearly identified and available. A preventive maintenance schedule, electrical and mechanical maintenance program, detailed lubrication program should be defined and strictly adhered to. 8) What is on the prospect in terms of fluid mixing technology? How will the fluid mixing technology of tomorrow be more effective/ efficient than the fluid mixing technology of today? Fluid mixing technology has made rapid advances in recent times. New impellers designs have ensured that mixing equipment are able to deliver precisely to the process requirements. These improvements have been catalyzed by advances in technologies such as Computational Fluid Dynamics (CFD), Digital Particle Image Velocimetry (DPIV), Laser Doppler Anemometry (LDA) and Laser Induced Fluorescence (LIF). CFD provides detailed analysis of fluid flow early in the development process. The effects of vessel geometry and internals such as baffles can be factored into the system design. Mixing problems, such as low-velocity areas, circulation zones, staging and anomalies in the fluid flow and other potential problems can be identified and quickly resolved, instead of adopting the conventional and time consuming trial and error process. Using DPIV technology, it is possible to measure the fluid velocity field in the mixing vessel at all points almost instantaneously thereby making it possible to study large-scale, time-dependent phenomena which are responsible for the mixing process. LDA is probably the best method of nonintrusively determining mean velocity and turbulence data to high level of accuracy. This information may be used with CFD to accurately determine the flow in the mixing vessel. LIF is a measurement technique, which provides both qualitative and quantitative assessment of mixing. The development and implementation of these technologies shall minimize the unpredictability associated with the mixing performance. Issue 29 PECM
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boilers & maintenance
The UK’s longest-standing steam expert Fulton launches the most radical change to boiler design in nearly 70 years Fulton’s new VSRT is claimed to be the most radical change to vertical steam boiler design since the company pioneered the vertical tubeless boiler in 1949! By adopting a systems-engineering approach to design and using its own ‘PURE’ technology, Fulton’s VSRT challenges the traditional heat transfer and mechanical design principles of vertical boilers. It also boasts industry-leading performance with up to 84% gross efficiency from a fully-waterbacked design with no refractory. With 30+ worldwide patents pending, the spiral-rib tubeless design is a world first and creates a compact boiler with the industry’s smallest footprint (40% smaller than Fulton’s equivalent 30hp J Series).
There’s only one steam boiler company that can boast over 120 years of operation, class-leading energy-saving solutions, and UK-manufactured steam boilers - CFB Boilers. Trusted experts We’re the trusted steam specialist for hundreds of companies across tens of industries, all of whom receive qualityengineered, high performance, reliable and energy-efficient steam and hot water solutions. Our credentials for technical excellence and engineering expertise are renowned in the industry, as is our genuine commitment customer service and satisfaction. Complete steam solutions CFB Boilers offers a complete range of specialist steam services, from design and installation to maintenance and repair. We pride ourselves on delivering exemplary customer service, fast quotation response, quick order turnarounds, and competitive pricing as standard. 01255 224500 sales@steamboilers.co.uk www.steamboilers.co.uk
Boilers & Maintenance www.fulton.co.uk
Babcock Wanson provides new boiler house & plant for Stolthaven terminals
Babcock Wanson has designed a new thermal fluid system to accommodate its high efficiency Thermal Fluid Heaters at Stolthaven Dagenham Ltd bulk liquid terminal situated on the river Thames in Dagenham, Essex. Babcock Wanson worked closely with Stolthaven Dagenham’s consultants to provide the final design of the boiler house and then install and fit it out with its EPC ES and TPC B Thermal Fluid Heaters. A large proportion of the thermal design was also carried out by Babcock Wanson with the supply of all the system valves and ancillary equipment to provide a complete system with single point of responsibility. The system also incorporates a secondary circuit to provide lower temperature thermal fluid for the bitumen pump casing heating. The project was a fast moving one with tight deadlines, all of which Babcock Wanson met.
Tel: 020 8953 7111
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PECM Issue 29
‘Real Time’ Remote Monitoring For The Boilerhouse HALO’ uses cutting edge technology, creating a monitoring system which uses analogue, digital and mod bus for a critical overview into asset performance. Benefits include: t Cost savings through optimal performance. t Instant alerts on failures – ‘when it matters’. t The ability to determine both maintenance and investment strategy. t Predictive maintenance to prolong equipment life. t Minimal downtime resulting in increased revenue. t Calculate and improve efficiencies, reliability and availability. t Anticipate service requirements and reduced risk of further damage. t Reduced labour costs. For details see ‘http://www.jbcindserv.co.uk/ halo-real-time-remote-monitoring-system
with single point of responsibility. The system also incorporates a secondary circuit to provide lower temperature thermal fluid for the bitumen pump casing heating. The project was a fast moving one with tight deadlines, all of which Babcock Wanson met.
boilers & maintenance www.babcock-wanson.co.uk
Tel: 020 8953 7111
Boilers & Maintenance Babcock Wanson provides new boiler house & plant for Stolthaven terminals
Babcock Wanson has designed a new thermal fluid system to accommodate its high efficiency Thermal Fluid Heaters at Stolthaven Dagenham Ltd bulk liquid terminal situated on the river Thames in Dagenham, Essex. Babcock Wanson worked closely with Stolthaven Dagenham’s consultants to provide the final design of the boiler house and then install and fit it out with its EPC ES and TPC B Thermal Fluid Heaters. A large proportion of the thermal design was also carried out by Babcock Wanson with the supply of all the system valves and ancillary equipment to provide a complete system with single point of responsibility. The system also incorporates a secondary circuit to provide lower temperature thermal fluid for the bitumen pump casing heating. The project was a fast moving one with tight deadlines, all of which Babcock Wanson met.
Tel: 020 8953 7111
CERTU Unit 45 Tyburn Birming B24 8T
www.babcock-wanson.co.uk
Gas Process Burners 24
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Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions. FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple high/low control options Heat Input Range: 9 kW – 1550 kW
D D D
D FD-C high turndown oven/
FD-E low cost high turndown
dryer air heating burners.
oven/dryer air heating burners.
FD-GA modulating gas + air process air heating burners.
TX Series Gas Fired Process Tank Heating Systems High efficiency (80%+) heating of all types of spray and dip process tanks Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space Accurate performance modelling using Lanemark TxCalc design software Heat Input Range: 15 kW (1½") – 1150 kW (8")
D D D D
Midco HMA Series Air Replacement or “Make-Up” Air Heating Burners Direct fired, high efficiency burner systems, for high volume air heating applications such as paint spray booths, ovens and dryers. Supplied either as Midco burner heads for OEM system integration or as Lanemark DB or FDB complete packaged systems including modulating gas valve trains and controls Wide range of firing rates to suit alternative temperature rise and air velocity system requirements DbCalc system design software
D D D
Midco HMA high efficiency,
high turndown, air replacement or “make-up” air heating burners.
TX high efficiency small diameter
D immersion tube tank heating systems. CERTUSS (UK) Limited
Unit 45 Gravelly Ind Park Tyburn Road Lanemark Combustion Engineering Limited Birmingham Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United B24Kingdom 8TG
Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.lanemark.com
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X4620 Lanemark Ad SDAW.indd 1
Tel : 0121 327 5362 Fax : 0121 328 2934 sales@certuss.co.uk www.certuss.co.uk COMBUSTION ENGINEERING
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31/08/2016 09:04
complete conveying solutions from advance automated systems
ith the e-commerce sector continuing its rapid growth, business processes and supply chains are becoming increasingly complex. Logistics operators are being forced to develop processes which are productive, flexible and as cost-effective as possible. Typically this will be reliant on warehouse modernisation and automation, particularly in optimising workflow efficiencies.
Advance SmartLine
Advance Automated Systems is one of the UK’s largest conveyor manufacturers, providing a single source for conveyors, conveyor systems and turnkey materials handling solutions including:
Based on 24v DC drive rollers, with options of round bands and V belts to drive individual zones, SmartLine provides cost effective accumulation and flow control for many end-of-line warehousing systems - perfect for handling delicate or varying shapes and sizes of product which need to be queued without contact.
W
t
Pallet handling conveyor
t
Tote and carton handling conveyor
t
Belt conveyors
t
Automated conveyor systems
t
Bespoke handling solutions
With a team of designers using the latest in 3D CAD software, Advance Automated Systems has worked with some of the UK’s largest blue chip companies, installing high quality conveyor systems across a range of industries, including press shops, logistics warehouses, food production firms, pharmaceuticals and many more.
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In addition to developing bespoke conveying solutions to suit customer requirements, Advance Automated Systems manufacture a solution called Advance SmartLine - a ZLP (zero line pressure) system, used extensively in manufacturing and logistics warehouses. Ideal for tote, box and carton conveying, the solution offers flexibility, modular design and efficiency.
The system can be controlled via a number of modules pre-fitted to operate independently, or on ASI, Profibus and Profinet with PLC control. Various control options can be utilised to provide basic routing through to unit tracking and reporting, thereby allowing integration with WCS and WMS systems. The Advance SmartLine system is also used as a pallet conveyor in a modular capacity, handling equipment for palletised product with capacities ranging from empty pallets to several
thousand kilos. The system can be used with individually driven pallet modules allowing for accumulation of pallets on the system or a single drive system where transportation without accumulation is required. The solutions provided can incorporate options of pallet de-stacking or stacking, pallet labelling and wrapping or pallet lifts and transport carts. Control options are similar to those included in the SmartLine tote/carton conveyor system which makes it easy to combine both systems for a complete turnkey package. Advance Automated Systems can incorporate third party equipment into conveyor systems to offer a full turnkey package and all systems can be fully mechanically and electrically installed by their experienced engineers. For more information call 01325 328 930 or visit www.advanceautomation.co.uk
Complete Conveying Solutions UK Manufacturing Pallet Handling Systems Carton & Tote Handling Systems 3D Design & Turnkey Solutions
advance a a uu tt oo m ma a tt ee d d ss yy ss tt ee m m ss
T: 01325 328 930 E: sales@advanceautomation.co.uk www.advanceautomation.co.uk
EMOLICE: POSITION DETECTION, MEASUREMENT & CONTROL With its wide range of position detection, measurement and control products, Emolice is quickly becoming the trusted technology partner to Manufacturing and Engineering companies across a wide range of vertical markets.
What’s more, POSITAL Product Finders accessed through the emolice.com website allow users to significantly reduce the time it takes to specify a sensor by selecting from simple drop down filters to zero in on a sensor that exactly meets an applications’ requirements.
Emolice is a leading manufacturer, distributor and service provider of position measurement technology based in Bracknell, UK. Offering complete sales and application support across a comprehensive range of position measurement technologies, Emolice are increasingly present in construction, general industry, manufacturing, oil & gas, agriculture, machine building and more.
Many more of the applications that Emolice support require process control and visualisation; whether as part of a building automation process, manufacturing process or discrete machine. Emolice successfully deliver the control and visualisation using Unitronics HMI and PLCs and act as their distribution partner for the UK.
At the core of many of the applications that Emolice support is the determination of Linear and Rotary position. As the UK & Ireland exclusive distributor for the POSITAL FRABA range of rotary encoders, inclinometers and linear position sensors, Emolice represent one of global leaders in position technology. As a member of the international FRABA Group, POSITAL is a market-leading enterprise which embraces Industry 4.0 in its’ own advanced product design and manufacturing processes. The result is that over a million variations of POSITAL rotary and linear products are available with short leadtimes and competitive pricing, including variants with specialist classifications such as ATEX and SIL2.
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Unitronics has been producing PLCs, automation software and accessory devices since 1989 and continues to set the benchmark for full-function, combined PLC and HMI operating panels with the lowest total costs of ownership available. All Unitronics software & utilities plus future updates and ongoing personalised Technical Support are provided at no charge. Full details on Emolice position detection, measurement and control products can be found at:
www.emolice.com or sales@emolice.com
All-in-One compact PLC + HMI with built-in I/Os • 5-inch colour-touch HMI • Supports: EtherNet/IP, Webserver, SQL, VNC, FTP and more • All software, utilities and support are provided at no additional cost
EMOLICE are UNITRONICS’ UK Distribution Partner
+44 1344 266530 | sales@emolice.com | www.emolice.com
Configure Premium POSITAL FRABA Encoders Online at
emolice.com
+44 1344 266530 | sales@emolice.com | www.emolice.com
SCADA Upgrade Refines Biodiesel Production taly's leading producer of refined biodiesel has optimised its production process by investing in Movicon SCADA, available in the UK through Products4Automation. The upgrade has enabled the green fuel producer to meet increased demand for its biodiesel product, with improved production management.
I
Located in Vasto in the Abruzzo region of the west coast of Italy, Fox Petroli built its name refining oil by-products,
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but in recent years has focused on the development of environmentally friendly fuels. The company's most recent development is biodiesel called BIOFOX, derived from rapeseed oil, and designed to produce less harmful emissions from diesel engined cars. With increasing demand for the product, short comings in the plant were becoming apparent. For example, each reactor had to be started up manually, and without full automation in both start up and operation there was regular
downtime. Making matters worse, the causes of downtime were often difficult to pinpoint, prolonging the production stoppages. Fox Petroli realised that it needed to improve production control and management with a solution capable of guaranteeing maximum efficiency and productivity. Making the whole process more cost-effective. The solution needed to be reliable and readily scalable, while being easy to control and simple to maintain in mission critical processes.
To realise these goals, the company turned to automaton systems integrator ESEA, that recommended Progea's Movicon SCADA solution. A plant control and monitoring system was installed with three redundant Movicon supervisory stations, connected to a Siemens S7-300 PLC over Ethernet. This architecture provides reliable control and security for all the biodiesel plant's processes. The platform is designed to monitor and supervise the whole plant, which is divided into nine process sectors corresponding to nine reactors that produce biodiesel. The sequential reaction processes refine the raw rapeseed oil with alcohol in a process called transesterification, producing a combustible fuel with properties very similar to diesel oil.
A by-product from the process, glycerine, is sold on for use in other types of industrial processes. The supervisory control system receives inputs from 50x analogue measurement points, including flow metres, level probes and temperature probes. And it provides control of 60x motors and pumps, as well as 45x valves. The Movicon software provides simplified production recipe management, enabling workers to easily identify and manage all operational parameters. Alarms and automated reporting of anomalies guide maintenance staff to restore production, and the system also provides information on targeted interventions or preventive actions based on historical analyses and statistics taken from data recorded on the most frequent or longest
downtimes. By using purposely designed Movicon graphical screens; the operator can control and monitor all the operations and the different phases of the processes comfortably from the plant control room. This extends from warehouse storage to refining and reactor processes, plus stockholding of produced materials. Redundant terminals guarantee the highest levels of security and continuity for the complex and sensitive process. In addition to the supervision of the production process, the system also highlights overall efficiency through each process, by recording data into a SQL Server database relating to quantities of raw materials used versus the final product quantities attained from each of the reaction systems.
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All of the analogue data is also archived to the database, along with details of events, enabling production analysis reports to be generated. Data is recorded at specific intervals according to the particular process, and historically logged data is displayed in trend windows. This provides essential feedback on how the plant is performing so that setup parameters can be refined to optimise product quality and plant efficiency. Detailed curve graphs representing production trends and can be printed according to defined or zoomed-in time ranges, or for the whole production period in general.
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With demand for biodiesel growing rapidly, there is a need for the suppliers in this new and dynamic industry to improve their efficiency. Thanks to its Movicon SCADA upgrade, Fox Petroli is now well placed to respond to growing demand, with the assurance of reliable, optimised processes and comprehensive historical analysis. www.products4automation.co.uk
Control & Automation
The world
never stands still We’ve been supporting the imagination of engineers for 80 years, bringing innovative products that inspire new solutions to tomorrow’s challenges. With the broadest product range available online for next day delivery, we make it easy; letting you get on with what really matters.
Visit RS Online today
uk.rs-online.com
MYTH #2
Robots will take over my job!
Myth busted: ”After adding robots to the production we increased incoming orders to such an extent we had to hire 50 new employees”. Dragan Jovanovic, Trelleborg Sealing Solutions
FIND OUT HOW TRELLEBORG INCREASED ORDER INTAKE URROBOTS.COM/TRELLEBORGCASE
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How the right choice of circuit breaker can open up new opportunities for savings
witch-mode power supplies (SMPS) have come a long way in recent years, and for many are now preferred in industry to their linear predecessors. Advantages include greater efficiency, smaller size and lower heat generation, making them ideal for use in densely populated cabinets.
S
It’s important to choose a circuit breaker that will work in tandem with the power supply in order to extract the best reliability and productivity performance with minimal down-time. Specifying the right circuit breaker and power supply early on in the design process can greatly reduce development costs later on. Whilst a modern SMPS is far more efficient than its linear counterparts, it is also far more complex. Despite recent advances, an SMPS supplying a 24 VDC system is not considered to be properly protected when employing thermomagnetic miniature circuit breakers (MCBs) as their reaction time can cause modern SMPSs to quickly go into overload, causing other branches and networks to experience a dip.
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However this can be mitigated with the use of an electronic circuit breaker (ECB), which constantly monitors current and reacts quickly to faults as a Z curve MCB would, while still allowing high inrush loads during start-up. This allows companies to save money by using a lower end power supply whilst pairing it with an ECB for enhanced overload protection. Modern ECBs are also very thin, which saves cabinet space and can allow a larger power supply to be accommodated. In an MCB circuit a low overcurrent can result in a slow trip, which can be exacerbated further by the use of long wires which create increased resistance. This can prevent the overload current from ever being reached, delaying the trip and preventing the circuit breaker from performing its job. An ECB continuously monitors the current, and switches off the circuit quickly in the event of a fault, even in low overcurrent conditions.
Some engineers may prefer to stick with older MCBs, perhaps due to familiarity or cost reasons, and there are solutions available for these configurations too. In such cases the reduced functionality of an MCB compared to an ECB can be offset up to a point by specifying a higher end SMPS and built-in overload features such as WAGO’s TopBoost function, which provides sufficient power with a multiple of the rated current for up to 50ms. The added functionality of a newer SMPS makes it more suitable with older MCBs, which means that companies can save time and money by only uprating the devices that they need to for the required level of protection. For more information about WAGO’s EPSITRON range of power supplies and ECBs, contact Product Specialist Phil Thompson at WAGO on 01788 568008. WAGO Limited Visit: http://global.wago.com/uk Telephone: 01788 568008 Email: ukmarketing@wago.com
SMALLER SMALLER JUST JUST GOT GOT STRONGER STRONGER
PFC100 PFC100 Controller: Controller: High High performance performance packed packed into into aa smaller smaller footprint footprint
•• Extremely Extremely compact compact and and maintenance-free maintenance-free design design saves saves control control panel panel space space
•• 600 600 MHz MHz processing processing power power allows allows seamless seamless automation automation of of complex complex industrial industrial systems systems •• Cost-e Cost-effective ective con configuration guration via via ee!COCKPIT C C engineering engineering software software •• Scalable Scalable modular modular system system ready ready for for future future challenges challenges •• Comprehensive Comprehensive on-board on-board data data security security packages packages
•• Two wo E ETHERNET HE E interfaces interfaces for for extensive extensive compatibility compatibility operating system system •• Linux Linux®® operating
•• C CODESYS ES S 3 runtime runtime system system
•• Blends Blends together together the the best best of of two two software software worlds worlds in in one one package package Telephone elephone 001788 568 6 00 008 E-Mail E-Mail ukmarketing@wago.com ukmarketing@wago.com Internet nternet www.wago.com www.wago.com Search Search for for “WAGO PFC100” C 00
More and less
Discover your freedom with rockStar® Moduplug RockStar® ModuPlug enables the flexible combination of all the necessary functions for power, signal and data transmission in a single application-specific interface.
HALF THE PITCH SIZE, TWICE THE
MORE SIGNALS – LESS SPACE -
MODULE SLOTS
TRANSFER MORE SIGNALS WITH THE
Up until now, there were two standard module widths for heavy-duty connectors: ‘Single 1.0’ and ‘Double 2.0’. Weidmuller has created new dimensions with the intermediate sizes of ‘Half 0.5’ and ‘Single Plus 1.5’. Four different module widths make for unprecedented levels of flexibility and allow for the construction of particularly space-saving connector solutions.
SAME ENCLOSURE DIMENSIONS
The sophisticated frames and modules can be installed with extreme ease and integrated into HDC enclosures with the IP65 and IP68 protection classes.
MORE POWER – LESS WEIGHT Users have the option of either using more functional modules within the same installation space or having the same functions as before but with a smaller frame and housing. The latter option helps to achieve weight savings, making it particularly suitable for applications in the fields of railway engineering and wind energy.
Thanks to a higher contact density – 36 signal contacts at a rated voltage of 250V, the double module HD36 achieves 50 percent more contacts in the same space as the market standard.
MORE OPTIONS – LESS COSTS - SAVE INSTALLATION SPACE, WEIGHT AND COSTS You can choose between four different module widths. The halved pitch size allows twice the number of module slots in the frame, plus the reduced pitch separation allows more functionality in the same space.
MORE CONVENIENCE – LESS RISK
MORE DATA – LESS LIMITS - A NEW LEVEL OF DATA TRANSFER
RockStar® ModuPlug offers assembly and disassembly without tools. A fixed locking position provides stability for faster and easier assembly. Incorrect connection is avoided through a unique coding system. In addition, there’s less wiring work required thanks to the ability to connect two PE cables of up to 10 mm².
Two Cat.6A cables each with 10 Gbits can now be integrated in a single module. The use of standard M12 connector technology achieves optimal EMC values and the 360˚ shield connection offers maximum protection against external interference.
PRODUCT SELECTION GUIDE You can find the right product quickly and accurately, using our product configurator. For more information, visit the Weidmuller website at www.weidmuller.co.uk or call them on 0845 094 2006.
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More freedom - Less effort RockStar® ModuPlug is setting new standards Let’s connect. Across all industries, the requirements placed on functionality are becoming more extensive and complex. RockStar® ModuPlug sets new standards. The modular connector system solves space problems by offering increased functionality with a reduced installation space. And all this with more convenient installation. Discover your freedom with RockStar® ModuPlug. Sales: 0845 094 2006 Tech: 0845 094 2007 Email: marketing@weidmuller.co.uk www.weidmueller.com/moduplug
over 100 new klAriUS CoMponentS BooSt AfterMArket eMiSSionS CHoiCe larius Products has further increased customer choice by expanding its range with over 100 new exhausts, catalytic converters (CATs), diesel particulate filters (DPFs) and accessories. The latest new-to-range list details every component released by Klarius during Q2 2017, which bolsters its 10,000+ product range to support an ever-larger range of vehicles.
k
As the UK's largest manufacturer of aftermarket emissions components, Klarius delivers new parts to market on a daily basis - enabled by its in-house R&D centre. New products in this release include centre pipes for the immensely popular Fiat 500, boxes with tailpipes for the famously indestructible 1995 Toyota Landcruiser 2.5TDI, CATs with pipes for the Volkswagen Transporter T5 2.5TDI, DPFs for the Ford Kuga 2.0 TDCI crossover and new front pipes for the stylish Alfa Romeo Mito 1.4.
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The latest list demonstrates Klarius' initiative to support the vast majority of vehicles on public roads, with a wide range of applications supported. The Klarius Emission Control range is aimed at both new and old hatchbacks, saloons, light commercials, MPVs, SUVs, sports cars, luxury cars and superminis – providing customers with unrivalled choice. Doug Bentley, Head of R&D at Klarius Products added: "This new range of components is proven to preserve or enhance the performance and efficiency characteristics of the intended vehicle, just like the rest of our range. Currently, we are bringing a series of new highquality components to market based on physical demand, this responsiveness we believe differentiates us from other manufacturers in the market. WE aim to deliver range, quality and availability to our customers throughout the UK and EU." All applicable Klarius exhausts, CATs and DPFs are type-approved to comply with EU legislation.
Parts are independently tested to emissions and noise standards defined and tested by regulatory organisations such as the VCA and TÜV. All products are fit tested to real world vehicles of correct make, model and production year – which allows Klarius to offer a 'Fit First Time' guarantee across the range. In addition, every component is delivered with a 2 year warranty as standard. Orders are delivered by the business' dedicated logistics fleet, which offers next morning delivery for UK customers. To see the full list of new-to-range components, download here. To search via the Klarius web catalogue, please click here. To keep pace with the latest Klarius news, check out the company Facebook and Twitter.
Control & Automation
ligHtweigHt HeAvy-DUty Drive SySteMS For harsh environments and rough handling conditions, the nsd tupH Sealed Surface Conversion System from NORD DRIVESYSTEMS provides corrosion-protection that penetrates deep below the drive surface. The treatment is available for worm, helical inline, and helical bevel gearboxes, smooth-surface motors, distributed frequency inverters and motor starters with an aluminum casing. Notably, users will benefit from the very long lifespan of drive technology with nsd tupH protection, which considerably lowers maintenance requirements and costs and increases plant availability. www.nord.com
Why You Need...
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Great Price 5 Comm Ports, Inc. Ethernet Real-Time Data On Display Easy PID Free No-Limit Programming Hardware Auto-Discovery Hot-Swappable I/O Built-in Data Logging Slim Form-Factor Multiple Wiring Options Integrated Web-Server Motion Made Easy
Lamonde Automation Ltd | +44(0)203 026 2670 | sales@lamonde.com Issue 29 PECM
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rAre rADiAl SteAM tUrBine rejUvenAteD
p
recision reverse engineering resolves vibration issues
Overhauling a steam turbine as part of a planned maintenance schedule is a regular task for many large-scale industrial enterprises that depend on these units to generate electrical power. However, for one pulp manufacturing plant in Eastern Canada, the refurbishment of its 25 MW Stal Laval radial steam turbine would need expert engineering to resolve the vibration issue – the first time this repair has been completed in North America and it would be successfully delivered by Sulzer.
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Industrial processes that have high power consumption often use on-site power generation to provide a cost effective power supply, but this entails also providing the necessary levels of maintenance support to keep the turbine operational. In many cases, this will be provided by a specialist service engineering company that has the necessary facilities and expertise to deliver timely repairs and maintenance. Minimizing repair times Steam turbines are used around the world to generate power, but the vast majority are of the axial flow design. In situations where radial flow designed units need to be repaired, they are usually shipped to
Europe, where they are more accustomed to this design. However, this increases the total repair time, which is a crucial factor when the entire manufacturing process relies on this power source. Manufactured in the 1970s, the 25 MW Stal Laval radial turbine uses steam that enters along the center-line of machine and expands outwards through two contra-rotating rotors until it reaches the exhaust pipework on the periphery of the turbine. The two rotors, left hand (LH) and right hand (RH) are made up of nine and eight stages respectively and are each coupled to a generator.
Sulzer is the leading worldwide, independent service provider for the repair and maintenance of rotating machines including turbomachinery, pumps and electro-mechanical equipment.
Although more common in Europe, radial turbines are also used in marine applications due to their relatively compact dimensions, compared to an axial turbine with a similar power output. Their design means that they are limited to a maximum output of approximately 30 MW, making them more suitable to small industrial generating sets rather than power generation for the grid.
In-depth assessment Initially, the customer contacted Sulzer asking for assistance with investigating a vibration issue on the steam turbine. Working with the customer, the Sulzer team examined the vibration data and also conducted a visual inspection of the rotors during a brief shutdown period. Analysis of the inspection showed that the RH rotor had helical linear cracks on all of the steam inlets, both rotors had excessive steam seal clearances and both of the rotor couplings would need to be replaced. Due to the design of the turbine, the only way to repair the steam inlets would be to completely remanufacture the right-hand stub shaft.
As the depth and complexity of the repair became apparent, it was clear that the project would require some of the specialist facilities in the Edmonton Service Center, which has considerable experience in reverse engineering complex components. With the aim of delivering a more reliable and efficient turbine, Sulzer instigated a metallurgical root cause failure analysis of the damaged shaft to determine if there were any design modifications that could be implemented before remanufacturing began. Even the repair of conventional steam turbines requires a considerable amount of high specification machine tooling and large capacity overhead cranes as well as a highly skilled workforce. When the repair involves an almost unique design, the experience and skill of the engineers really comes to the fore.
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Reverse engineering improvements
Precision manufacturing
The Edmonton Service Center specializes in the refurbishment and delivery of performance upgrades for large compressors and turbines.
Finally, the repair team turned their attention to the creation of two new rotor couplings, which connect the turbine rotors to the generators. The couplings are installed using a set of eight high tensile, tapered pins and a series of large, threaded sleeves that together ensure a uniform torque transfer.
The ability to design and create replacement parts through reverse engineering enables the team in Edmonton to deliver improved reliability and extended service life for a wide range of plant assets. The initial investigation showed that the material used to create the RH stub shaft could be replaced with ASTM A470 class 7 forging, which is commonly used in the modern turbine industry. The class 7 material has a higher nickel and chromium content, giving it a higher yield strength and better resistance to heat and corrosion than the original.
The rotor couplings also act as a journal bearing, supporting the overhung rotor. As such, the couplings had to be machined to a very tight tolerance with a high quality surface finish to ensure the perfect fit. The Edmonton Service Center is equipped with modern machining technology that allowed the high precision couplings to be manufactured on time. At-speed balancing
The new stub shaft was designed, machined, tested and inspected before it was ready for final assembly. In the meantime, the rotors were also refurbished with special attention paid to the steam seals which provide a uniform pressure drop between each turbine stage.
Once all of the machining was complete, the left and right hand rotors were reassembled, checked for run-out and then low speed balanced in Edmonton. The last operation required the completed rotors to be shipped to Sulzer's Houston Service Center, where the company has its own at-speed balancing facility.
The original seals featured an outdated design that was machined out and modified to accommodate the common 'J-Strip' seal which was installed and gave a tighter clearance between each stage of just 0.010".
This crucial process uses vibration diagnostics to analyze the radial vibration at the bearings and ensures that the optimum balance is achieved at operating speed as well as minimizing the deflection and vibration amplitudes during ramp up and coast down.
With the balancing complete, the rotors were returned to the pulp manufacturing plant, where the field service team assisted with the installation and commissioning of the turbine. Rod Whittaker, Project Manager at Sulzer's Edmonton Service Center concludes: "Being the first time such a repair has been attempted in North America, there were some considerable challenges in this project, not least the precision machining of the new couplings. Fortunately, our extensive experience and technical expertise has ensured that the turbine refurbishment was completed on time and the generator will continue to provide reliable service for many years to come."
Drives, Motors & gears Cross + Morse
Power Transmission Manufacturing Specialists in the UK Since 1984
◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Spur Gears ◊ Worms & Worm Wheels ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening ◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development
Yes we can make it.
Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 Fax: +44 (0)121 325 1079 www.CrossMorse.com
PC-Sep17-Comus.qxp_Layout 1 08/09/2017 12:14 Page 1
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Drives, Motors & gears
etA enCloSUreS introDUCe new etr SUSpenSion ArM ASSeMBlieS rAnge Just introduced by ETA Enclosures UK and offered in 3 specification variations subject to weight requirements is a new range of ETR Suspension Arm assemblies. The structure of the support arm system is defined by machine size, enclosure dimensions and enclosure weight, the number of connection elements and the profile lengths. t
ETR040 – has a 400N Load Capacity
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ETR060 – has an 800N Load Capacity
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ETR120 – has a 1200N Load Capacity
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Load capacity is defined for a total of 1 meter profile including enclosure
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The ETR range is produced from extruded Aluminium ensuring a light weight strong construction
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Available in Grey RAL7035 with grey fittings as standard
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These new suspension arm assemblies are ideal for mounting controls away from the floor space onto the control cabinet or machine assembly. For further information a new 16 page product catalogue is available. All ETA Enclosure product ranges are fully supported by comprehensive stocks of accessories and associated components. For product training opportunities or full product specifications and the complete range of ETA Enclosure products please call ETA Enclosures on 01709-386630
AEMT Becoming A United Nations Of Engineering
he increasing international membership of the Association of Electrical and Mechanical Trades (AEMT) is reflected in the newest members, from Europe, South East Asia and from the Gulf; as well as new associate members.
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Coming from as far afield as Indonesia, Malaysia, Poland and Portugal, the new members join about 285 member companies, with nearly one-third of them headquartered overseas. Thomas Marks of the AEMT says, "More and more, we are arranging international training and events to reflect the increasingly global nature of the technology industries. These tend to generate applications for membership, while other overseas companies hear about us through the media or third-party references."
Membership of the AEMT has many benefits including providing an input into developing new industry and technical standards, legislation and best practice documents, data and intelligence gathering and analysis, communications within the industry, to academia and lobbying of governments, and easy participation in national and international events. "Creating networking and learning opportunities is a vital part of the work of the AEMT and other trade associations. It is impossible to accurately quantify their value, but they offer unrivalled chances to build relationships, win business and create alliances. "Our international members are benefitting greatly from the networking opportunities as well as the training courses we provide and the technical support freely available to them."
New International members are: Chupun Industrial Services, Thailand Doha Petroleum Construction, Qatar EFACEC Energia Maquinas e Equipamentos Electricos, Portugal Elektro Serve, Malaysia Magnetic Services, Malta PT Rotary Electrical Machine Service, Indonesia Zeltech ME Spolka, Poland New Members are: Disco Drives, King's Lynn Humber Rewind, Hull Associate Members: Fixturlaser UK, Laser alignment Grantham Engineering, Vibrating Motors Nestech, laminations PLD Collettori, Commutators Pole Star Products, Motors, Fans and Blowers, Von Roll UK, Products and systems for electrical power generation, power transmission and industrial applications. www.theaemt.com Issue 29 PECM
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Need to know more about safe isolation?
afe isolation procedures are in place to ensure that workers on site are not exposed to danger when working on or near live electrical systems and equipment. Both the standards for the equipment and the potential penalties for non-compliance have changed recently.
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With around 1,000 serious accidents in the workplace each year and 16% of all fatalities linked to electricity, it’s clear to see how following simple safe isolation procedures and using the correct equipment can keep your team safe and avoid heavy penalties of up to £10M for non-compliance. Keep up to date with the most recent changes to Health & Safety Guidelines for safe electrical maintenance with the latest ToolBox Talks on Safe Isolation from Martindale Electric at your workplace. Martindale Toolbox Talks will help you and your team stay safe and achieve compliance with the latest standards Providing valuable expertise and advice, the Tool Box Talks cover the practical implications of recent changes to the standards and discuss what it takes to stay compliant with the latest HSE guidelines
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when installing and maintaining electrical plant and equipment. They are useful refresher for maintenance teams, installation engineers and those responsible for electrical safety and are free of charge The essential test tools and equipment needed to lock off and prove dead before carrying out maintenance are a dedicated voltage indicator, a proving unit to verify the voltage indicator, locking off devices with unique keys and a clear method of labelling the hazard. With a wide range of voltage detectors and indicators available, it’s important to understand that some equipment, such as multimeters, should not be used. Martindale voltage indicators for safe isolation are fully compliant with the latest standards and are designed for safety, with no batteries or switches which could lead to false indication. There have been many developments which now make it easier to choose the right equipment and ensure the correct locking off device is always available. These include complete kits with voltage indicators, matching proving units and a comprehensive range of locking off devices for MCBs and fuse carriers. Kits are supplied in combination carry cases
to ensure that proving devices are always at hand and provide the simplest solution for implementing safe isolation practices on-site. For more information, please contact Martindale Electric on 01923 441717 or visit www.bit.ly/martindale-talk
Safe Isolation saves lives Stay safe, prove dead and lock off with Martindale VIPDLOK kits
The simple solution to safe maintenance /• Essential for compliance with Electricity at Work Regulations for safe working
/• New VI-15000 Voltage Indicator, CATIV 1000V for all installations categories
/• Includes industry leading voltage indicator, proving unit, locking off devices and tags
/• Safe because it’s simple, no batteries, no ranges, no switches
Now available NEW VIPDLOKPRO Get the right locking off device every time with Martindale PRO Kits
Available from your wholesaler and online www.martindale-electric.co.uk Call: 01923 441717 email: sales@martindale-electric.co.uk
introducing the retractor we don’t hang around!
t is an exciting time at Olson and following on from exhibiting at recent shows, we’ve noticed a high demand from our customers for a particular accessory to incorporate with one of our most eyecatching products in our range. Olson Electronics are proud to announce the introduction of The Retractor, which is a retracting option for our range of Suspended PDU’s. The Retractor is ideal for industrial applications where a suspended, strong and compact Power Distribution Unit is required.
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This type of accessory can also be used in many different environments, such as Hospitals, Tyre Shops, Broadcasting, workshops and so… The Retractor option has been introduced, complementing the strengths of the Suspended PDU’s further, The Retractor option allows the Suspended Unit to be lowered to the required working position, locked in place and then retracted back up when it is no longer in use. If you do not require the units to retract we offer chain and standard cable which is also very popular, particularly in the more industrial/heavy duty environments. We can also cut the chain / cable to any length required. The rise and fall operation of the product is also a much safer and easier option, particularly in busy environments. The maximum distance of travel is 2m and the end stop can be moved to adjust the starting height. Olson also offering a “spring” cable option to go with The Retractor unit to connect the Suspended Unit to a ceiling mounted power point. Three cable types are available; 1.5mm², 2.5mm² or 4mm² (to suit the rating of the socket on the unit) with bare ends or fitted with a 13Amp / 16Amp / 32Amp plug as required. The cable length from the Retractor is 5M, allowing further
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cabling above the unit and retraction system. The suspended PDU’s have a variety of sockets available, we have the standard UK 13 Amp (BS 1363) sockets which are often fitted with USB ports, meaning you can multitask while you work. We also have 16 Amp, (IEC 60309/BS 4343), 32 Amp (IEC 60309/BS 4343), available in 110V or 230V but of course we can modify the units to suit whichever socket types the customer requires. The units themselves are cube shaped and they are most certainly one of our more talked about products. These units allow maximum versatility and can allow for up to 8 sockets per unit. The units are not particularly heavy but they are easy to carry because they have a handle at the bottom of the unit, allowing for easy transportation. This new addition is extremely useful and the convenience of this product is second to none, it takes our suspended PDU range to a whole new innovative level. Here at Olson we are a customer focused company and who else is better to ask feedback from than our customers. We care about our customers’ needs and it’s exciting to be able to let people know we have something that will make a difference to how our PDU’s can be used. Being a British manufacturer, product development is at the forefront of our business and day to day activities and introducing new solutions that will enhance our products further is something we love to do and will continue to do. Along with this innovative new product, we have recently released our new website to enable purchasing of our products online for the very first time.
The website is a significant improvement from the previous version and was released in-line with our 56-years of British manufacturing celebration. With Olson being the market leader of PDUs and highly regarded within the industry, we can see this will be welcomed by all of our current and future customers. Marissa Maxwell of Olson Electronics told us more about the company’s core strengths: “We are one of the remaining few British manufacturers and we pride ourselves on our in-house design and production capabilities,” she commented. “Our focus has always been on quality and reliability and we can provide a fast delivery service (generally next day on most items)”. Not only is the new site much more aesthetically pleasing with a modern look, it also features an integrated easy navigation system to enable our customers to quickly find the product they need. Whilst offering the largest PDU product range on the market, it can often be difficult to pin-point the one product a customer requires for a specific application and the new website overcomes this. Thankfully we’ve responded from customer feedback, making this task a lot quicker and easier. It caters for quick navigation to the socket, plug / inlet, orientation or switching requirement you’re looking for within a power distribution unit, with further filtering to find the exact product thereafter. You can view individual product categories or just show every product listed and filter down from there. It also has an advanced search to lookup all of the attributes of a PDU you need and display the results immediately. To conclude this article, head over to the website now to purchase The Retractor, don’t hang around! T +44 (0)20 8905 7273 sales@olson.co.uk www.olson.co.uk
POWER DISTRIBUTION UNITS
SUSPENDED UNIT
THE RETRACTOR
AVAILABLE NOW! YOU ASKED, WE LISTENED. Designed Designed and and Manufactured Manufactured in in the the UK UK
+44 (0)20 8905 7273
sales@olson.co.uk
www.olson.co.uk
electrical & electronics
RELIABLE, ACCURATE CONNECTIONS EVERY TIME Discover more at: EDS, 19 - 20 Oct, Stand K42 ELECTRONICA, 8 - 11 Nov, Hall B2 Booth 219 or call +44 (0)23 9245 9600
Experts In Torque Measurement Having almost 30 years of experience under our belt, Datum offers a line of non-contact rotary torque sensors to provide accurate torque measurement for many industrial and test rig applications, inclusive of harsh and demanding environments. Datum’s M425 non-contact rotary torque transducer has been specifically designed for easy installation into virtually any test rig. The torque sensor has 14 standard torque ranges, offering high resolution and accuracy across the extensive range from as little as 0-10Nm and up to 60,000 Nm, with speeds up to 10,000 rpm. Paired with the Datum Universal Interface (DUI) with a built-in LED display, an M425 Torque Transducer provides you with torque, power & speed data in a format of your choosing (analogue, serial RS$85/232, Ethernet and USB) in real time. www.datum-electronics.co.uk
Precision connectivity solutions for high-performance ce instrumentation and data-logging applications: Low and high voltage
Eldon offers a wide range of user-friendly enclosures and accessories
IP68 / IP69 and hermetic sealing
Eldon’s comprehensive standard product range includes mild steel and stainless-steel wall mounted and floor standing enclosures as well as console systems, polyester enclosures, outdoor enclosures and terminal boxes as well as cable and thermal management solutions.
Fibre optic
Eldon enclosures are designed for many different applications in many environments, from exposed oil rigs to clean environments. User friendliness, both for panel builders and for the service and operational staff, is a key guiding parameter in Eldon’s engineering work.
360° EMC shielding Hybrid connectors Push-pull locking system facilitates fast, reliable connections every time Custom connector and cable assembly solutions
Contact Details: Mark Sanders Sales Director UK & Ireland Direct phone: +447969 100658 mark.sanders@eldon.com Eldon Electric LTD Way Hellaby Industrial Estate S66 8QN Rotherham, GB www.eldon.com
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THE RELIABLE EXPERT
www.fischerconnectors.com
electrical & electronics
IP67/68 Rated Waterproof
Coaxial Cable Assemblies
Waste Mgmt.
Agri-Tech
Security
Communications
Perfectly suited for harsh environments such as Waste Management, Agriculture Technology, and many others.
www.gradconn.com
pHoenix MeCAno Our extensive range of lifting devices offer fully integrated technology and are maintenance-free. Columns are selflocking, even under maximum load. They can withstand torsional and bending moments and can be used singularly or synchronously. They have a clear anodised aluminium profile surface and special versions are available on request. Applications include assembly workstations, control cabinets, wellness couches, instrument tables, conveyors, machines, screen adjustment, information boards. Electric cylinders have fully integrated technology and are maintenance-free. Self-locking even under max. load which means that no power is supplied when
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at a standstill which makes them an interesting alternative to pneumatic and hydraulic actuators.. Can be installed in any position and come in various stroke lengths and speeds. Special versions available on request. A large range of accessories for installation are available. Connection for up to 32 drives (bus system) Duty cycle monitoring as overload protection (can be activated as standard) Memory function Mains-independent battery mode Wide-range input www.phoenix-mecano.co.uk
electrical & electronics
SEISMIC Monitor System The 731A seismic accelerometer and P31 Power Unit Amplifier are a unique system for the measurement of extremely low level vibrations. This system has the capability to measure sub-micro g levels by combining a high sensitivity piezoelectric sensing element, a matching low-noise amplifier/filter/power supply. The amplifier also contains an integration circuit to provide an output proportional to velocity. This system is ideal for measuring low level vibrations in bridge, building, tower and dam motion studies, optical and photographic stability monitoring, electron microscope and microtome monitoring, as well as vibration-isolation table monitoring. KDP Electronics Systems
01767 651058 www.kdpes.co.uk
Environment Agency Chooses YorPower Generators for Upgrades to River Foss Barrier in York YorPower has been awarded the contract to supply Cummins powered standby diesel generators for the new Foss Barrier and Pumping Station in York, UK. The contract, worth in excess of ÂŁ1m, was won in the face of stiff competition and naturally the company and all its staff are delighted with the win. History The River Foss flood alleviation scheme consists of a floodgate coupled with a Pumping Station straddling the River Foss at its confluence with the River Ouse in York, just south of the city centre. www.yorpower.com
Creative cable solutions for your business Habia Cable is one of Europe’s leading wire and cable manufacturers. We develop, manufacture and market custom design cables and harness systems for demanding applications in harsh environments. Our customers are found in a number of diverse industries covering industrial, defence, offshore, nuclear and telecom. We aim to provide a high level of customer service and technical competence with competitive lead times and low minimum order quantites. The company has a global presence and worldwide sales of custom design and standard products in more than 50 countries. Discover more at habia.com
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BrAkeS for HolDing AnD pArking of Copper Mine HoiStS feAtUre preCiSion Control wiflex, part of Altra Industrial Motion, a leading global supplier of power transmission components, provided parking brakes for use on mine hoists at the Nkana site of Mopani Copper Mines in Zambia. Nkana is one of the largest copper and cobalt mines in Africa, with four underground mines, as well as an open pit.
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Leading mine hoist manufacturer FLSmidth worked with Twiflex and its South African distribution partner, Tritec Sintered Products, on this installation. FLSmidth supplied a double drum Blair Multi-Rope (BMR) rock winder and a single drum BMR man / materials winder to the Nkana project. The BMR winder is a variation on the double-drum winder and is used in extremely deep shafts as the second drums cable is used to balance the primary load. The drums on both winders are identical; each measuring 5.7 m in diameter, with two 1.8m wide rope compartments. The double-drum BMR has a payload of 47.5 tonnes and operates at speeds up to 17.6 m/s in a 1,278 m deep shaft. A precision control system designed by FLSmidth is used to achieve synchronous braking of all the brake units.
Twiflex brakes are used for parking and holding each time the mine winders stop. In exceptional conditions (i.e. power failure), the brakes can be used to bring the load to rest whilst maintaining a maximum deceleration of 2.3 m/s2. To meet the hoists high rubbing speeds and provide greater thermal capacity, Twiflex engineers designed a new large pad version (174,700 mm2 each pad) of its popular VMS3-SPS spring-applied, hydraulically-released brake, which is widely used on mine hoists around the world. Thermal capacity is a measure of the ability of the brake pad to absorb and dissipate heat. Known as the VMS3-VR the 16 off brakes (8 off on the fixed drum and 8 off on the clutched drum) operate on two 6,800mm diameter, 70 mm thick discs, producing a total braking torque of 12.2 MNm.
that when pressure is removed there is no stored energy. Twiflex has an in-house testing capability, comprising a climatic chamber which can simulate temperatures between -75 to +180 °C, as well as a fatigue room for brake cycling and an inertia test rig for dynamic stops. "All Twiflex modular brakes are subject to a cycling test and pressure test before leaving the factory," explains Steve Powell, product manager for Twiflex. "For mine hoists, all critical brake components undergo non-destructive testing. The main limitation for brake manufacturers is the friction material which needs to be carefully selected for the operating cycle." www.twiflex.com
For this application, each VMS3-VR is rated to 240 kN braking force (Âľ=0.4) using a 2mm air gap. At this braking force, the rated fatigue life is over two million braking cycles. To assist with maintenance, Twiflex brakes incorporate a monitoring system to signal brake pad wear and loss of braking force. The VMS3VR brakes also include Twiflex's unique 'parked off' feature: meaning they can be adjusted under hydraulic pressure so Issue 29 PECM
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pny prevAilpro workStAtionS
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A full complement of I/O ports, including HDMI 2.0, 2x mDP 1.3, 3x USB 3.1 Gen 1, 2x USB 3.1 Gen 2 Type-C, 1000BASE-T Ethernet, Wi-Fi, Bluetooth, audio input and output and a versatile media card reader are all provided. A full size English keyboard and numeric keypad, both with LED backlighting, and a touchpad with a built in fingerprint sensor deliver superior ergonomics and security. Weighing only 4.8 lbs (2.2kg), with dimensions of 14.95” x 9.8” x 0.73” (380mm x 249mm x 18mm), this system is fuelled by a 4 cell Li-Polymer 55WH battery pack good for up to 300 minutes in UMA mode. This system is optimized for and features Windows 10 Professional 64-bit. COMPACT, MOBILE AND PERFORMANT
PREVAILPRO lets you experience the world’s most powerful visual computing platform everywhere – for the ultimate in creative freedom. Whether you’re developing revolutionary products, telling spectacularly vivid visual stories, designing transformational architecture, or creating the most lifelike, immersive virtual environments, PREVAILPRO gives you the performance to do it brilliantly.
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PNY PREVAILPRO MOBILE WORKSTATION
Pro Performance. Anytime. Anywhere. NVIDIA Quadro P4000 Mobile GPU | 1792 CUDA Cores | 8GB GDDR5 NVIDIA Quadro P3000 Mobile GPU | 1280 CUDA Cores | 6GB GDDR5 Certified by Independent Software Vendors:
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© 2017 NVIDIA Corporation. All rights reserved. NVIDIA, the NVIDIA logo, and Quadro are trademarks and/or registered trademarks of NVIDIA Corporation. All company and product names are trademarks or registered trademarks of the respective owners with which they are associated.
By controlling usage, Optimas was able to deliver a further annual estimated cost saving of around £400,000 to the manufacturer.
optiMAS reDUCeS CoMponent oBSoleSCenCe for preMiUM AUtoMotive prototypeS treamlining the controlled build engagement process as an automotive manufacturer can bring a host of benefits, offering increased research and development speed and a reduced bill of materials. Businesses such as Optimas have built a reputation in such work, offering expertise during the capital intensive controlled build engagement process, to enable a unified and efficient approach to component specification and utilisation. It is this experience that has seen Optimas join forces with an iconic luxury car manufacturer during the controlled build engagement of a new model – the first supplier to ever engage with the marque’s production and engineering teams at such an early stage.
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The logic behind involving an expert component supplier, such as Optimas, during the early stages of production is the dramatic cost savings that can be achieved via an optimised approach. Component suppliers can gain familiarity with a project if involved from the design phase; standardising, originating or
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recommending component solutions that can save a manufacturer time and costs. This is particularly pertinent during the research and development stage, as many components included on the first cars may not be included on later variations, so particular care must be taken not to order components that are obsolete for a particular build. Doing so would increase costs to the manufacturer, slow development time and convolute this stage – not what you need when working to tight testing and release deadlines. To achieve this project familiarity and optimised approach, it was necessary for Optimas to select engineers to work full-time with the manufacturer during the research and development process. Having worked with Optimas prior to the new vehicle project, the marque knew Optimas had a reputation for streamlining component policy that suited their requirements. Furthermore, Optimas has worked with many other prestigious marques, so the manufacturer had confidence that Optimas could deliver quality as standard.
Andrew Woolley, Key Account Manager at Optimas explains: “We were brought in to aid with the prototype builds for a manufacturer. Our main objective was to reduce obsolescence throughout this production stage. This was a process of starving parts during the builds and ensuring engineers didn’t specify additional fasteners, which enabled us to control and record exactly what components were used. We achieved this by using parts bins with predefined car sets in - enough for 5 cars for example and then recorded the components we didn’t utilise every week. As we progressed through the iterations of the vehicle we could begin to actively reduce wastage.” Specifying parts for a prototype build is challenging. As a manufacturer, knowing exactly what parts will be used on the final production ready car is essentially consulting the crystal ball. However, with the involvement of Optimas, the bill of materials can be matured throughout the process, reducing obsolescence and optimising component choice. This can involve specifying items that are off the shelf and streamlining the supply chain to
eliminate shortages. The primary goal? Get the cars built.
About Optimas Solutions Optimas is a global distributor of fasteners and c-class products. Optimas at its
Andrew illustrates the cost savings that were achieved on axles alone: “The original axles were very expensive and specific for the design. Later in the project we found that we could divert orders from the supplier after we had reached the 50 cars that formed the prototyping process. By doing so, we have theoretically saved the customer approximately £350,000 in first year uptake obsolescence savings alone. However, this figure is a worst case scenario, based on a bill of materials that is not yet mature - so the actual saving is probably more.” During the prototype build phase, 136 components were identified as being no longer required from the initial fasteners list. By controlling usage, Optimas was able to deliver a further annual estimated cost saving of around £400,000 to the manufacturer. “The savings are substantial, even for a low volume premium vehicle,” Andrew explains, “but, thanks to being involved early, we were able to make informed decisions with the purchasing, engineering and production teams to drive a unified fastener policy that correlated to achieve these savings. I think this is something unique that we can provide at Optimas.”
core is a provider of integrated supply chain solutions and engineering support focused on delivering highly engineered fasteners to world-class customers around the world. Optimas has a diverse, global team of approximately 1,600 individuals, over 40 distribution centers, 9 quality labs and 2 manufacturing locations to support the complexities of our customers’ industries, enabling them to achieve their goals and be successful. The image(s) distributed with this press release may only be used to accompany this copy, and are subject to copyright. Please contact DMA Europa if you wish to license the image for further use.
In order to work closely with such a prestigious car company, Optimas has recently gained VDA 6.2 approval, an extension of ISO 9001 that is viewed in the industry as a fully recognised independent automotive standard. The certification is awarded with regards to the quality management systems employed by Optimas, and reinforces the business’ position as a trusted and proven component partner. As an automotive manufacturer, building an efficient relationship with a premium component supplier must begin at the
earliest stages of production. By utilising dedicated teams that work in tandem with manufacturers, these premium suppliers can not only standardise and streamline component specification to save time; but also track and record parts usage to mature the bill of materials and enable huge savings through the elimination of wastage. Even for a marque with prestige, luxury and vivid history, there is still a need to reduce costs at all stages of vehicle production to maximise return. With the help of Optimas, that is exactly what they have achieved.
Optimas is the first supplier to ever engage with the marque’s production and engineering teams at such an early stage.
Photos: iStock
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Chiller Hire Preserves Food During Plant Outage T
he he addition addition of of aa range range of of compact, compact, self-contained self-contained chillers chillers to to the the Andrews Andrews Chiller Chiller hire hire fleet fleet at at the the turn turn of of the the century century was was aa timely timely introduction introduction and and were were immediately immediately called called into into action action as as they they provided provided the the perfect, perfect, simple, simple, temporary temporary solutions solutions for for organisations organisations forced forced to to take take ininhouse house chillers chillers off-line off-line to to up-date up-date in in accordance accordance with with new new EU EU regulations regulations and and directives directives regarding regarding use use of of HCFCs. HCFCs. During During the the past past decade decade many many organisations organisations operating operating chilled chilled and and cold cold stores stores have have had had to to implement implement planned planned maintenance maintenance programmes programmes for for aa R22 R22 refrigerant refrigerant swap swap out out or or consider consider PECM 29 8084 PECM PECM Issue Issue Issue 16 16
aa more more costly costly option option of of investing investing in in totally totally new new plant. plant. Organisations Organisations had had to to consider consider whether whether the the converted converted plant plant using using refrigerate refrigerate such such as as ODS ODS would would be be able able to to deliver deliver and and achieve achieve the the same same cold-store cold-store conditions. conditions. Abiding Abiding by by the the rules, rules, new new equipment equipment using using HCFC HCFC refrigerants refrigerants like like R22 R22 was was banned banned from from 2001 2001 (or (or 2004 2004 for for small small air-conditioning air-conditioning systems) systems) and and since since 1st 1st January January 2010 2010 the the use use of of virgin virgin HCFCs HCFCs to to service service and and maintain maintain existing existing refrigeration refrigeration and and air-conditioning air-conditioning (RAC) (RAC) equipment equipment was was also also banned banned in in all all EU EU Member Member States. States. From From 1st 1st January January this this year year it it has has been been illegal illegal to to use use any any HCFCs HCFCs to to service service RAC RAC equipment, equipment,
As As aa major major specialists specialists in in chiller chiller hire, hire, around around 70% 70% of of Andrews Andrews Chiller Chiller work work isis solving solving emergency emergency situations situations
hence hence recycled recycled or or reclaimed reclaimed HCFC HCFC may may no no longer longer be be used. used. Lawful Lawful Gains Gains For For chiller chiller hire hire specialist, specialist, Andrews Andrews Chiller Chiller Hire, Hire, the the regulations regulations were were to to reap reap significant significant rewards rewards particularly particularly in in supporting supporting food food related related sectors sectors such such as as those those operating operating large large chilled chilled and and cold cold stores. stores. Within Within its its chiller chiller hire hire fleet fleet it it offered offered the the perfect perfect low-cost low-cost solution solution that that would would provide provide aa temporary temporary airaircooled cooled chilling chilling service service during during in-house in-house plant plant replacement replacement or or plant plant downtime downtime for for conversation conversation to to run run on on refrigerants refrigerants such such as as RA10A. RA10A. With With its its newly newly acquired acquired Fast Fast Chill Chill range range
of of self-contained self-contained chillers chillers it it prompted prompted one one major major European European food food distributor distributor to to call call upon upon the the services services of of Andrews Andrews Chiller Chiller Hire Hire to to provide provide 100kW 100kW of of cooling cooling at at -10°C -10°C to to ensure ensure its its stock stock did did not not degrade degrade during during aa schedule schedule plant plant shutdown shutdown for for aa R22 R22 change. change. Following Following discussion discussion with with Andrews’ Andrews’ sales sales engineers engineers it it became became apparent apparent to to the the customer customer how how quickly quickly and and easily easily Fast Fast Chill Chill models models can can be be installed installed ready ready to to run. run. As As aa major major specialists specialists in in chiller chiller hire, hire, around around 70% 70% of of Andrews Andrews Chiller Chiller work work is is solving solving emergency emergency situations situations where where in-house in-house plant plant underperforms underperforms or or fails fails totally totally causing causing unexpected unexpected rises rises in in core core te te peratures peratures affecting affecting production production processes, processes, working working environments environments or or chilled chilled storage. storage. The The major major food food chain chain distributor distributor fell fell into into the the 30% 30% bracket, bracket, where where it it had had pre-planned pre-planned for for closure closure of of its’ its’ in-house in-house cooling cooling plant. plant. Andrews Andrews delivered delivered and and installed installed on on the the scheduled scheduled date date aa total total of of ten ten Fast Fast Chill Chill 90 90 Low Low Temperature Temperature Chillers Chillers to to keep keep the the warehouse warehouse at at aa te te perature perature of of -C. C. his his effecti effecti ely ely preserved preserved the the stock stock until until maintenance maintenance work work was was completed. completed. as as ill ill All All FC90 FC90 units units for for this this application application were were placed placed at at high high level level within within the the storage storage area area and and connected connected to to aa bank bank of of exterior exterior heat heat exchangers exchangers to to dissipate dissipate the the extracted extracted heat heat to to atmosphere. atmosphere. The The main main advantage advantage of of Andrews Andrews Chiller Chiller Fast Fast Chill Chill 90 90 units units is is their their portability portability
achieved achieved by by aa design design that that draws draws hot hot energy energy into into the the system, system, this this passes passes over over aa cold cold coil, coil, is is converted converted into into water water which which is is then then pumped pumped to to aa condenser condenser within within the the heat heat exchanger exchanger where where it it is is discharged discharged outside outside the the building. building. The The Fast Fast Chill Chill 90 90 has has aa powerful powerful fan fan delivering delivering outstanding outstanding performance, performance, cooled cooled air air flow flow with with aa capability capability down down to to -10°C -10°C and and ability ability to to maintain maintain local local environments environments to to within within +/+/- 0.5°C. 0.5°C. FC90 FC90 models, models, the the largest largest in in the the Andrews Andrews Fast Fast Chill Chill hire hire range range requires requires three-phase three-phase power power which which is is often often
picked picked up up on on site, site, however, however, where where none none is is available available aa separate separate generator generator can can be be supplied, supplied, as as was was the the case case for for this this application. application. The The simplicity simplicity and and speed speed of of install install of of the the Andrews Andrews Chillers Chillers Fast Fast Chill Chill hire hire range range makes makes these these units units ideal ideal for for many many applications applications especially especially in in the the food food and and ee erage erage sector sector as as well well as as specific specific process process cooling cooling needs, needs, pharmaceutical pharmaceutical and and agricultural agricultural industries. industries.
Andrews Sykes Hire Limited Chiller Division Unit 54 Gravelly Industrial Park Tyburn Road Birmingham B24 8TQ Tel: +44 (0)1902 328725 E: shdinternalsales@andrews-sykes.com www.andrews-sykes.com
SteCo power offerS entire klAriUS eMiSSionS CoMponent rAnge witH next DAy Delivery
Photo: The Klarius range available through Steco incorporates over 10,000 premium emission product combinations including exhausts, catalytic converters (CATs), diesel particulate filers (DPFs) and accessories.
teco Power has announced that its range of OEM quality automotive batteries will now be complemented with the entire type-approved emissions components range from Klarius Products Ltd. The Klarius range available through Steco incorporates over 10,000 premium emission product combinations including exhausts, catalytic converters (CATs), diesel particulate filers (DPFs) and accessories. The entire range is available for next day delivery from central stock at Steco in Outarville and other regional locations.
S
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Providing components of OEM quality is a key proviso for both Steco and Klarius, ensuring that distributors and repair garages in France can benefit from a single source for automotive battery and emissions requirements. Klarius emissions products are independently tested by TÜV so product performance is assured. Klarius components are designed to achieve OEM levels of performance and efficiency, which is in line with the minimum quality level Steco offers to the market. Vehicles supported by the Klarius range include popular models, SUVs, hatchbacks,
MPVs, saloons, sports cars, luxury and light commercial. All components are supplied with a ‘Fit First Time’ guarantee and a 2 year warranty as standard – offering complete compatibility with the intended vehicle. Jerome Habsieger, Sales & Marketing Director at Steco Power, said: “Expanding our portfolio with the Klarius emissions control range offers the French market a single point of purchase for OEM quality batteries and exhausts. Cumulatively, the Steco and Klarius ranges are designed to support the vast majority of vehicles on
Photo: Jerome Habsieger, Sales & Marketing Director at Steco Power (right) with David Mormentyn of Klarius Products Ltd, pictured in the Steco warehouse at Outarville.
our roads, so customers can benefit from the dual benefits of extended choice and reduced lead times for components.� Steco Power offers OEM quality batteries to support a full range of applications, supporting marques from Volvo to Ferrari. The business also offers specific battery accessories such as chargers and testers for a comprehensive range of vehicles. In addition, Steco also offers batteries for heavy duty applications, as well as caravans, motorhomes, boats, solar panels and wind turbines.
About Klarius Products Klarius Products is a dedicated Emission Control Products manufacture and supply company servicing primarily the UK and EU markets. The business supplies type approved exhausts, CATs and DPFs designed, developed and manufactured in the UK and delivered via its own logistics operation. Klarius Products operations are centred on the manufacturing, R&D, test track, logistics and stock facility hub based in Cheadle in the UK. The image(s) distributed with this press release may only be used to accompany this copy, and are subject to copyright. Please contact DMA Europa if you wish to license the image for further use.
Process
Manufacturing
Control &
Engineering
Buyers’ Guide
the uK’s leading Buyers guide for key professionals within the Processing, Engineering and Manufacturing industries.
E: info@pecm.co.uk t: 01843 830249
www.pecm.co.uk/directory
facilities Management
Stonegrove Holchem Holchem has supplied dispense and application systems to the Food and Beverage, Catering, Hospitality and Retail Industries for over 30 years. Projects have been implemented in various locations across the UK and have ranged in size from small local dispense systems to integrated storage, dispense and application systems fitted within large production facilities. Our in house team of qualified service engineers provide their expertise throughout the UK and Ireland in dosing and application equipment. In addition to the routine planned service visits, they also provide a speedy response to breakdowns and can provide an advisory and investigative service. To complete the whole engineering solution and achieve the desired standards of hygiene and health & safety requirements we also supply a range of wash down and cleaning accessories. For further information please visit www.holchem.co.uk
Multi-award winning Stonegrove Refrigeration Services Ltd are one of the leading independent refrigeration companies in the UK, with in-house expert capability to design, install, service and maintain industrial refrigeration and air-conditioning systems. Being independent means that we are not tied to any one equipment manufacturer or supplier, so can provide the most suitable solution for your cooling needs. Our project designs and installations have won awards for our practical approach to energy saving whilst meeting client’s budgets and programmes. Our service and maintenance teams look after all types of industrial refrigeration systems to ensure optimum performance and reliability. For all your food and beverage processing, storage, and distribution cooling requirements, speak to the expects Contact us on 01279 408690 ed@stonegroverefrigeration.co.uk www.stonegroverefrigeration.co.uk
Cooltherm Since 1992 Cooltherm have been providers of professional chilled water services, including the repair service and maintenance of all types of industrial and commercial cooling plant, with over 40 in-house trained engineers covering the whole of the UK. We are so confident you will be impressed with our level of service we offer new customers a 2-hour free trial. http://www.cooltherm.co.uk/ twohourtrial We also have an award-winning team who specialise in the design and installation of new chilled water and process cooling solutions; be it straightforward or bespoke, large or small. We pride ourselves on our green credentials, with our TurbomiserTM chiller offering the best levels of energy efficiency available today, and pioneering the use of new environmentally friendly HFO refrigerants. Cooltherm www.cooltherm.co.uk Tel: 0117 961 0006 Email: enquiries@cooltherm.co.uk
Facilities Management
SEAMLESS
01732 01732 441015 441015
www.darcy.co.uk www.darcy.co.uk
INDUSTRIAL FLOORING
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Environmental Environmental risk risk management management
Resurfacing of badly worn floors and new build installations Impact, abrasion and point load resistance Anti-static, anti-bacterial, slip resistant, chemical resistant & suitable for heavy traffic plus high bay category one and two Fast installation for minimum downtime
Storag
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Environmental Environmental Services Services Industrial Marine Marine Industrial Liquid Monitoring & Control
Integrate corporate colour schemes, colour matching and corporate logos into the same hardwearing and durable flooring For a complete Nationwide service from FREE survey and recommendations, to preparation and installation with single source, uncomplicated warranties‌
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Contact us on 01732 441015 or visit our website www.darcy.co.uk
LEADING PROVIDER OF PRACTICAL POLLUTION CONTROL PRODUCTS AND SERVICES
Securikey stands for
Issue 29 PECM
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DUoMo – Being ADAptABle in tHe wAke of Brexit
Sales and Marketing Beth Collett Beth@duomo.co.uk
As reported by The Telegraph in July, small-to-medium sized enterprises account for 99% of all companies in the EU, acting as a backbone to the European economy. With the anniversary of the Brexit vote, Duomo (UK) Ltd have been reflecting on the challenges that they have faced and will continue to face. Duomo (UK) Ltd has been designing, developing and manufacturing gas detection equipment and gas proving systems since 1994. Technical Director, Phillip Wild states that “In order to survive, a company needs strength to repeatedly embrace change and have the dogged determination to overcome unforeseen challenges”. Duomo has been no stranger to such challenges. Throughout its history, along with many other companies, Duomo has been subjected to outside influences that are beyond prediction, but the company has survived and prospered.” For example, Duomo was established to manufacture gas valve trains that controlled the flow of gas into packaged gas burners for commercial boilers and air heaters.
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The continental manufacturers for these burners had distributors based in the UK who found it beneficial to buy a valve train from a UK based company in order to suit the diverse, individual requirements of their customers. However, overnight, Brussels decided that the valve train HAD to be manufactured in the country of origin of each packaged burner. Due to this EU policy, Duomo had to react quickly. They set about using their tools and abilities to build a new range of gas proving systems for school kitchens and laboratories that were made for clients such as Birmingham City Council and many other local authorities throughout the UK. Phillip added “The biggest challenge we face now is the uncertainty caused by Brexit. We are sourcing a lot of our raw materials from Europe. Large currency fluctuations have made predictions about growth impossible. The Bank of England or the European Central Bank issue a statement and the Sterling to Euro exchange rate tumbles.” Phillip goes on to say “I’m really proud that Duomo has continued to be successful in this uncertain climate and has moved into fields such as environmental monitoring
sensors – an area of incredible growth for us. The strength of Duomo has come from a willingness to diversify and launch new products that have a true value to customers and allow compliance with current gas safety and building standards in order to make our future more certain”. Phillip firmly believes that now is the time to remember that Britain is great, and to relish the fight for, not just survival but success on a Global stage. www.duomo.co.uk www.twitter.com/DuomoUKLtd www.linkedin.com/company/3682842/
NEW PRODUCTS IN THE DUOMO GAS DETECTION RANGE
BX444-Mc GS300-Mc This microprocessor based gas detector control unit is compatible with the complete range of Duomo gas sensors and has a secure test facility which allows sensors to be fully tested by applying test gas without disconnecting the electrical supply to gas valves. Additionally, the GS300-Mc has new emergency stop connections which triggers a notification on the panel once the button is pressed.
Replacing the BX444M, this new unit boasts a test timer function that permits the main alarm relay to remain on during the alarm phase of a gas test. This is a great feature in situations where shutting down the gas supply to the boiler plant and other appliances is not desirable. The New sensor test function allows sensors to be fully tested with calibrated test gas without turning off the connected solenoid valves. Additionally, the BX444-Mc has a new oxygen depletion or excess function when connected to the NEW ceiling mounted Duomo SGF104 Oxygen Sensor.
COMPLETE YOUR GAS DETECTION SYSTEM WITH‌
SGM595
CO100Ar
SG895
Natural Gas or LPG sensor
Carbon monoxide sensor
Atex certified
www.duomo.co.uk
VMR Solenoid gas valves coiled and flanged
sales@duomo.co.uk
To discuss your application requirements in more detail, call Duomo today on 01905 797989
fasteners & fixings
BULK BAG DISCHARGER BULK-OUT® Model BFC Bulk Bag Discharger is enclosed on five sides and vented to a centralised dust collector to contain errant dust escaping through seams or fabric of unlined bulk bags. Works in concert with a manual SPOUT-LOCK™ clamp ring atop a pneumatically actuated TELE-TUBE™ telescoping tube that allows quick, dust-tight connections between the bag spout and hopper, and automatically elongates the bag as it empties to promote flow and evacuation. A POWER-CINCHER™ pneumatically-actuated flow control valve cinches the bag spout concentrically with no leakage of material, allowing gradual opening of the bag spout as well as retying of partially empty bags. FLOW-FLEXER™ bag activators raise and lower opposite bottom edges of the bag, promoting material flow and total discharge.
New EMKA Catalogue – small and medium quarter-turn latches/locks In their new 2017/2018 catalogue EMKA describe the Program 1012 and 1022 quarter-turn latches and locks in their small to medium size range, for use on small cabinets, wall mounted enclosures, control desks, machine controls, boxes and instrument cases. In these applications their simple insert keys, uniform profile cylinder locks and wing knob options will be of interest to manufacturers and installers alike. Rated at IP65 the 1012 and 1022 series utilise the traditional small EMKA cut-out with the 1022 type offering in addition vibration resistant compression locking or IP69K sealing with quick-fit assembly. Materials include zinc die chrome plated, zinc die black powder coated, stainless steel AISI 303 and black polyamide. The EMKA catalogue can be obtained free from EMKA on 024 7661 6505, email: emka@emka.co.uk or downloaded from their website at www.emka.com/uk_en/products/download/industry/.
Flexicon Europe Ltd +44 (0)1227 374710 sales@flexicon.co.uk www.flexicon.co.uk
Readers can find the latest information and news on the EMKA blog – www.emkablog.co.uk or follow them on twitter - http://twitter.com/emkauk.
jetpress.com
YOUR GLOBAL SOURCE FOR
FASTENERS & COMPONENTS
• Extensive stocks available for rapid delivery! • Vast range of proven solutions to choose from • First class technical support & customer service • Bespoke design, development & manufacturing
Find your solution at jetpress.com sales@jetpress.com 92
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•
01623 551 800
fluid Handling
Fluid Carrying
Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders
Swivel Joints Swivel joints allow pipework to rotate whilst carrying fluid under pressure 1/4� to 20� and beyond. Vacuum to over 6000psi. Stock and bespoke production. Unique bearing/seal design for longer life. ISO 9001 CE marked where applicable.
Tel: Rotaflow FV Limited | Rotec House Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY
01663 735003
E-mail:
sales@rotaflow.com
www.rotaflow.com
Stand number C4.
Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres,
PTFE Fluid Handling from Bohlender Bohlender offers a vast range of finished and semi finished products in technical and fluoroplastics. A variety of different materials like PTFE, FEP, PFA, PEEK and others enable innovative products to be produced with excellent chemical resistance and high thermal resistance.
PREMEX and AMAR high pressure autoclaves, POPE wiped film or short path evaporators and distillation systems, Nutsche filter dryers, BOLA labware in PTFE and other technical plastics, Vacuubrand vacuum pumps, ASECOS storage solutions for hazardous materials to BS EN 14470-1 and SICCO desiccators. We also work with LLG Germany, the 3rd largest lab supplies distributor in Europe and have a catalogue of 20,000 items from over 200 respected brands.
Screw joints and ground joint components, tubing and connectors allow an infinite number of combinations to create sophisticated systems of fluid transfer using standard laboratory bottles and containers. For distillation of strong acids or alkaline products BOLA manufactures reaction vessels up to 6 litre capacity in PTFE or PFA. All parts exposed to the medium are either made completely of PTFE/PFA or jacketed like the thermometers. The BOLA catalogue also includes a wealth of technical information on the materials used including physical properties and chemical resistance and the safe use and care of fluoroplastic labware. Further advice on the pressure resistance of tubing and the correct choice for pressure or vacuum applications make the catalogue a useful reference. www.labtex.co.uk
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Health & Safety
intelligent SySteMS for proCeSS optiMiSAtion froM werMA WERMA has already established an industry standard with its range of modular signal towers, beacons and sounders. Now Werma also designs and manufactures easy to install and use, low cost andon light based intelligent systems for process optimisation. StockSAVER: the new Kanban replenishment system The system, simple to retrofit to existing FIFO flow racking, solves many typical Kanban issues, increases the floor space for value adding activities and improves cash flow. StockSAVER automatically calls up material replenishment requirements and thereby reduces the margin for human error and will significantly cut the amount of line-side safety stock being held. StockSAVER deploys sensors fitted to the FIFO flow racking system to detect the passage of all sizes of commonly used bins. Data on bin movements is transmitted wirelessly to a control station view on a PC and triggers automatically precise replenishment orders. The system solves the problem of mislaid, damaged or untimely Kanban card re-ordering processes. SmartMONITOR: the intelligent alternative for machine monitoring and data collection SmartMONITOR helps to make processers lean, faster and more efficient. The wireless based data collection and transmission system is easy to
retrofit and enables monitoring of downtime and disruptions to production. Control station displays on the PC or automatic notification to your smartphone will help to reduce reaction to downtime considerably and help identify ways of optimising manufacturing processes. Detailed reports and analyses of the data can be produced automatically which will then enable improvements to be made to and increase productivity.
www.werma.co.uk uksales@werma.co.uk Tel: 01536 486930
AndonSPEED Call for action system that keeps things moving The system is a unique and innovative intelligent monitoring and call-for-action system. AndonSPEED not only gives a clear local visual signal of a disruption or change in status on the line or workstation, but also documents and analyses downtime. The wirelessly connected system passes information to a control station display on a PC or screen and can also despatch call for action e-mails automatically to personnel required to intervene and resolve a problem.
Intelligent systems for process optimisation StockSAVER
A retrofit solution for FIFO flow racks to monitor stock movements and launch replenishment orders automatically - Kanban without cards.
SmartMONITOR
Machine and workstation data collection and monitoring system - reduce downtime, get lean.
AndonSPEED
Call-for-action system for logistics operations identifies bottlenecks and gets things moving again quickly.
Made in Germany
WERMA (UK) Ltd. email: uksales@werma.co.uk
Shop online at: www.werma.co.uk Issue 29 PECM
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BurstIng dIsc kuB serves needs of varIous applIcatIons and IndustrIes REMBE has developed a unique two-layered REMBE reverse acting buckling-pin bursting disc: KUB. Other bursting disc manufacturers still use the outdated technology of mechanical scoring of the disc, this can weaken the disc integrity and lead to premature failure of mechanically scored discs, leading to expensive plant downtime. The KUB mechanism is based on the buckling-pin principle discovered by Leonard Euler. The fact that the REMBE response pressures are accurately defined by Euler’s buckling-pins engineered and positioned by state-of-the-art laser technology, means that end users can operate their plants safe in the knowledge that rouge emissions are now eliminated. The KUB waives any mechanical scoring. Customers all over the world use this disc for years. In the Oil & Gas Industry with it`s rugh production and demanding processes as well as in the food and pharma industry with it’s specific hygienic needs. More than 40 years of experience, highest quality and customised solutions – that is what REMBE stands for.
T +49 2961 7405-0 | info@rembe.de | www.rembe.de 96
PECM Issue 29
T +49 2961 7405-0
Made in Germany
Your Specialist for PRESSURE RELIEF and EXPLOSION 6$)(7<
Consulting. Engineering. Products. Service. Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | info@rembe.de | www.rembe.de © REMBE | All rights reserved
Health & Safety
Process safety certificate pilot
Slip resistant footwear
Health, safety and environmental training specialist RRC International has been chosen by NEBOSH to help it pilot the NEBOSH HSE Certificate in Process Safety Management.
Because the workplace floor cannot always be relied on to be non-slip and may be contaminated with water, oil, grease, food or other residues, anti-slip safety shoes are essential in many industries such as construction, food manufacturing, offshore oil and gas and utilities.
This new qualification is designed specifically for those with safety responsibilities in the process industries and aims to provide candidates with the knowledge and understanding they need to contribute effectively to managing process safety risks. The qualification has been developed through a collaboration between NEBOSH and the Health and Safety Executive (HSE).
Wearers of any of RedLion’s 40 different, sporty, high-performance models, which are all classified SRC, meaning they have more than met the specified requirements when tested on both wet ceramic tiles and steel with glycerol, can be confident of their safety.
This course is suitable for those who work in process industries all over the world, such as oil and gas, chemicals, plastics and pharmaceuticals. Given the hazardous nature of these industries, this qualification has been designed to give managers, supervisors and safety professionals working in them the specialist knowledge and understanding they need to keep their staff, sites and surroundings safe. RRC is running pilot courses in both their London and Dubai training centres.
To have maximum slip-resistance, safety footwear should fit properly, be extremely comfortable, and have a flexible sole with an effective tread pattern that grips the floor, no matter what the conditions. The RedLion is designed to fulfil all these criteria with ease.
www.rrc.co.uk
www.u-power.it
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The RedLion has a coefficient of friction (CoF) of 0.82, double the industry standard, demonstrating its impressive resistance to slip accidents.
Safety first! We care about you and your safety. From safety sensors for machinery to safety vests for children. Panasonic, one of the leading manufacturers of safety engineering technology, takes a proactive approach to keep children safe on the road. Panasonic cares about children’s safety Unfortunately, children are involved in many road accidents – they are easy to overlook in busy road traffic. This is why we would like to give your child a safety vest so that they can walk to kindergarten or school more safely. But there’s more: We’ll throw in 20 safety vests for the class or kindergarten group of your child. Simply fill in the order form and we will send you the safety vests at the end of the campaign. www.panasonic-electric-works.co.uk Gaynor.Bromley@eu.panasonic.com
Health & Safety
DENIOS cares, DENIOS delivers
In the world of industry, many sectors handle hazardous materials on a daily basis, therefore all the more reason to protect your workforce and your environment. With DENIOS UK, safety in the workplace is always first on the agenda when advising customers on how best to store hazardous substances.
JUMP INTO THE INNOVATION STREAM The JSP Innovation stream is in full flow with a new range of truly ground breaking safety products that we can’t wait for you to see...
The sheer scale of the enhanced punishments for health and safety offences – with average fines in the region of £20,000 not to mention possible imprisonment – underlines the fact that absolutely every company must avail itself to the hazardous material storage solutions from DENIOS UK – a principal specialist of its kind. DENIOS is a global leader in storing hazardous materials, industrial environmental protection and work safety and offers the largest product range available on the market, combined with professional advice and real value for money. The extensive product catalogue includes indoor and outdoor storage solutions for hazardous materials, cabinets for heating, melting and cooling substances, storing and handling gas cylinders, equipment for the safe handling of hazardous materials, DENSORB sorbents for premium spillage protection and work safety equipment. DENIOS’ range of steel IBC and drum storage solutions should be regarded as a standard requirement for peace of mind and to intrinsically cover the demanding needs of the likes of HSE, Environment Agency and the DSEAR regulations. The superior construction standards and scope of choice offers easy access, increased efficiency and time saving and longer performance life for the liquids stored. For the past 30 years, DENIOS has helped companies, both large and small, in the protection of the environment and minimising risks with hazardous substances. Originated in Germany, the company today is fully established throughout Europe and the rest of the world. Its UK subsidiary, DENIOS UK, opened its Shropshire office in 2000 which has a production plant of 37,225ft2 and manufacturers a whole variety of large standard and custom-built storage cabinets on site. For over 15 years the subsidiary has used its extensive knowledge to meet the practical needs of its customers thanks to its own production facilities and team of dedicated engineers, DENIOS UK is able to produce standard solutions which can be adapted to specific applications or create bespoke solutions tailored to job specific requirements whilst respecting UK regulations. For more information please call free on 0808 178 07 23 or email sales@denios.co.uk
Tel: 01993 826050
uksales@jsp.co.uk www.jsp.co.uk
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HYDRAULIC POWER & CONTROL WORLDWIDE Industrial
Energy PFBK-065 A mid-sized, highpressure, dualdischarge pump.
Defence
Mobile
Subsea
SSR-05 A subsea regulator, without the ocsillation. The Oilgear Subsea Pressure Regulator is a robust, precision device that controls the pressure within a given circuit by serving as both a pressure reducer and as a pressure relief. The SSR is available in various sizes and control options (pilotoperated, mechanicallyset, and electricallycommandable).
PVG-048 An extremely responsive high-speed pump. The PVG is a variabledisplacement, axialpiston pump with fast control response. The PVG thrives on low viscosity fluids and is available in a variety of control and porting options. It is designed to be a highperformance solution for your demanding applications.
PVV-200
PFBA-4
The flagship, highhorsepower pump.
A compact, highpressure pump.
The PVV line of Oilgear pumps represents the pinnacle of performance in a variabledisplacement, axialpiston pump. Pressure and flow demands continue to rise for our customers. The PVV is a pump that rises to the challenge.
The PFBA pump has proved itself successful for use with high water content and lowviscosity fluids. These axial piston pumps are used in a wide variety of applications, including oil and gas die casting and injection molding machines, high pressure test rigs, civil and marine projects, intensifier systems, extrusion presses, forging presses and high pressure forced lubrication systems for long turbines as well as metal forming machines.
Wide variety of applications: high pressure test rigs, civil and marine projects, intensifier systems, extrusion and forging pressure and other heavy duty metal forming machines.
Introducing the PVV-180 and PVV-355 New additions to the ultra high performance line of PVV variable displacement pumps.
BEST UNDER PRESSURE The Oilgear Company provides robust hydraulic solutions for customers who prefer a partner not a vendor Our vision is to be the No.1 choice for hydraulic solutions in our target markets Oilgear Oilgear engineered engineered hydraulic hydraulic solutions solutions are are amongst amongst the the most most reliable reliable and and cost cost effective effective on on the the market. market. We We drive drive the the reduction reduction of of life life cycle cycle costs costs through through innovation innovation and and engineering engineering excellence excellence We We pioneer pioneer multi-fluid multi-fluid testing testing to to promote promote the the use use of of alternative alternative hydraulic hydraulic fluids fluids As As aa partner partner we we value value customer customer satisfaction satisfaction and and being being easy easy to to work work with with Oilgear Oilgear promote promote customer customer confidence confidence through through qualification qualification
E: enquiries@oilgear.com T: 0113 394 7300
OILGEAR OFFER AN EXTENSIVE RANGE OF MULTIFLUID, HYDRAULIC PRODUCT RANGING FROM 70 TO 1000 BAR ENERGY ENERGY
OILGEAR ENGINEERING SOLUTIONS & CAPABILITY
INDUSTRIAL INDUSTRIAL
TESTING & AFTERMARKET CAPABILITY đƫ đƫ Hydrostatic Hydrostatic Testing Testing up up to to 1000 1000 Bar Bar đƫ đƫ 6000 6000 Bar Bar intensifier intensifier rig rig
đƫ đƫ Offshore Offshore Motion Motion Compensation Compensation
đƫ đƫ Pump Pump dynamic dynamic performance performance testing testing (1000 (1000 Bar) Bar)
đƫ đƫ Subsea Subsea Pumping Pumping Control Control đƫ đƫ ROV ROV Control Control
đƫ đƫ Multifluid Multifluid trials trials
đƫ đƫ Blow-Out Blow-Out Prevention Prevention
đƫ đƫ Rapid Rapid response response emergency emergency repair repair
đƫ đƫ Hydraulic Hydraulic Press Press Control Control
đƫ đƫ Routine Routine service service checks checks
đƫ đƫ Electrical Electrical Amplifier Amplifier Control Control
đƫ đƫ Preventive Preventive maintenance maintenance đƫ đƫ System System performance performance diagnostics diagnostics đƫ đƫ Remote Remote condition condition monitoring monitoring đƫ đƫ Trouble Trouble shooting shooting đƫ đƫ Retrofit Retrofit of of new new technology technology đƫ đƫ System System optimisation optimisation audits audits
đƫ đƫ Sluice Sluice & & Bridge Bridge Control Control đƫ đƫ Transfer Transfer Barrier Barrier Control Control
MOBILE MOBILE
đƫ đƫ Finite Finite Element Element Analysis Analysis đƫ đƫ Computational Computational Fluid Fluid Dynamics Dynamics –– System System Simulation Simulation (SimulationX) (SimulationX)
đƫ đƫ Power Power On On Demand Demand life life cycle cycle cost cost reduction reduction
đƫ đƫ Variable Variable displacement displacement pumps pumps đƫ đƫ Fixed Fixed displacement displacement pumps pumps Hydraulic Hydraulic intensifiers intensifiers đƫ đƫ Bespoke Bespoke hydraulic hydraulic control control systems systems đƫ đƫ High High pressure pressure check check valves valves đƫ đƫ Pressure Pressure regulating regulating valves valves đƫ đƫ High High pressure pressure logic logic manifold manifold valves valves đƫ đƫ Subsea Subsea function function valves valves đƫ đƫ High High speed speed relief relief valves valves đƫ đƫ Screw-in Screw-in cartridge cartridge valves valves
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OPM GrOuP are PrOud tO annOunce ZerO LabeLs 2 LandfiLL scheMe certificatiOn awarded
O
PM Group is proud to announce that it has recently been awarded their Zero Labels 2 Landfill Certification.
The certificate was issued by BPIF Labels following Prismm Environmental confirming that OPM’s waste was being treated according to the scheme compliance requirements. OPM has worked closely with recyclingled waste management company Prismm Environmental Services. Prismm who offer a total waste management solution to businesses on a national scale commenced with an initial
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audit of the system, processes and waste streams. Prismm introduced various equipment to accommodate the waste being produced, as well as maximise efficiencies, the aim was to reduce the impact on the environment by utilising the latest technologies to divert waste from landfill sites. A baler, an on-site compactor, and various bins were introduced to encourage waste stream segregation. The OPM teams received training as to the benefits to the environment of recycling as well as from a health and safety perspective in the correct usage of equipment. The OPM Management team assisted with
staff training to help all members of the OPM team gain a strong buy-in to segregation and its importance in keeping recycles clean to achieve the highest levels of recycling.
Chris Ellison, MD commented “OPM take their environmental responsibility seriously, we are proud to assure our customers that their label products are being produced with as little impact on the environment as possible”.
The Key to Retail Success ... M P O t a k o o r l s e l c o Take a lp y ou increase we can he . n i r t p f o r w o e sa les w ith the p tition ! e m o c e p th st in a g a u o d n t ta S
At OPM (Labels & Packaging) Group weĘťre experts in delivering innovative, agile printed packaging solutions to forward-thinking organisations. An intelligent brand owner uses print and packaging to inform and inspire the user, with a balance of decoration and functionality creating an identity that is as emotional, colourful and multi-layered as the consumer.
OPM work in partnership to deliver quality print that protects your brand equity ensuring our clients are positioned in the market to achieve positive consumer experience for their brand and its products. Get in touch to discuss your print needs today
sales@opmgroup.co.uk
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OPM offer services for customers of all sizes, across all sectors. From long runs to convenience quantities with short lead times. At OPM we take great pride in the superior quality of our printed products across our portfolio. Our technical team are always looking for ways to improve pack decoration without impairing product function by providing innovative packaging solutions.
OPM manufacture Performance products for a variety of applications to exacting GMP standards providing : High barrier to moisture, light and gasses, high mechanical resistance, address physical challenges , whilst maximising packing efficiency and maintaining excellent image and text definition. Certified to PS9000 : 2011, ISO 9001 : 2008, BRC/ IoP Global Standard Food Packaging Standards Grade AA Full low migration ink site
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Security, Authenticity & Tamper Evident Labels, Peel and Reseal, I.V. Hanger Labels, Braille & Tactile Warning Labels, Multi-ply Peel and Reveal Labels (AKA Peel & Read), Industrial, Blank Labels, Sequentially Numbered, Thermal Print, ID Labels, Thermochromic Labels.
Lidding Films and High Grade Papers, Laminated Films, Stick Pack, Flow Wraps (foil & non foil), Blister Foils, Wet Wipe Wraps and Re-Seals, Liquid Pouches, Peelable Pouches.
OPM (Labels & Packaging) Group Limited, The Colour Box, Gelderd Road, Leeds, LS12 6TG
Lifting & handling
Tradition in Dynamic Innovation
RUD Chains Ltd
NEW VLBG Plus Offers 45% Higher Working Load Limit • NEW VLBG Plus offers an impressive 45% higher working load limit than VLBG • Full working load limit in all directions, rotates 360° & suspension ring pivots 180° • Safety factor of 4:1 & operational to temperatures as low as -40° • NEW ICE-Bolt offers up to 110% higher working load limit • Perfect for complex lifts where the load has to be lifted & tilted in all directions • Used across offshore, engineering, rail, heavy duty lifting & handling
new VLbG PLus nOw Offers 45% hiGher wOrkinG LOad LiMit (M8-M30) UD Chains is a leading manufacturer of lifting and lashing equipment that helps guarantee ultimate safety when lifting and moving heavy loads. Their diverse product range offers over 600 tested and certified lifting and lashing points for bolting and welding covering a working load capacity range from 0.6-250 tonnes. The ever popular RUD VLBG load ring has been developed to offer the new VLBG Plus. The innovative VLBG Plus now includes RUD’s robust ICE- Bolt. The ICE-Bolt is made from their revolutionary patented fine grain steel which is operational to temperatures as low of -60°C.
r
Lifting points are often used for turning, rotating and tilting which adds a considerable risk to the lift. When lifts are turned under full load it results in high friction between the bolt head and the rotating connecting element, which subsequently can lead to the opening of the bolt mid lift which can occur with DIN 580 / standard eye bolts. However this does not happen with the new RUD VLBG plus. The VLBG Plus bolt offers a considerable safety feature to the operator and equipment being lifted; it will stay firmly fastened under full loads, vertically or horizontally. The ICE-Bolt is quick and easy to install and assembly is possible with a flat/ ring wrench or Allen key. The VLBG plus offers an impressive 45% higher working load limit (M8-M30) compared to the VLBG. It rotates 360º and the suspension
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ring pivots 180º. The clamping spring works as a noise reduction function and holds the suspension ring in the requested position. A clear marking of the minimum working load limit for all loading directions is also highlighted on the load ring. Complex lifts where the load has to be manoeuvred and tilted in all directions can be safely and effectively done with the use of the VLBG-Plus load ring. The VLBG Plus can be used across a variety of working environments from engineering, construction, rail, offshore, handling and MOD projects to name a few. For more information please call 01227 276 611 Email Katie.crane@rud.co.uk or visit us at www.rud.co.uk
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interView QuestiOn and answer On ‘MicrObiOLOGicaLLy infLuenced cOrrOsiOn’
icrobiologically Influenced Corrosion (MIC) can be addressed as an electrochemical corrosion in which the role of microand macro-organisms is undeniable. Between 20 to 40% of the economic loss of corrosion is due to MIC. In Canada, 50 % of external corrosion cases of gas pipelines are attributed to MIC. Being electrochemical in nature means that MIC can be treated by conventional ways of controlling corrosion: coating, CP, use of chemicals, materials selection and design. Being microbial in nature, however, adds more into these measures as well as if they can be applied with 100% success: the chemical used are called biocides (other than inhibiters), Not all coatings are resistant to MIC, CP may or may not control MIC and all known engineering materials (except Titanium and its alloys) have been reported to be vulnerable to MIC. If MIC happens in non-metals (such as concrete or composites), it is more technical to address it as MID (Microbiologically influenced deterioration).MIC can be operate as a pre-commissioning factor in increasing the risk of corrosion in
M
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common practices such as hydrostatic test or during inspection practices such as intelligent pigging. There are two groups of methods to be used for the recognition of MIC: Culture-dependent and culture-independent. Both groups have serious drawbacks in addition to their undeniable advantages. Likewise, there are four ways to treat MIC: physical (use of coating)/mechanical (pigging, scrubbing) - Chemical (use of biocides), electrical (CP) and microbiological (Bacteria against bacteria). All these treatment methods also have their own intrinsic limitation and disadvantages. 1.
WHAT IS MICROBIOLOGICALLY INFLUENCED CORROSION (MIC) AND HOW HAS IT ATTRACTED ATTENTION OVER THE PAST DECADES?
Microbiologically influenced corrosion (MIC), or as Europeans mostly prefer to say microbiologically induced corrosion is an electrochemical process in nature where micro-organ isms (such as bacteria and Archaea) and macro-organisms (such Barnacles) are capable of affecting
the severity of corrosion by initiation, acceleration and sometimes deceleration it. Due to its very high costs, both economic and ecologic, the interest in MIC always shows an ever-increasing trend. 2.
WHAT ARE THE KEY TECHNOLOGIES AVAILABLE IN MARKET TODAY IN TERMS OF MONITORING AND DETECTING MIC?
Culture-dependent methods such as MPN (most probable number) and serial dilution as well as simple absence/presence cultures are available. However, these methods all have the drawback that about 99% of bacteria are not culturable. Recently, culturedependent methods that rely on molecular microbiology methods, such as PCR, DGGE, ATPG2 and the like have been developed. While Culture-independent methods do have accuracy advantage over their culture-dependent methods, they also suffer from serious limitations. In addition, unlike culture-dependent methods that are the base for all field tests such as but not limited to BART, culture-independent methods y have not been “Field-friendly”…yet!
3.
WHEN SELECTING THE RIGHT MIC MONITORING AND DETECTION METHOD, WHAT ARE SOME
KEY CONSIDERATIONS AN ENDUSER SHOULD MAKE TO ENSURE APPLICATION SUCCESS?
I.
Always at the beginning, assume that your case of corrosion is NOT MIC. When all your attempts showed otherwise, then go on to call it MIC!
II.
Consider working conditions that may serve to sustain microbial communities: do not look for mesophilic bacteria in your turbine house but in your wet cooling tower, stagnant water is a highly likely source for MIC, be more attentive to your hydrant rings and systems, observe pH and Temperature ranges.
III.
Study the corrosion products and their colours while still fresh.
IV.
Take water and corrosion products samples very carefully and subject them to both microbiological and chemical specific tests.
V.
Most important of all: either consult with an MIC expert or do organise systematic training on this subject for your technical staff and yourself!
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4.
WHAT ADVANCEMENTS HAVE BEEN MADE IN TERMS OF MIC PREDICTIVE AND PREVENTIVE TECHNOLOGIES OF TODAY WHEN COMPARED TO THOSE OF PREVIOUS GENERATIONS?
WE have been coming along with plenty of success in this area, both in theory and practice. Introduction of culture-independent methods as a routine testing procedure, introduction of electrical MIC theory (EMIC), finding anti-bacteria properties of Graphen, use of mathematical models such as Fuzzy model in predicting MIC risk are just a handful of what is currently going on.. Also discovering new groups of corrosion-related bacteria (CRB) in addition to the role of Archaea in corrosion must not be forgotten either. These were not common in 1980s for example.
5.
FROM THE INDUSTRY STANDPOINT, WHAT ARE THE FUTURE PLANS OF
MIC PREDICTIVE AND PREVENTIVE TECHNOLOGIES? I have always compared MIC with Physics: in the same way we have applied physics and theoretical physics, we must talk about applied MIC and theoretical MIC. Meaning that both the detection and treatment techniques of MIC must be developed (practical MIC) as well as theories that try to understand and describe MIC (e.g. application of Fuzzy calculations in MIC, or more research on EMIC, or the like). What I personally see is that it is now time for more microbiology in applied MIC and more mathematics in theoretical MIC. Excellent opportunities are out there and in parallel to publishing thousands and thousands of papers that measure corrosion rate of such and such metal in such and such environment against such and such bacteria, we have to jump forward to grab a general
MIC theory that can guide us in both defining and treatment of MIC. Many of currently used predictive models of corrosion (such as Cassandra and its newer versions) still do not include MIC in their calculation approaches because simply the maths which is there is not enough. MIC is a multidisciplinary area and this is its driving force. Right now we have various corrosion and microbiology journals but we do feel the empty place of an MIC journal. Ina addition to all that, from a practical point of view, it is the (sometimes very tough act of) convincing top managers about corrosion in general and microbial corrosion (MIC) in particular. Over the years, I have developed a system that I am calling â&#x20AC;&#x153;Corrosion Knowledge Managementâ&#x20AC;? (CKM) to address corrosion for decision-making and strategist managers. By applying CKM into MIC, one can hope that in a company both the top management and the engineering expert will be on the same page about corrosion in general and MICV in particular.
Dr. Reza Javaherdashti holds a double degree in Materials Science and Metallurgical Engineering. In addition to being an internationally renowned expert on microbial corrosion, He has several internationally referenced books and papers on the subject. He is the first scientist who has applied Fuzzy logic in prediction the risk of microbial corrosion successfully. He is also an international referee on disputes related to corrosion. His recent books is on microbial corrosion and hydrotest (coauthored with Farzaneh Akvan, Published by CRC Press, USA, 2017).
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aw-Lake cOMPany intrOduces tw series turbine fLOw Meter that inteGrates with siGnaLfire fLOw tOtaLiZer as Part Of a wireLess fLOw cOntrOL systeM
ak Creek, Wisconsin-September 19, 2017- AW-LAKE COMPANY is pleased to introduce the TW Series Turbine Flow Meter for the most rigorous flow measurement applications. Ideal for use both on and off the oil field, the TW Series Turbine Flow Meter provides highly accurate (to ±1% of reading or better) and repeatable (0.1% repeatability) flow measurement of oils, water and some chemicals with a low cost of ownership.
O
Besides new installations, the meters or meter internals are cost effective and easy dropin replacements to Kimray, NuFlo, Haliburton, Cameron and Blancett turbine flow meters in existing applications.
flow data to a Gateway for remote monitoring and control on a PC, PLC or other control system. AW-Lake’s TW Series Turbine Meters are available in flow ranges from 0.6 to 5,000 gallons per minute and feature a 316 stainless steel construction, tungsten carbide rotor shaft and tight machining tolerances for excellent durability and long life. With working pressures up to 5,000 psi and fluid temperatures from -150º to 350° F, the TW Turbine Flow Meters are ideal for a variety of liquid flow applications such as: t
Chemical injection: turbine flow meters work upstream, midstream and downstream.
The TW Flow Meters are available in a wide range of sizes and easily integrated with the SignalFire Flow Totalizer as part of a wireless flow control system. Working together, the Flow Meter and Totalizer can measure, locally display and wirelessly transmit intelligent
t
Drilling applications: When packaged as a battery-powered solution, the TW Turbine Flow Meter is ideal for well drilling applications where the power for the drilling rigs originates from mobile generators.
About AW-Lake Company
About SignalFire Wireless Telemetry
AW-Lake Company, a TASI Group company, is a leading North American design, manufacturing and service company of flow measurement technology for the fluid control needs of various industries, including oil & gas, chemical processing, paints & coatings, hydraulics & pneumatics, food processing, and fluid power. Together with its European sister companies, KEM-Kueppers, Vogtlin Instruments, and LitreMeter, AW-Lake services and distributes a broad portfolio of flow measurement instrumentation throughout North America, South America, Europe, and Asia. For information, please contact Marcia Reiff, Marketing Manager, at 800-850-6110, e-mail mreiff@aw-lake.com, or visit AW-Lake’s Web site at www.aw-lake.com.
SignalFire Wireless Telemetry designs and manufactures wireless telemetry products that enable robust, long-distance wireless communication connecting multiple devices in challenging outdoor environments. In 2015, the company became a part of the TASI Group and the TASI Flow Division. SignalFire joins the TASI Flow family, a global leader in flow instrumentation, with brands including TRICOR Coriolis, AW Gear Meters, KEM Küppers, LitreMeter, and Vögtlin Thermal Mass Flow Meters and Controllers. For more information about SignalFire, visit http://www.signal-fire.com/.
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About the TASI Group
t
Fracking and Flowback: Metering of used and reclaimed water is a primary application for these turbines. The TW Turbine Flow Meter monitors the water as well as the chemicals used to treat the water.
t
Natural Gas pipeline (midstream): The TW Series Turbine Flow Meter works in a variety of pipeline installations including those for metering stations, chemical injection, and offloading to smaller pipelines for delivery or truck loading stations.
For more information on the TW Series Oil & Gas Turbine Flow Meter, refer to the website at http://aw-lake.com/product/tw-turbineflow-meter/or contact Marcia Reiff, Marketing Manager, at 800-850-6110, e-mail mreiff@aw-lake.com.
The TASI Group of Companies is comprised of three technologically advanced product platforms commonly linked by a disciplined focus on Test, Measurement, and Assembly. Each TASI company delivers products and services to today’s world manufacturing environments, focusing on Automotive, Medical Devices, Oil and Gas, Plastic Containers, Consumer and General Industrial markets. For more information about the TASI Group, visit their Web site at www. tasigroup.com.
C O M PA N Y
A TASI GROUP COMPANY
WWW.AW-LAKE.COM 414.574.4300
SEVEN BRANDS MULTIPLE INDUSTRIES ONE GLOBAL FLOW COMPANY
cOrdeX annOunces Launch Of aLL new tOuGhPiX diGitherM diGitaL iMaGinG caMera series
t
he CorDEX DIGITHERM are the most advanced, intrinsically safe portable digital imaging cameras yet.
MIDDLESBROUGH, UK. (October 9th 2017) CorDEX have announced the release of the all new TOUGHPIX DIGITHERM camera series, comprising of a world’s first – an intrinsically safe combined 5mega pixel digital camera and onboard thermal imager. Offering ground-breaking affordability in exchange for an impressive array of features, the TOUGHPIX DIGITHERM series sets a new industry standard for delivering a compact and lightweight, yet rugged, digital imaging camera. The new cameras allow users to quickly detect issues, conduct accurate measurements and document findings for remedial action. The TOUGHPIX DIGITHERM cameras feature a rich set of new hardware, software and technical specifications designed from the ground up to set the highest standard in the industry. Manufactured from lightweight but tough, aircraft grade aluminium, every single component in the TOUGHPIX
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DIGITHERM has been selected with one goal in mind – quality that’s built to last. Douglas Walker, Research Director said “CorDEX have pioneered an intrinsically safe dual mode radiometric camera. DIGITHERM provides digital and thermal imaging in a compact tough package with a low entry cost. The high resolution visual image combined with the capable 80x60 IR image opens up many application areas. Problem hot spots are easily made visible and located accurately in tough environments.” With its industry leading, 5 megapixel visual sensor, motorised automatic focus and ultrabright LED flash, TOUGHPIX DIGITHERM takes crystal clear, high resolution digital images in broad daylight a swell as darker environments. Not only this, but the cameras include a thermal imaging camera, meaning its duel functionality is the perfect hybrid for any situation. Additionally, the cameras offer adaptive thermal blending, WIFI, onboard analysis tools, a removable memory card and removable battery. Tony Holliday, CEO confirmed CorDEX had gone back to its roots “CorDEX made
a name for itself by introducing the first ATEX certified digital camera with flash almost ten years ago. Today, with the launch of TOUGHPIX DIGITHERM, CorDEX has again set the bar not only providing a ground up developed digital imaging camera, but a camera more resembling mainstream compact cameras with the additional benefits of a rugged Intrinsically Safe design, plus onboard thermal imager.” The TOUGHPIX DIGITHERM series is available through select distributors and directly from CorDEX Instruments. To buy the TOUGHPIX DIGITHERM or to learn more about the series, please visit www.cord-ex.com.
Professional features in a pocket sized package.
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Non-intrinsically safe version available
Introducing the ToughPIX DIGITHERM Intrinsically Safe Digital Imaging Camera. Rugged, powerful and with ground-breaking affordability, CorDEX DIGITHERM sets the standard with compact digital imaging cameras.
The ToughPIX DIGITHERM is a ruggedized, compact, high resolution digital imaging camera capable of capturing true 5MP visual images along with fully radiometric thermal images, making this camera your go-to tool for fault finding documentation, whether your work is safety & process inspections, electrical repair or facility maintenance. â&#x20AC;˘ 5 megapixel visual sensor
â&#x20AC;˘ Removable memory card
â&#x20AC;˘ 80x60 thermal sensor â&#x20AC;˘ -10 to +380°C
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â&#x20AC;˘ LED flash â&#x20AC;˘ WiFi for image download
â&#x20AC;˘ Alarm triggered recording
with auto-focus
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removable, rechargeable battery pack
via CorDEX Mobile App
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Vibration Analysts; Worth their Weight in Gold Genuinely good vibration analysts are worth their weight in gold. But how do you create good vibration analysts? A good vibration analyst provides an early warning of faults, with a clear statement of what’s wrong, what must be done, and the urgency of the required action. Good vibration analysts are accurate and confident. How do you make a “good” vibration analyst? You train them at an Authorized Mobius Institute Training Partner Center. The difference is in the unique way we train them. In the old days, with “death-by-PowerPoint” presentations, the analysts just had to take the word of the instructor - “I know it is confusing, but take my word for it, this is how it is – and now we need to move to the next topic” is the attitude of too many instructors. People often came home from the course more confused than they were before. And sadly, this is still the case with the majority of (non-Mobius) courses today. But Mobius approved instructors are different. Mobius Institute approved instructors use training materials rich with 3D animations and sophisticated simulations – hundreds of them! The animations and software simulations explain the machinery failure modes, the vibration signals, signal processing, and the instrumentation. They make everything crystal clear. To achieve the best possible results, without extra charge, students attend online training before the course to get them up to speed – they get so much more out of the live
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course. During the course, in addition to seeing the animations and simulations, they receive repeated anonymous quizzes and exam standard “worked examples” to ensure that everyone understands what they need to know. No student is left behind! And that’s the real difference. Mobius students understand the machine, the failure modes, the root causes, the vibration patterns and analysis techniques, and the analyzer; they are not just forced to remember. Since just 2005, we have trained over 24,000 people from 174 countries, in over 20 languages, according to the ISO 18436 standards. The certification is accredited to ISO 17024. There is no higher standard. So please visit www.mobiusinstitute.com or e-mail learn@mobiusinstitute.com to learn where the next course will held. You may like to Google the Mobius Institute YouTube channel to see some of our training techniques in action.
MORE THAN
24,000 VIBRATION ANALYSTS TRAINED* *Since 2005, MOBIUS INSTITUTE has provided classroom training to over 24,000 vibration analysts. We train more analysts than any other training organization throughout the world. In addition to our classroom training in vibration analysis, we have trained thousands more through our DISTANCE LEARNING (via the web), and our iLearnVIBR iLearnVIBRATION software. MOBIUS INSTITUTE also provides classroom and distance learning training in FIELD BALANCING, SHAFT ALIGNMENT, and CONDITION MONITORING PRACTICES.
We are ISO/IEC 17024 and ISO 18436-1 accredited and provide vibration analysis training and certification per ISO 18436. Visit our website to find out how you can join the largest and most capable community of VIBRATION ANALYSTS that have been taught by MOBIUS INSTITUTE.
www.mobiusinstitute.com
Call us in the USA & Canada at (877) 550-3400 or international at +1 (206) 842-4000 or email us at learn@mobiusinstitute.com
Measurement & Monitoring
Industrial-strength temp profilers and infrared thermometers
New industrial accelerometers from Hansford Sensors are smaller, lighter and offer higher performance
METREL – we deal in quality
The new family of HS-100 and HS-150 accelerometers is designed for use throughout industry, typically on drives and rotating shafts such as those found in pumps, fans, motors, gearboxes and compressors. In common with all vibration devices from Hansford Sensors, the new versions are designed and manufactured in the UK, to offer a robust, reliable and extremely accurate solution when used with condition monitoring, predictive maintenance and plant management systems.
METREL is one of the world leading manufacturers and suppliers of high quality, technically advanced, innovative electrical test and measurement instruments, and associated software and mobile applications. With over 60 years of experience, Metrel recognise and understand the testing requirements of electrical contractors and maintenance staff in today’s challenging environment, with development focus on technical capability, enhanced user interface, and practical time-saving features. MI 2892 Power Master is a hand-held three phase power quality analyser with a large easy-to-read graphical colour display enabling the user to detect harmonics, phasors and waveforms anomalies in the installation simply by connecting the device. The instrument is designed for a long term recording as well as for troubleshooting power quality problems in three-phase and single-phase power distribution systems.
www.flukeprocessinstruments.com
www.hansfordsensors.com
www.metrel.co.uk
Mydax Offers Liquid Chiller System Solutions for Industrial Temperature Control Needs
Monitor and Control Indoor Air Quality (IAQ) with a PPMonitor
The temperature monitoring experts Fluke Process Instruments will showcase a wide range of sensors for various industry sectors and applications at the 2017 Advanced Engineering exhibition. The latest addition to the noncontact, infrared thermometer portfolio, the Endurance series covers measured temperatures from 50 °C to 3,200 °C. It comprises monochrome and ratio pyrometers with various spectral ranges. The sensors feature a stainless steel IP65 housing, galvanically insulated I/Os, a versatile range of sighting options including a high-resolution onboard video camera, remote monitoring via Industrial Ethernet, and a built-in web server for process troubleshooting and traceability. Applications include the metals, glass, plastics, and semiconductor industries.
Mydax stands apart from other chiller manufacturers by providing the elite chiller system on the market, utilizing Advanced Temperature Control Technology 0 to 100% proportional process cooling and heating control, rugged tubular steel frames and state of the art touchscreen controls. Expert use of flowmeters, pressure transducers, pulse width modulated valves and variable frequency drives allow precise temperature and fluid flow control. The Mydax CryoDax series of low temperature chiller systems can deliver process control fluid temperatures as low as -70°C and are utilized in Industrial applications including Hydrogen Fuel Cell Fueling, Semiconductor Manufacturing and Test, Thermal Vacuum Chambers, Space Simulators, Environmental Test Chambers, and Biotech Pharmaceutical applications. 530-888-6662 www.mydax.com
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Hansford Sensors, the leading UK manufacturer of industrial accelerometers, has launched the latest versions of its proven HS-100 and HS-150 Series vibration sensors. The new sensors are over 10% smaller and lighter than existing versions, and offer even greater frequency response, with a significant improvement in resonant frequency.
PPM Technology Ltd is pleased to announce our latest range of IAQ monitoring instruments - the PPMonitor range. The PPMonitor has been designed to give a good visual representation of IAQ in a building. A great number of units may be networked together via the ZigBee wireless mesh system to show precise changes in concentration of selected IAQ parameters over time for an entire building. Each unit can monitor temperature and humidity as well as up to 5 different IAQ target gases including formaldehyde, carbon monoxide, carbon dioxide, nitrogen dioxide, sulphur dioxide, VOC’s, ozone, ammonia and many more. PPMonitor software enables the data to be viewed graphically, produce reports and run schedules as well as alarm functions and notifications for effective building management. Please contact info@ppm-technology.com or visit www.ppm-technology.com for more information.
Rexnord Offers the Latest in Industrial Torque Monitoring Monitorq is a robust and reliable torque measuring device which can be integrated into a drive line using standard power transmission products such as couplings, pulleys and gears. It provides a true measurement of torque, from any location in a drive train. “The design of this latest version of Monitorq has been driven 100% by feedback from our customers,” said Rob Hucker, Product Manager. “We have removed batteries from the torque ring and replaced them with a stateof-the-art inductive power system. We have increased the accuracy of the torque signal to 1% of full-scale torque while at the same time increasing the sampling rate to 1kHz.” Contact information: More information is available at www.rexnord.com/monitorq Ordering information is available at +44 (0) 1285 640333 or monitorq@rexnord.com
News & Events EKOGRID Technology Becomes In-Situ Breakthrough for Planet Remediation
YOUR ULTIMATE PROJECT PARTNER FOR ENGINEERING DESIGN & PROJECT MANAGEMENT
FMCG
CHEMICAL
ENERGY
PHARMA
Giving you the capability
Greentech specialists Eko Harden Technologies Oy today announces that completion of a year-long controlled test of contaminated creosote soil in Canada using its pioneering EKOGRID technology allows it to proceed with the development of a breakthrough in-situ solution for the environment. Railroads authorities, oil and gas producers and timber firms can now use EKOGRID to eliminate the creosote health risk from soils previously considered untreatable and unreachable by current oxidation or bioremediation methods in the market.
The completed test complements the firm's earlier results recorded from measurements of contaminated soil samples from a number of customer projects. The results of the latest test speak volumes ... groundwater poisoning BTEX's were degraded in less than a month, lighter PAHs in under half a year and heavier PAHs and remaining aliphatic hydrocarbons in less than one year. Overall, the decomposition rate of the samples was about 1,500 mg of organic contaminant /kg soil / month. www.ekogrid.fi
LG Motion becomes UK distributor for Baumeister & Schack GmbH & Co. KG Basingstoke based LG Motion design and manufactures a wide range of motion control products and systems. The capability is complemented by close working relationships with a number of other international manufacturers of drive systems and components. LG Motion is now pleased to announce that it will represent baumeister & schack in the UK. Founded in 1980 the company which is located to the south of Stuttgart baumeister & Schack design, develop and manufacture DC motor drive systems and actuation products for diverse applications in the automotive, medical, machine tool and furniture industries. Tel: +44 (0) 1256 365600 info@lg-motion.co.uk www.lg-motion.co.uk
CALL US FOR A FREE CONSULTATION 01484 711 333 sales@projexsolutions.co.uk
www.projexsolutions.co.uk
Eisele Pneumatics GmbH & Co. KG Eisele Pneumatics GmbH & Co. KG is a multinational family-owned company with headquarters in Waiblingen. With 150 employees, Eisele develops, produces and distributes premium quality all-metal connectors and has become established over the past decades as a leading supplier of innovative connection solutions. The Eisele portfolio – manufactured virtually 100% in Germany – comprises all important standard connection components, such as push-in connectors, quick-release connectors and tube fittings, as well as numerous innovative products with unique selling properties that set standards, such as an extensive line of multiple connectors. Worldwide distributors and the subsidiary Eisele Connectors in Michigan, USA, ensure the global availability of Eisele products. www.eisele.eu
Sandvik sponsors and brings ‘next generation’ materials to Stainless Steel World Sandvik is among the sponsors of the upcoming Stainless Steel World (SSW) Conference & Exhibition 2017 in Maastricht, The Netherlands (November 28-30), one of the world’s most important events relating to the manufacture and use of corrosion resistant stainless steels and other corrosion resistant alloys. “We are very proud to sponsor and be so closely involved with SSW 2017. Attendees can learn about the significant operational advantages of Sandvik’s hydraulic and instrumentation (H&I) tubing. Also, our hyperduplex stainless steels which Sandvik regards as being the ‘next generation’ in stainless steels,” said Hans Boudewijn, Sandvik’s Regional Sales Director for Benelux, France & Iberia. materials.sandvik
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news & events
HPI GT-Variflow HPI’s GT-Variflow is a proven alternative solution for control of liquid fueled gas turbines. This eliminates the need for the traditional fuel valve and pump arrangement, while meeting, or exceeding, the performance of the traditional approach. GTVariflow is based upon the use of a variable speed pump. The system utilises a positive displacement pump driven by a 3 phase AC motor that is controlled by an Allen Bradley variable frequency drive. HPI Global Headquarters
United Kingdom
New technical article reveals how to optimise machine automation in food and beverage manufacturing Lenze, the motion control specialist, has published a new technical article explaining how to optimise automation in machinery for food and beverage manufacturing. The technical article is available as a free PDF download from the Lenze website. The new technical article explores the challenges facing engineers designing and building machinery for the food and beverage sector, before proceeding to outline the critical elements that enable the correct technology and development tools to be selected.
SOLUTIONS FOR THE PROCESS INDUSTRY 15503 West Hardy Rd.
HPI Energy Services, Ltd
Houston, TX 77060
Units 1-4
+1 (713) 457 7500 (main)
Gallagher Enterprise Park,
+1 (713) 457 7501 (fax)
Runcorn Road,
Key to optimising machine automation is alongside an experienced technology RMIG is the world’s largest manufacturer andworking supplier of provider, which has the knowledge and Lincoln LN6 3QP perforated metal and related products. We know our customers’ resources to provide full project lifecycle info@hpi-llc.com +44 (0) 1522 519944 requirements for price and quality and meetsupport. their demands with (main)
uncompromising service. Email: uk@hpi-llc.com
www.lenze.com/en-gb/
Solutions For The Process Processing encompasses a vast number of potential applications Industry for perforated products and is probably the Rutronik sector where presents the TCQ series RMIG is the world’s largest manufacturer and applications for perforation are most varied. RMIG has significant from AVX supplier of perforated metal and related prodexperience theour chemical, paper and shore Electronics ucts. Wein know customers’ pharmaceutical, requirements Qualified to the off Automotive for price quality andameet demandsfromCouncil’s specification for passive industries, toand name but few.their Ranging small, AEC-Q200 high-precision with uncompromising service. components, the TCQ Series meets the AEC’s perforation in thin materials to large holes inchallenging thick sheets, we have 125°C lifetime stability test and Processing encompasses a vast number of the knowledge, expertise, tooling and the materials to deliver humidity bias testing at 85°C and 85% relative potential applications for perforated products humidity for up to 1,000 hours. Operation products according your requirements. and is probably theto sector where applications for perforation are most varied.
www.rmig.com
RMIG has signifcant experience in the chemical, pharmaceutical, paper and offshore industries, to name but a few. Ranging from small, high-precision perforation in thin materials to large holes in thick sheets, we have the knowledge, expertise, tooling and the materials to deliver products according to your requirements. www.rmig.com
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temperature ranges from -55°C to 125°C. The capacitors of this series offer a conductive polymer electrode and have a benign failure mode under recommended use conditions.
They are lead-free and RoHS (Restriction of Hazardous Substances) compliant. The TCQ Series are currently available in three case sizes: 1210 (EIA Metric 3528-21), 2917 (EIA Metric 7343-31) and 2917 (EIA Metric 7343-20). www.rutronik.com
German component distribution posts double-digit growth in second quarter. The German component distribution market (according to FBDi e.V.) grew 12.2% in the second quarter, with orders up almost 18%. The second quarter of 2017 was extremely positive for the German component distributors. From April to June sales by companies registered with the Fachverband Bauelemente Distribution (FBDi e.V.) in Germany grew by 12.2% to 904 million euros - almost equaling the record Q1 result. The order situation remains positive, with an increase of 17.7% to 946 million euros. The book-to-bill rate was 1.05. As a result, the first half of the year has seen a record-breaking performance with sales of 1.8 billion euros and orders valued at 2 billion euros. www.fbdi.de
A new kind of certainty in beverage production Carbo 520 Optical is a new process CO2 sensor for beverages easily installed directly inline. The robust, hygienic sensor is entirely maintenance-free and provides linear, drift-free CO2 readings over the entire measurement range. The basis of this breakthrough: A cutting-edge optical measuring principle called ATR. Carbonation is a key element to the taste and perceived freshness of a beverage. For complete control of this parameter in production, where beverage producers naturally seek to minimize their raw material investment and run their production tightly within specifications, the concentration of dissolved CO2 is ideally measured continuously and directly inline. www.anton-paar.com info@anton-paar.com
FLEXIBLE SOLUTIONS FOR ANY ATMOSPHERE A
® meriflex, meriflex, Inc. Inc.® provides provides flexible flexible solutions solutions from from conceptual conceptual design, design, protoprototypes types to to mainstream mainstream production production and and operates operates on on aa simple simple philosophy philosophy based based on on Integrity, Integrity, Service, Service, and and Quality. Quality. Our Our commitment commitment to to this this philosophy philosophy is is put put into into practice practice on on aa daily daily basis basis in in the the manufacture manufacture of of our our precision precision bellows, bellows, flanges, flanges, and and other other quality quality products. products. With With the the latest latest in in technologies technologies we we supply supply aa wide wide range range of of industries industries ranging ranging from from Semi Semi Conductor, Conductor, Medical, Medical, Oil/Gas, Oil/Gas, Food Food and and Beverage Beverage and and Automotive. Automotive.
Our Our bellows bellows and and expansion expansion joints joints are are designed designed to to absorb absorb and and reduce reduce
vibration vibration and and relieve relieve structural structural stress stress from from working working under under pressure, pressure, extreme extreme temperatures, temperatures, and and other other variables. variables. We We specialize specialize in in thinthinwall wall bellows. bellows. We We also also offer offer the the highest highest quality quality metal metal braided braided flex flex hose hose in in the the industry. industry. Our Our braided braided hose hose is is designed designed for for high high pressure pressure applications. applications. It It provides provides the the protection protection needed needed for for the the inner inner convoluted convoluted hose hose to to withstand withstand high high pressure pressure and and for for vacuum vacuum or or partial partial pressure pressure applications applications requiring requiring protection protection from from hazards. hazards. Our Our stainless stainless steel steel braided braided hose hose can can be be found found on on NASA’s NASA’s Curiosity Curiosity Mars Mars Rover, Rover, on on still-in-development still-in-development commercial commercial spacecraft, spacecraft, and and in in countless countless other other applications. applications.
Also Also produced produced is is aa full full line line of of bellows bellows assemblies assemblies to to complement complement our our metal metal bellows. bellows. We We manufacture manufacture bolt-style bolt-style and and clamp-style clamp-style bellows bellows assemblies, assemblies, flanges, flanges, valve valve assemblies, assemblies, and and expansion expansion joints. joints. Every Every bellows bellows assembly assembly we we make make is is ultrasonically ultrasonically cleaned cleaned prior prior to to welding, welding, and and helium helium leak leak tested tested after after to to ensure ensure weld weld integrity integrity and and defect-free defect-free construction. construction.
2390 2390 Railroad Railroad Street, Street, Corona, Corona, CA CA 92880 92880 Tel: Tel: (951)737-5557 (951)737-5557 www.amerifl www.ameriflex.net ex.net
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Process technologies Proccess Technologies
Tel: +44 (0)161 430 4000 Fax: +44 (0)161 494 1461 www.bonut.co.uk sales@bonut.co.uk
Unit 12, Latham Close Bredbury Industrial Park Stockport SK6 2SD
Flow metering & instrumentation Since 1986 Mydax has offered Pressuretemperature Reducing Valves—WRP2 process control Designed for pressure regulation solutions for solutions for OEM and one of a kind all Available from 1/4”-3/4” inlets custom chiller applications. with a variety of connections With the ability to provide extreme Theindustrial Dereve Pressure Reducing Valve type WRP2 has been developed for low flow temperature stabilities of ±0.05°C situations is suitable for WATER for criticaland applications, even withand applications AIR duties. high cooling power requirements UNITED KINGDOM
up to 70kW, Mydax is bringing Call for more information, pricing, laboratory precision to Range the technical support & Flow to receiveWater our - L/min (gal/min) 0-10 (0-2.2) Flow Range Air - L/min (cfm) 0-150 (0-5.3) industrial market. extensive catalogue.Max. Inlet Pressure - barg (psig) 10 (150) Mydax also offers the CryoDax Outlet Pressure Range barg (psig) 0.2-4.0 2-60) series of chiller systems Maximum for the Working Temp - °C (deg F) 60 (140) Weight - gms (lb) 87 (0.19) most demanding requirements with fluid temperature ranges of -70°C to +150°C withValves—WRP4 cooling Pressure Reducing capacities from 2kW up to 15kW @ The Dereve Pressure Reducing Valve type -50°C WRP4 available. has been developed as an alternative to
Process Technologies
Specialist Power Screw Products Ex stock power screws & nuts Precision-machined components Self-reversing screws and followers Accredited by Aerospace, Nuclear & Chemical customers Specialist leadscrew & power screw products
the metal made online mainly for from Acetal Please callversions, or visit is Mydax plasticinformation. and is suitable for WATER and AIR more duties.
Inlet and Outlet connections are 1/2” BSP female and are formed to accept 15mm compression fittings
0800 433 4770
ax n . rn
a e i e n. www.ukflowtechnik.com sales@ukflowtechnik.com Certificate Number 9027 ISO 9001:2015
Call C all 01482 325676
www.m
a.
UK Flowtechnik
ax.
m
Tel: 0208 339 7370 462 Ewell Road, Surbiton, Surrey KT6 7EL, England 54120 PECMPECM Issue 9 Issue 29
Fax: 0208 339 7371
Email: sales@blackfast.com Web: www.blackfast.com
Kingston Engineering Co (Hull) Ltd, Pennington Street, Hull, East Yorkshire, HU8 7LD, UK Fax 01482 216438 Email: sales@kingston-engineering.co.uk
www.kingston-engineering.co.uk
W: www.reftrade-uk.com
Process technologies Total Process Protection Flameless Venting
Explosion Venting
Dust Detection
Bursting Discs
In these demanding times companies have a lot to deal with to meet financial targets. On top of that EHS departments have to ensure that adherence to the relevant H&S legislation such as ATEX and DSEAR for potentially explosive atmospheres and environmental legislation such as VOC & IPPC for fugitive emissions are dovetailed into safe working practices. Fike are the experts in providing protection against dust/hybrid explosion protection and over-pressure or vacuum conditions. We can work with you to protect your plant and personnel against such incidents and also assist in meeting the relevant EHS requirements of your site. Our Total Process Protection capabilities include: ■ ■ ■
ʻStandardʼ Bursting discs – flange mounted, to prevent against over pressure or vacuum conditions. Customised bursting discs – to suit bespoke mounting requirements.
ValveGuard Bursting discs – to protect PRVʼs and reduce fugitive emissions.
Explosion venting – where the product is not an environmental problem and can be vented into a safe area. ■ Flameless venting – where you have to vent inside a building ■ Active or passive explosion isolation – to prevent propagation. ■ Active explosion suppression – where it is not suitable for flameless, or the product does not want to be released for economic or environmental reasons. ■
■
Dust detection systems – to validate the protection strategy of non-zoned areas.
Please call 01622 677081 or email sales@fike.co.uk and our specialists will provide sound advice every step of the way to meet your goals. Fike UK, 35 Earl Street, Maidstone, Kent, ME14 1PF, F United Kingdom T: +44 (0) 1622 677081 E: sales@fike.co.uk W: www.fike.co.uk
Process Technologies a e ener
3715 - Hazardex July14 Edn.indd 33
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ir r er e n is an independent specialist company providing service and after sales support on all types and makes of compressed air gas dryer ltration and condensate management systems. The main activity is providing technical support and comprehensive packages for on-site servicing of compressed air/gas treatment equipment and desiccant air drying plant. ir r er e n also provides consultancy and equipment upgrades to increase e ciency and reduce energy costs etro tting a dryer control system pro ides signi cant ene ts y operating to actual site conditions rather than original design speci cation t will also restore customer con dence in e uipment operation and performance Installing a dewpoint control system to a compressed air desiccant dryer will save energy, considera ly reduce operating costs and pro ide e cient dewpoint control eatures and ene ts include Controls Compressed Air Monitor Dewpoint Extends Service Time Extend Cycle Time Constant Dryer Knowledge etro t Design Record Performance Data Installation Service/Technical Support e
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Save Money Reduce risk Maximise desiccant life Reduce switching valve wear Increase confidence No equipment modifications required Predict dryer failure Peace of mind .
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cLad MetaL sPeciaLties ong before smartphones and smart devices were ever imagined, the world of “wireless connectivity” was achieved through smoke signals, drumbeats and the drone of bagpipes. Now, we stay connected in the Cloud, through satellite technology and through the integration of miniaturized components that send and receive signals communicating data and instructions to other connected devices. You can remotely turn your house lights on or off with your smartphone, learn a bit about how “fit” we are with a wristband tracking device, or wear a tiny sensor that sends biometrics data to your physician (blood pressure, heart rate, etc.).
L
It’s all possible thanks to wireless technology and the Internet of Things (IoT). The IoT is changing everything. It’s affecting not only our private worlds, but the world at large from jet turbines to the engines that run our railway cars. Estimates say that by 2020 between 26 and 200 billion devices will be sending and receiving information wirelessly via the Internet.
We haven’t even scratched the surface of possibilities. Soon we’ll be transported by self-driving cars, wear smart clothing, and have entire cities connected to the Internet to help optimize energy efficiency, control traffic flow and bring us unimagined conveniences. The Internet of Things has created a giant wave of opportunity for industry with virtually unlimited growth potential. Clad Metal Specialties is proud to be immersed in this swiftly evolving field. Our specialized, custom; inlay and overlay clad metal products are finding new applications daily. We are already integrated into many of today’s aerospace, military and consumer products including scanners, satellites, medical devices, automobiles and appliances which are connected to the Internet of Things. We have seen exponential expansion in the IoT trend, in just a few years, and we’re extremely excited to be a part of helping to bring the world together through connectivity.
We would like to take this opportunity to introduce you to Clad Metal Specialties, Inc. Clad Metal Specialties has set itself apart with its responsiveness, dedication to customer satisfaction and exacting product standards. For 30 years, Clad Metal Specialties has solidified strong partnerships by prioritizing its customers’ need for quick response time on quotes and rapid turnaround on specialized, high-quality, precision clad metal materials. Clad Metal Specialties is proactive in product development, working alongside cutting-edge
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technological aerospace, automotive, telecommunications, medical, military, appliance, computer and electronics companies to help brainstorm solutions that ensure optimum functionality and cost effectiveness from prototype to production. Despite rigorous time constraints, Clad Metal Specialties remains faithfully compliant to ISO-9001/AS9100 standards and takes no shortcuts that might compromise quality or efficacy.
As an innovative company, Clad Metal Specialties prides itself on continually evolving its processes to create full clad metal overlays as well as inlays and thru-lays that promise impeccable performance. The use for clad metal strip is endless. All metal strips are custom made to your exact specifications. Please contact us to discuss your needs.
There’s no Getting Around it, We’re All Becoming Part of the Internet of Things Denise Marcoccia, CEO of Clad Metal Specialties
1516 Fifth Industrial Ct., Bay Shore, NY 11706 P: 631.666.7750 or 1.800.666.0670 | info@cladmetal.com | www.cladmetal.com Issue 29 PECM
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Product News
Harald Pihl Harald Pihl was founded in 1912. We have established contacts worldwide, offices throughout Europe and one in China and have an extensive knowledge of metallurgy. We hold one of Europe’s largest stocks of Nickel Alloys, Titanium and Copper Alloys which we trade in sheet, plate, strip, bar, wire, Contact tube, pipe and welding material. Our quality Nerian Vision Technologies management system is certified in accordanceDr. to ISO 9001 andSchauwecker AS9120 which permits Owner: Konstantin us to stock Gotenstr. 9 and sell to the aerospace industry, showing the high standard that permeates 70771 Leinfelden-Echterdingen our organisation. We offer in house cutting Germany services including Water jet cutting and have a coil handling machine.
Phone: +49 711 / 2195 9414 Company service@nerian.com Contact Details: Email: Harald Pihl Webseite: Gary Salterhttp://nerian.com UK Sales Manager 01902 833 839 01902 462 001 07505565971 Gary.salter@haraldpihl.com
Nerian Introduces a High-Pro Figure 1: SceneScan and SceneScan
Performance Successor for the Proven SP1 System Stereo vision, which is the three-dimensional perception of our environment with two sensors like our eyes, is a well-known technology. As a passive method – there is no need to emit light in the visible or invisible spectral range – this technology can open up new possibilities for three- dimensional perception, even under difficult conditions.
Indestructible Paint Completes Rationalisation Of The ColourTherm Range Indestructible Paint Ltd. has completed an extensive rationalisation of the Colour-Therm range of thermochromic paints – a move that is set to be of major benefit in a long list of application environments worldwide. The well-established range of indicating coatings has been associated with Indestructible Paint for some time, but the company has now undertaken a re-evaluation designed to ensure the product choice fully matches user needs and, importantly, complies with all relevant standards, not least those defined by the REACH regulations.
Niton UK’s handheld laser plastics analyser, the TSI PolyMax™ is being used in waste sorting and in high end Positive Material Identification (PMI) where using the correct polymer is crucial. Users can identify over 100 plastic polymers: Polyethylene (PE), Polystyrene, Nylon, Polyvinyl Chloride (PVC), Polycarbonate (PC) and Polypropylene. The instrument features a large 5” colour touch screen and camera. Niton UK also offers X-ray fluorescence (XRF) analysers for identifying metals, precious metals and alloys. Since 2000 Niton UK has established itself as an expert in fast, accurate, handheld material analysis, and has installed over 2500 analysers.
www.indestructible.co.uk
www.nitonuk.co.uk
Millers Oils
MISUMI – Your Manufacturer,
01256 397 860 info@nitonuk.co.uk
Millers Oils is a leading independent British Distributor & Online Platform ©supplying marca gráfica blender of oils and fuel treatments, for All Industry Demands to 60 countries around the world across the Manufacturing, Automotive, Classic Car and 16 million configurable components in 0.01 Motorsport sectors. mm increments 2017 marks the company’s 130th year in business, having opened in 1887 in Brighouse, West Yorkshire, originally serving the local textile industry. Today Millers Oils offers not only high quality lubricants to the manufacturing industry, but also expert fluid management services via the Millers-Xtra programme, enabling manufacturers to focus on their core business.
erate the image processing.
Visit: www.millersoils.co.uk
www.nerian.com
E-mail: sales@millersoils.co.uk
PECM Issue 29
Identifying plastics accurately is key to profitability for reprocessors and manufacturers. Guessing can result in overpaying, equipment failure and damaged reputation.
“Our commitment to the Colour-Therm concept and product range has prompted us to create a specialist division within Indestructible Paint,” says John Bourke, Indestructible Paint’s Global Sales Manager. “This has enabled us to provide a highly focused service in an area which can be central to both equipment performance and safety,” he adds.
But as often, the devil is in the details: for most applications, the software implementation with standard PCs, but also with graphics Services include condition monitoring, oil processors, is too slow. Another complicating filtration, clean-outs, technical support and factor is that these hardware platforms are training, which help customers to reduce expensive and not energy-efficient. The soludown-time and waste, as well ensuring a safe Figure 2: High resolution camera image and corresponding depth map tion is to instead use specialized hardware working environment. for image processing. A programmable logic Tel: +44(0)1484 713201 device – a so-called FPGA – can greatly accel-
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No more guessing with Niton UK’s new PolyMax™ plastics analyser
MISUMI is a global producer and leading supplier of mechanical components. You can obtain standard and configurable components in our online shop. We offer a large variety of stock items, which are shipped out on the day of your order. MISUMI has recently launched products from over 700 third-party manufacturers. This allows you to choose from a large product portfolio in a single one-stop shop. Free 3D CAD models in different native formats For almost all configurable components you can obtain free 3D CAD models, which you can transfer directly into your CAD program. During the configuration you can also view a 3D preview. www.misumi-europe.com
If you are involved in drilling in Exploration, Mining/Quarrying; Geotechnical, Environmental or Geothermal/Ground source and you want to provide accurate positional and orientation information to your clients then GeoMEM have a Devico solution for you.
Email: sales@geomem.com
Product news
www.geomem.com
after veh
For more Jon Cole Peter Mu Hawco S sales@h
LARGEST MANUFACTURERS OF INDUSTRIAL HEATING ELEMENTS IN THE UK
Leading the way
t Mica Heaters t Nozzle Heaters t Cartridge Heaters t Ceramic Knuckle Heater t Thermocouples t Immersion Heaters t Tubular Heaters t Square Section Heater t Air Duct Heaters 5FM t 'BY Email: sales@elmatic.co.uk www.elmatic.co.uk
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PECM January/February 2014
the VersatiLe huckÂŽ MaGna-LOkÂŽ structuraL fastener faMiLy PECM114.indd 64
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he HuckÂŽ Magna-LokÂŽ is an all-encompassing fastener. Available in steel, aluminium and stainless steel (including A4, 316) and in 4.8mm, 6.4mm, 9.5mm and 12.7mm diameters.
Its wide grip range accommodates large variations in joint thickness and the expanding sleeve creates a tough, long-lasting joint. This excellent joint tightness results in a high-quality resistance to liquid penetration. The Magna-Lokâ&#x20AC;&#x2122;s unique 360 internal locking technology enables the pin to be mechanically locked to the sleeve, virtually eliminating pin pushout. The new Huck A4 (316) stainless steel Magna-Lok Offers corrosion resistance - beyond anything else in the Huck blind fastener range. Referred to as â&#x20AC;&#x2DC;marine gradeâ&#x20AC;&#x2122; - due to its preferred use in the construction of boats, ships, oil and gas rigs, and off-shore wind farm towers, 316 is an austenite stainless steel which contains 18 percent chromium and 12 percent nickel. The Unique Huck 12.7mm Huck Magna-Lok Bigger Size, Bigger Benefits.
Fewer Fasteners Needed (vs. small diameter fasteners) - The 12.7mm Magna-Lok's larger size has the potential to reduce the amount of fasteners needed, hence facilitating in the production of lighter weight products and reducing inventory, re-work and costs. High resistance to joint failure - Due to its large diameter the 12.7mm Magna-Lok has a huge shear (44.4Kn) and tensile (31.1Kn) strength. Wider Grip Range - Bigger size accommodates larger variations in joint thickness. Unmatched Installation Speed Bigger size does not alter MagnaLok's quick visual inspection for correct installation, and flush pin break eliminates grinding and filing, leaving a smooth and even surface. Large Hole Filling - The sleeve expands during installation for excellent joint tightness and provides resistance to liquid ingress*.
As Arconicâ&#x20AC;&#x2122;s largest UK Huck Fastener distributor, Star Fasteners UK) Ltd have successfully worked with some of the world's leading manufacturers to develop unique and cost-effective fastening solutions. For more information on the full Huck product range contact us on: Tel. +44 (0) 1159 324 939 Email sales@starfasteners.co.uk www.starfasteners.co.uk
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In a R s H S to a v te p p o
interView QuestiOn and answer On â&#x20AC;&#x2DC;Paints and cOatinGs in the cOrrOsiOn industryâ&#x20AC;&#x2122; 1.
What is paints and coatings in relation to the corrosion industry and why use it?
Metallic materials comprise of a significant portion of industrial infrastructure and are often subject to harsh service environment. The referred environment could be a combination of moisture, oxygen, heat, industrial salts or atmospheric pollutants. The rate at which metallic materials degrade with respect to corrosion depends on the environment that surrounds them. Paints and coatings tend to provide a protective barrier between the harsh service environment and metallic materials and hence, prolong their service life span.
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2.
How have paints and coatings in the corrosion industry evolved over the past decade? How is the paints and coatings technologies of today more effective/efficient than the technology of previous generations?
infrastructure from corrosion and erosion damage, (ii) higher industrial throughput requiring higher temperature and pressure to operate and hence creating a need of higher performance-based coating specifications and (iii) growing demand from environmental and health conscious end-users.
The use of paints or coatings is not new to humans. Lacquer which was derived from tree sap or through resinous secretion of lac insects was known in Indo-China about 7,000 years ago. Since those times, paints and coatings have kept evolving and changing. The key drivers of the changing trend are mainly (i) the industrial requirement to protect its
The paints and coatings of today offer broad temperature and pressure range to be applied in varied service environment. They also offer more resistance to chemical attack and a range of colors and shades for decorative purposes.
3.
In order to extend the life of process equipment’s, are there key considerations (from the end-user) when selecting the appropriate paint and coating?
Coating selection is a specialized task and requires knowledge of multiple engineering disciplines as well as a thorough understanding of the requirement of intended applications. Apart from ensuring that the surface finish of the material to be coated is properly prepared, the effect of temperature and pressure on coating’s adhesion and permeability are just few key selection parameters to be primarily evaluated. The electrical properties of the coating are also a factor in the selection process in certain applications. 4.
pipelines and storage tanks, there are practical and cost effective technologies available that keep the surface of the coating clean from debris and deposits. In a given environment, if the coating surface is not kept clean, corrosion can develop under the deposit and debris and the protective role of paint and coating is severely compromised. 5.
What are the plans for the future, from the industry stand point?
The paints and coatings industry can be categorized into three sectors which are: (i) decorative and architectural, (ii) general purpose industrial and (iii) special purpose coatings. All the three sectors have their own needs, requirement and future projections. Some of the common
requirements of the 03 sectors could be listed as (i) faster application and preference of single layer rather than multiple layers, (ii) short curing time, (iii) improved chemical and abrasive resistance, (iv) ‘smart’ properties such as self-healing or ability to transmit certain electrical or thermal signals as well ability to dampen those signals for defense application. 6.
From your viewpoint, what are the high-level best practices you typically propose?
I would greatly emphasize that coating selection to be carried out by individuals having the required knowledge and expertise of material properties and their behaviours in various environments.
What are some best practices you can offer end-users in the areas of design, specification and maintenance of paints and coatings to ensure their long-term performance?
To ensure long-term performance, the foremost and important step is to select an appropriate paint and coating for the application. Economic factor also comes into consideration in coating selection in view of the anticipated designed life of the equipment to be coated. A very importance parameter in ensuring longterm performance of coatings is to keep the coating surface clean as practical as possible. With specific reference to
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Once an appropriate coating is selected, the surface preparation and its coating application to be performed as per the specification. It may be added that temperature and humidity level at the time of coating application plays a significant role in determining its service life and protective characteristics. 1.
What are the plans for the future, from the industry stand point? How will the paints and coating technology of tomorrow be more effective/efficient than the paints and coating technology of today?
Regulatory compliance to meet stringent conditions aimed at protecting environment and public are driving future trends in paint and coating development
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and selection. End-users are also now asking and making sure that the paint and coatings they are procuring meet the regional as well as international health and safety requirements. Apart from the requirement for improved durability and extended life cycle, end-users are also willing to pay for â&#x20AC;&#x2DC;smartâ&#x20AC;&#x2122; properties of paints and coatings. These include temperature sensitive paints, self-healing coating and enhanced electrical and optical signal transmitting properties. Another emerging area in coating is the development in nanotechnology. There are a host of patents issued recently for industrial coatings where a very small quantity of ceramic or metallic particles are added to significantly modify the
properties of paints and coatings. For general awareness, the average size of nano particle ranges between 10-80 nanometer. A non-meter is equivalent to a billionth of a meter which can also be visualized as 10,000 times smaller than the diameter of a human hair. To visualize the effect of nano particle, at 2 nanometers the conductivity of metal particle changes and at 20 nanometers, the transparency of ceramic particle changes. Reportedly, for 20 nanometers particles, gold turn red and their plasticity disappears. Hence, one can visualize that riding on nano technology, the future development in this area would change the entire landscape of applications of paints and coating for industrial as well as decorative applications.
Pumps
Pumps The Energy Savings Opportunity Scheme (ESOS) and Pump System Audits
NOV MONO Launches New Solar-Powered Pumping Solution
The Energy Savings Opportunity Scheme (ESOS) Regulations A new product launched by NOV Mono offers 2014 came into force on 17 July 2014 and are a mandatory an effective solution for pumping water on energy assessment and energy saving identification scheme for small-scale farms and rural lifestyle properties. large undertakings (and their corporate groups). The scheme The new SUN-BUDDY™ is a solar powered applies throughout the UK. ESOS Energy Audits have the submersible pumping system that has been designed to combine outstanding potential to increase businesses profitability and competitiveness by identifying costVerderhus® screw centrifugal pumps combine performance, long life and minimal maintenance requirements. effective savings which, if implemented, will improve energy efficiency. The scheme is
VERDERHUS
the best features of centrifugal and positive
estimated to lead to £1.6bn net benefits to the UK, with the majority of these being The result of Mono’s™ 30 years of solar-powered pump experience, the SUNdisplacement a new directly felt by businesses as a result of energy savings. BUDDY™ is a genuine, easy to install ‘plug and play’ solution. Its pumps minimalto define standard for low head, highESOS flowispumping. maintenance requirements can be handled onsite, making the SUN-BUDDY™ the UK Government’s approach to transposition of Article 8(4) of the EU a set-and-forget solution which delivers high-quality and cost-eff ective Efficiency Directive, which requires all large (non-SME) enterprises to Verderhus® pumps transferEnergy your product undertake energy audits by 5 December 2015 and every 4 yearsdemand thereafter. performance. Driven by solar energy, this small but efficient pump requires Soaring US process industry for gently and efficiently. The open impeller no diesel, grid power, wind or batteries to run. This environmentally-friendly The scheme’s regulations arethermal published on system the government’s legislation website fluid support, maintenance allows solids toallbe easily pumped that method enables the operator to quickly recover the initial cost large by eliminating http://www.legislation.gov.uk/uksi/2014/1643/contents/made and risk-management services has prompted reduces the risk of cavitation, which can future fuel and electricity bills.
Gast introduces new, proprietary vane material that provides reliable performance with or without lubrication
Thermal Fluid Solutions First To Launch US Subsidiary
More information about the Energy Savings Opportunity Scheme can be found on the
Thermal Fluid Solutions (TFS) to become the cause serious damage to aESOS pump and tohttps://www.gov.uk/energy-savings-opportunity-scheme-esos the webpage Tel: 0161 339 9000 www.mono-pumps.com first UK company in its market to open an GAST – a leading designer and manufacturer production process. A Verderhus pump will American operation. of precision air products and member of IDEX lower both energy use and ownership costs. Corporation – has launched NEW LubeFree Active in the US since 2008, TFS has since ADVANTAGES VERDERHUS SCREW CHANNEL options for their AM series air motors that established a broad and expanding customer PUMPS utilize a proprietary vane material that base in the North American process industry, provides versatility, allowing users the options especially within the panel board sector; √ Clog free operation, reliability for your to oil or not oil the motor. the company counts global manufacturing process The vertically-mounted high pressure E-Range pumps offer giants Arauco and Norbord as long-standing outstanding reliability and efficiency for applications where This new LubeFree option has expanded Highly efficient, low energy consumption particularly abrasive or viscous fluids are being handled.√ They customers. A new range of dosing pumps launched by NOV Mono offers an efficient, GAST’s range aofhelical 2AM, 4AM 6AMwithin Seriesaair incorporate rotor and turning resilient rubber reliable and low maintenance solution for applications where South low flow, √ Solids TFS’ new US subsidiary in Greenville, motors affords operators flexibility stator,and providing a smooth low the shear action which ensures the pumping up to 13% of the flow accurate dosing is required. The new MonoTM dosing pump provides a of themaintenance coating mix remains intact. volume Carolina, is headed by one of its senior tointegrity modify their schedules or smooth pumping action with no pulsation and very low shear. The pump is engineers, Aarondosing Coult,duties who has transferred Themoney pumpsbyalso feature Mono’s unique Flexishaft™ drive save eliminating oil, lubricator ideal for either intermittent or continuous in high pressure, √ Low-shear, gentle pumping action, results system that provides a single component link between the fromrepresents the company’s UK headquarters low flow applications, and a cost-eff ective andinreliable components and system maintenance. in less damage to the product rotary motion of the drive shaft and the eccentric motion alternative to the more expensive gearThe pumps usedlocal for these Derbyshire. firmtraditionally plans to recruit offurther the helical rotor. The number of moving parts For information onreduced Gast’s LubeFree of duties. employees within 12 months. √ Minimal wear, even with types abrasive fluids, in the drive train eliminates wear and makes lubrication AM Series, call +44 (0)1527the 504040, The new dosing pump offers advantages, not least unnecessary, eliminating risk ofemail contamination.longest The life time For many further details, please visit of which is the gastgroup.uk@idexcorp.com or visit Flexishaft design extends routine maintenance intervals and option to transfer low flows at high pressure (up to 72 bar/1044 psi). carries a 10-year warranty. www.thermalfluidsolutions.com www.gastmfg.com. www.verderliquids.com For more details on MonoTM visit www.mono-pumps.com or call +44 (0)161 339 9000. Tel: 0161 339 9000 www.mono-pumps.com
NOV MONO Helps Increase Capacity for Pulp and Paper Producer
NOV Mono provides a new pumping solution for dosing/metering applications
Oil-in-Water Analysis by IR Absorbtion, Training Offshore oil and gas operators are required under DECC guidelines to take regular oil-in-water samples in order to meet current UKCS produced water discharge/re-injection limits. Oil Plus Ltd, in partnership with, Oleochem Project Management Ltd, now offers a 1-day course for offshore production chemists and laboratory personnel to gain certification in the OSPAR methods of sampling and analysis required to meet these strict regulations. The day consists of a theory session, followed by laboratory practical work using standards to generate the oil-in-water content calibration curve followed by test samples, using solvent extraction and Infra-Red analysis. Courses are being held in our Aberdeen and Newbury facilities: for more information please contact Christina Kingston, c.kingston@oilplus.co.uk, telephone: +44 (0)1635 30226, or visit our website http://www.johncrane.com/en/Services/ Training.aspx
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PECM Issue 11
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seaLLess PuMPs fOr safety reLiabiLity & PrOfitabiLity he magnetic drive pump was invented 70 years ago, yet they remain a niche solution typically used for solving hazardous pumping applications.
An ultrasonic instrument detects vapour in liquid down to 1 percent by volume. It provides early and direct indication of a potentially damaging operating condition.
t
While sealless magnetic drive pumps feature fewer leak paths and their component parts boast higher reliability than traditional sealed pump designs, some engineers are still reluctant to use this proven technology, the legacy of a handful of early historical failures. However, new technologies and tools are now available to help avoid misapplication plus further advance and enhance the safety and reliability of magnetic drive pumps. The potential failure modes associated with sealless magnetic drive pumps are known and documented. The first is when metallic containment shells are used. Inductive heating can occur because of the eddy currents created by the rotation of the magnetic coupling around the containment shell. Overheating of the metallic containment shell can happen within seconds if the inner rotor assembly is seized, or more slowly if vapour or gas is allowed into the pump. This unexpected eddy current heat generation may flash the process liquid and disrupt bearing lubrication. Without lubrication, the bearing system can catastrophically fail, potentially damaging the containment shell. For a magnetic drive pump, this condition can now be addressed in three ways: t
Elimination of a potential failure mode by the use of a composite containment shell
t
Use of instrumentation to detect and shut down the pump when causal factors are present
t
Mitigating the risk of the pump leaking through containment shell failure with secondary containment/ control
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COMPOSITE CONTAINMENT SHELLS The use of a nonmetallic containment shell is the preferred method for preventing this type of failure, since it eliminates the key source of heating that can lead to pump breakdown. Lined process pumps include a nonmetallic containment shell that eliminates eddy current heat generation and its related failures. Metallic magnetic drive pumps have also adopted nonmetallic containment shells. This is a composite shell that is nonconductive and will not generate eddy currents from the magnetic flux passing through it. Composite containment shells are chemically resistant and exceptionally tough. They feature fire, erosion and impact tolerance that in many cases are superior to metallic options.
INSTRUMENTATION The second method of mitigating risk of a potential containment shell failure is to employ instruments that can enable the pump to detect when causal factors or early failure symptoms are present. Historically, this has included installing power control monitors on the motor to detect a low-load condition from a rundry situation. Running a sealless pump dry, without liquid, can result in damage, because without process liquid flow, heat removal from the containment shell is lost as well as a loss of lubrication for the internal process lubricated bearings.
Other monitoring techniques include temperature sensors on the containment shell to detect the temperature rise in the containment shell, leak detection sensors, and low-level or low-flow monitoring of the process liquid to detect if a run-dry or loss of cooling condition might be present. These are indirect measures of a key operating parameter critical for providing bearing lubrication and heat removal. Direct measurement of the gas vapour content of the process liquid is now available using an ultrasonic sensor that is fitted to the pump housing. One ultrasonic instrument is capable of detecting gas bubbles on the order of less than 1 percent by volume.
SECONDARY CONTAINMENT The final way of mitigating the effects of containment shell failure is via secondary containment or control. In this situation, with a failure of the primary pressure boundary, the leak path of the process liquid is directed into a secondary housing. The secondary housing is either a further containment shell wrapped around the primary shell or the magnetic coupling housing with the inclusion of a leakage restriction device on the outer magnet assembly driving shaft. A secondary containment shell typically requires thinner primary and secondary containment shells to enable the process fluid in the internal flow regime to provide suitable cooling for both shells.
Cutaway of a magnetic drive pump that shows the nonmetallic containment shell.
Perfected Sealless Pumps Additionally, the secondary containment shell is subject to the same induction heating as the primary containment shell, so a common failure mode is present even with the secondary shell. Using the magnetic drive housing for either secondary containment or control requires the use of a leakage restriction device or a mechanical seal. In this situation, the pump acts as a hybrid tandem sealed pump, with the primary seal being the single containment shell of a magnet drive pump. This arrangement has the advantage of separating the primary and secondary sealing devices such that the initial failure mechanism that caused the primary device to fail does not negatively impact the integrity of the secondary device, in this case the secondary seal. A further benefit of this arrangement is that it allows the use of a nonmetallic containment shell or a thicker and more robust metallic containment shell. These new technologies are significantly improving the reliability of sealless pumps. The elimination of seal support systems and higher reliability of the magnetic drive pump components over sealed pumps make sealless pumps a compelling alternative choice for process engineers. As environmental safety and the safety of personnel come under increased scrutiny, sealless pumps should be considered as a favourable option to reduce the high operating costs associated with emissions monitoring and seal support systems. David Clark is the General Manager of HMD Kontro Sealless Pumps. David is a Chartered Engineer and a serving member on API and ASME Committees, including API 685 and ASME B73.3. He has implemented numerous sealless product developments, including high pressure pumps, API vertical pumps, ZeroLoss™ Composite shells and the VapourView® condition monitoring device.
Continuous innovation means HMD Kontro magnetic drive technology is now even more robust, reliable, economic and suited to even more applications ZeroLoss™ Composite containment shell / shroud that significantly reduces power requirements meaning smaller motor sizes and less energy consumption.
VapourView™ Non-intrusive instrumentation that uses ultrasonics to detect the presence of gas in a liquid from outside the confines of the pump. Secondary Containment Options to enhance even further the environmental, health & safety attributes of sealless pumps.
With new derivatives including vertical, high-pressure, low-flow, multi-stage, even extended sump versions, there is a HMD Kontro sealless pump that is perfect for your next project. Enquire today.
Magnetic drive pumps with nonmetallic containment shells are available to comply with API 685 specification.
+44 (0)1323 452141 vince.lee@sundyne.com www.hmdkontro.com Issue 29 PECM
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xation
loss of quality to the dosing process.
the
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A water purification plant in Malaysia was experiencing significant problems lime chemical as part of problems their treatment process. A water purification plant in Malaysiawhen washandling experiencing significant when handling lime chemical
as part of their treatment process. reviously, the plant had solenoid metering pumps pumps installed for the dosing of the installed for the dosing of chemical. Solenoid metering pumps are the chemical. Solenoid meknown for their highly accurate delivery of tering pumps are known for however in the case of handling theirchemicals, highly accurate delivery of chemicals, lime this pump typeofoften experiences however in the case handling lime this difficulties due toexperiences the nature of the lime pump type often difficulties chemical. Lime of chemical is achemical. suspension due to the nature the lime
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Limedistinct chemical is a suspension theofmilled tendency to â&#x20AC;&#x2DC;coatâ&#x20AC;&#x2122; all of areas the lime pump in water, hasparticles a distinct tendendue which to the lime falling out of cy tosuspension 'coat' all areas of the pump due to the and culminating in a stubborn lime particles falling out of suspension and build-up. As the fluid passes through the culminating in a stubborn build-up. As the metering pump, the ball valves, small tubes fluid passes through the metering pump, and chambers begin to block, similar to a the ball valves, small tubes and chambers artery furring with fatty deposits. beginhuman to block, similar to a human artery furring with fatty deposits. This eventually causes a significant
This blockage eventually significant andcauses a rise inaback pressure,blockage which and acauses rise any in back sealingpressure, to fail and which causes any sealingleak, to fail and the catastrophcatastrophically coating icallysurrounding leak, coating the surrounding envienvironment with the chemical, ronment with the chemical, which is very which is very difficult to remove. For every difficult to remove. For every failure, infailure, inspection and service, the plant was spection and service, the plant was losing losing many hours in downtime, expense many hours in downtime, expense of the of the labour and spares charges and the labour and spares charges and the inconinconvenience of clean-up costs. venience of clean-up costs. A local contractor called solvethis A local contractor waswas called inintotosolve this problem. The contractor recommended problem. The contractor recommended the move from solenoid pumps the move from solenoid metering metering pumps to Verderflex peristaltic hosepumps. pumps. to Verderflex peristaltic hose As As part part of of this recommendation, both this recommendation, both the the contractor and local Verder team contractor and the the local Verder team worked worked together to deliver a presentation together to deliver a presentation of data, of data, reference sites and operational practices to demonstrate the quality and success of the pumps in other installations.
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revolution of the rotor assembly delivers a cient passage of lime slurry with a BEP in flow rate proportionate to the rpm. This excess of 70%. The pump is insensitive to reference sites and operational practices to The installation of 4 Dura 35 pumps (35mm results in an accurate delivery of chemical clogging and changes in viscosity. The cusdemonstrate the quality and success of the hose ID) has seen a great improvement in which can be easily controlled through tomer gains the benefits of a positive dispumps in other installations. the dosing process: The pumps are now an inverter and if necessary an analytical placement pump in terms of the viscosity operating for a consistent and unbroken handling and the benefits of a centrifugal probe such as a pH meter. Presented were the key benefits of using period with only a planned inspection and pump for larger flows. a Verderflex peristaltic pump The installation of 4 Dura 35 pumps (35mmmaintenance procedure necessary. The With the provencontractors performance of the Verhose ID) has seen a great improvement inexpenditure A Excellent at handling abrasive, viscous on service visiting derflex the reduced plant has 4 thefluids dosing The pumps are nowthe plants such process: as liquid lime haspumps, been greatly withspecified no further 3 dosing processes operating for compression a consistentand and unbrokenloss pumps A The constant relaxation of qualityeach to theatdosing process. period only a planned inspection and with additional Verderhus pumps to enof thewith flexible hose which prevents the maintenance procedure necessary. The ex- sure the smooth circulation of the lime. lime coating the flow path penditure on service contractors visiting A Faster and easier to service than other the plants has been greatly reduced with www.verder.co.uk pumps as there is just a simple hose and no loss of quality to the dosing process. lubricant change to perform
A The constant revolution facility of the rotor The water purification were
so imassembly delivers flow rate to their facilipressed with the aupgrade to the rpm. Thishave results in ty,proportionate the engineering team specified theanVerderhus screw-channel centrifugal accurate delivery of chemical which pump circulating lime can befor easily controlled the through an chemical within the holding tanks, which maintains inverter and if necessary an analytical theprobe homogeneity the suspension. This such as a pHofmeter. has an exponentially beneficial effect of reducing the cleaning of the tank due to sedimentation and prevents the pump from having to work as hard drawing in extra-viscous lime slurry. By choosing the Verderhus screw-channel, the purification plant has the perfect pump for handling a high flow rate of a viscous, yet flowable slurry. Thanks to its open impeller and helical, corkscrew-like impeller, the Verderhus excels at the effi-
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rification plant in Malaysia was experiencing significant problems ing lime chemical as part of their treatment process.
if yOu Make stuff we’LL heLP yOu Make it if yOu haVe a warhOuse we’LL heLP yOu ManaGe it if yOu hOLd stOck we’LL heLP yOu cOntrOL it SAPMANV12 LOOKS TO PUT A COMPREHENSIVE ERP SYSTEM INTO THE FINANCIAL REACH OF ALL MANUFACTURING BUSINESSES uying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay.
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For manufactures looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software! For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be £2,450. Our licencing is £50 per month ( plus VAT) per user licence with no minimum contract obligation. Additional users can be added as required and, indeed, reduced. A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapmanv12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50 and Sage200, and we still have some clients on Sage Line 100 yet to upgrade. One of the great advantages of Sapmanv12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from
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At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution. Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution. Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100. Sapman v12 is highly customisable to operate with virtually any business model. With successful installations in a huge range of industry types from manufacturers of medical products to disposable BBQs our customers rely on Sapman v12 to run their businesses. Sponsored development of specific functionality is possible where customers require some modification to allow the software to exactly map their business’s operational model.
Sage50 to Sage200. This is an additional cost saving benefit We’d be delighted to visit you to demonstrate the product, or you can arrange to visit our demonstration suite in Bristol
For more information on Sapmanv12 please visit our website at Sapmanv12.co.uk Email us on info@sapmanv12.co.uk Or please telephone us on : 0333 456 12 12
saPMan V12 and saGe 50 it aLL starts with a saLes enQuiry! SELL IT Quotations: Quote ( including price breaks)& Drawings & Pricing : v12 can attach drawings to the Quote SoP : The Sales Order Processing gets underway
MAKE IT Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock? If not it may generate a Purchase Order for more Stock If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works
Stock values from v12 update Sage50 Nominal Ledger
Machine Variances & produce management reports -
PoP Purchase Order Raised
Every stock issue is linked to an original GRN - ensuring full Serial Number and Batch Traceability
Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT
Stock Finished item is booked into Stock
WoP The confirmed order has to be manufactured & v12 produces the works order
v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors
BOM V12 produces the BoM : tree-view with collapsible/expandable nodes
Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times
SFDC Shop Floor Data Capture : using barcodes v12 manages the job though the shop floor
SEND IT
WiP With Shop Floor Data Capture SFDC v12 knows :
Stock Stock records updated, Despatch note raised; Certificates of conformity produced
What Material/Subcomponents have been used, Who has worked on the job and on what machine - Get Material, Labour &
Sales Invoice raised & Sage 50 updated for Nominal Codes, Sales Ledger & VAT
WHAT THEY SAY “We really like the Shop Floor Data Capture
“V12 offers us greater productivity, improved
“V12 was a complete transformation for our
system which enables us to see the current
communications with third parties and the
business back in 2014, with the added bespoke
status of any Works Order live and onscreen.”
interconnectivity between the various menus
service and repair package designed by the
and our Sage Accounting software makes
SMS team the customer input and traceability
operating our company infinitely easier.”
became seamless.”
Colin Mallard, Finance Director,
Mike Perkins, Managing Director, Encoders UK Ltd
Alan Saitch, Managing Director, Lada Engineering Services Ltd
Lakeland Laboratories Limited
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reLease the POwer Of yOur PrOduct data he single biggest challenge for designers and engineers is to be in agreement and of one mind, which is key to making better decisions and better products overall. It’s really about effective communication. Many job functions around the enterprise require information that comes from Engineering documents and CAD files.
t
The PLM Value Gap: For more than 20 years Actify has been providing visualization software to the discrete manufacturing industry overcoming the challenge of sharing and communicating engineering type documents across the extended enterprise or supply chain. The challenge that traditional PLM systems face is that their usage is constrained to the engineering department, often because of limited time, budget or through lack of adoption due to sheer complexity of PLM offerings for non-technical users. When you restrict the organization’s ability to efficiently and effectively manage the flow of product data across the enterprise, information workers are confronted with
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incomplete data or barriers to access data. This then leads to two possible outcomes; information workers make bad decisions or they waste time waiting for more data while disrupting the engineering team to gain access to crucial information. As a result, engineers spend valuable time administering information to the wider enterprise. It is imperative manufacturing companies automate as much mundane work as possible through better use of software tools. With the ever-increasing rates of data creation combined with a global shortage of engineers, this ‘barrier to data’ problem is only going to get worse. Chris Jones – CEO and President, Actify, Inc. Gather, Organize And Enrich Data: To mitigate this information bottleneck, Actify has developed Centro™ which acts as an enterprise data platform, collecting information from multiple data sources to enable enterprise data accessibility, delivering value to all stakeholders. Actify Centro is used to integrate a variety of organizational disciplines both within and outside of engineering, providing
an information-rich and connected work environment that integrates product data, product development and enterprise information workers. Overcome The Information Discovery Challenge: Actify Centro is a set of business solutions and tools designed to support the creation, management, dissemination and collaborative use of product data (i.e. all product definition information including BOM structures, CAD files, specifications, requirements, manufacturing instructions, etc.). Get a faster, more accurate view of enterprise data with Actify Centro, our Product Data Intelligence solution. With user and role-based data governance, Centro connects stakeholders directly with the data they need. You can accelerate, simplify and improve the efficiency of business decisions at the speed your business needs. Learn More: Visit: www.actify.com Email: info@actify.com
Storage, storage, handling & distribution
Handling & Distribution
More Hart’s Speedors in Africa
Global launch of Konecranes’ Crane Advisor customer support tool Konecranes has simplified the overhead crane specification process with the introduction of its innovative on-line tool, Crane Advisor. The menu driven application may be accessed via desktop computer, iPad, tablet and smart phone, allowing convenient use of the tool from any location. Crane Advisor has been introduced successfully in North America and has now been launched in the UK, Europe and selected regions worldwide. Crane Advisor is a user friendly, icon driven platform designed to help customers narrow down potential lifting equipment options, according to their specific material handling application. Users are prompted to input parameters, including industry type, crane capacity, girder span and lifting cycle duty. www.konecranes.co.uk
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These two Hart Speedors, the high-speed environmental doors, are the latest to be installed at the Bakhresa Group’s Buguruni flour mill, Dar es Salaam,Tanzania, Africa’s largest flour mill. The Speedors were installed with internal and external wind bars to cater for wind pressures from both sides of the opening. They are the result of continued successful operation of four Speedors installed in the Kurasini grain intake areas also in Tanzania. “This is our third visit to this Tanzania and we must thank our friends at Bakhresa for their assistance and cooperation during the installation,” says John Loftus, a member of Hart’s export team. Africa has also been a very successful export market for Hart in particular at international airports at Julius Nyerere Airport, Tanzania, Harare Airport, Zimbabwe, Bole International Airport, Ethiopia and Casablanca Airport. Hart has also been successful in a variety of commercial projects with more work in the pipeline. www.hartdoors.com T: 0191 214 0404
Blue Diamond Expands Storage And Distribution Capability Blue Diamond Technologies of Southampton, designers and manufacturers of custommade mechanical components, has expanded its storage and distribution capability with the purchase of a new 1250 sq metre warehousing facility just along the road from the company’s existing headquarters. To see a video of the preparation of the new facilities, go to YouTube and enter Blue Diamond Technologies Enhanced Storage. For further details, contact Blue Diamond Technologies Ltd, Rolwey House, School Close, Chandler’s Ford Industrial Estate, Eastleigh, Hampshire SO53 4BY. Tel: (023) 8025 8966 Fax: (023) 8025 8989 E-mail: bdsales@rolwey.com Website: www.blue-diamond.co.uk
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switches & sensors PC-Sep17-Comus.qxp_Layout 1 08/09/2017 12:14 Page 1
WTF: Water Tank Full The new language of SMS for the IIoT
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Businesses need visibility to make the rapid changes that can be the difference between cashing in and missing out. Red Lion’s Sixnet® series RAM industrial cellular RTUs bring remote monitoring to the Industrial Internet of Things (IIoT), delivering the insight you need to remain in control of remote assets regardless of location. Using an intuitive web-based interface and a variety of connectivity options, our rugged RAM RTUs provide a secure all-in-one platform that seamlessly integrates with existing equipment to enable data visibility. Whether a tank level is too high or valve pressure out of range, the RAM event engine will take action and send you an SMS text notification to keep you in the know. Visit www.redlion.net/control to learn more.
00800 733 54667 Toll Free I europe@redlion.net I www.redlion.net © 2015 Red Lion Controls, Inc. All Rights Reserved.
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Make Reliability a Reality What is the difference between successful reliability improvement programs, and the very high percentage that failed? We know. And we have put all the keys to success in iLearnReliability.
modules), through to the people who needs special skills (with Skills Training).
The most successful reliability improvement initiatives are owned and controlled by a team within the company. They do not involve large consulting or software software companies. companies. They did not start start with with extensive extensive (expensive) reliability analysis. They did not start with huge budgets. But they did start with passion and knowledge.
OK, so what’s the alternative?
If you have the passion and desire to succeed, we can provide you with the knowledge. What else made programs successful? They always have senior management support. iLR will help you achieve that. They all have a transformed culture, with people at all levels in the company understanding the value of reliability and contributing to the initiative. iLR will help you achieve that. They all have a plan, with goals, with knowledgeable and skilled people involved in maintenance, design, operation, and engineering. iLR will help you achieve that. What is iLearnReliability? Imagine a suite of e-learning modules, filled with animations and engaging interactions, that have been specifically designed to help people at all levels of the organization, from the front-line operators and tradespeople (with Toolbox Talks), to the managers (with Manager Briefings), to the reliability engineers, planners, and many others (with Program Management Training
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The entire process is delivered on-line via your own customized “Learning Management System”. It is affordable to ensure that you can train everyone – because you really do need to train everyone!
You could pay consultants to fix your problems – but that often ends up being expensive and ineffective. You have to take responsibility and ownership of this process. You could develop the training for all of your staff. Do you have time for that (or the skills)? You could have someone come in and train everyone once. Those who receive the training will receive a short-term lift, but six-months later it will be back to the old way of doing things. Or you could start a small vibration program, add some other technologies, tackle a few issues like shaft alignment, lubrication, and so on. You will benefit, but it will be a fraction of what is possible. No, you need to engage everyone, train everyone, and then update that training. And you need a proven, detailed roadmap that will help you avoid the roadblocks and enjoy real success. iLearnReliability is the only way to do that. Please visit www.mobiusinstitute.com/reliability to learn more, more, or or e-mail e-mail learn@mobiusinstitute.com. learn@mobiusinstitute.com. You You can can join join other other leading leading companies companies across across all all industrial industrial areas areas that that are are on on their their way way to to improving improving reliability reliability in in their their plants. plants.
Mobius Mobius Institute Institute is is aa worldwide worldwide provider provider of of reliability reliability improvement, improvement, condition condition monitoring monitoring and and precision precision maintenance maintenance education education to to industrial industrial plant plant managers, managers, reliability reliability engineers engineers and and condition condition monitoring monitoring specialists, specialists, allowing allowing plants plants to to be be successful successful in in implementing implementing reliability reliability improvement improvement programs. programs.
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Valves & flow control
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Fabrication
Valves & flow control
rOtary VaLVes – air LeakaGe and PerfOrMance All rotary valves leak air (or gas) even where there is no pressure differential as even the product entering the valve displaces air into the inlet area. This is significantly increased when operating under a pressure differential due to losses past the operational clearances and carry-over of pockets of high pressure decompressing into the inlet. The total of such losses are normally referred to as ‘leakage’ and given a single quantity value. There are many factors that affect the rate of leakage and the ratio of the elements that make up the total. All are affected by the system conditions prevailing at any given time. In practical terms most manufacturers only offer leakage charts based on tests measuring leakage past valves in a static, product-free condition. Because the presence of product has a mitigating effect on leakage, known as the ‘Blocking Factor’, the manufacturer’s published rates are seen as having adequate contingency for providing allowances
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for sizing blowers, fans etc. Where leakage rates are considered critical then better analysis will be necessary, taking into all aspects of the duty conditions. What is important is that upward leakage can have a significant effect on the system performance either positively or negatively especially where the valve is operating in a flooded condition. The upward flow can reduce throughput by opposing product flow as well as aerating the product and reducing its bulk density. Allowance for this must be made when sizing the Rotary Valve. This is progressively less of a problem as valve sizes increase as the larger throat sizes make for better dispersion of leakage air. Valves should also be fitted direct to the outlet of any hopper so that leakage air can disperse easily. This is less of a
problem when the valve is not controlling the throughput but care needs to be taken if the conditions could result in flood feeding at any time. For more details on air leakage, contact Gericke RotaVal + 44 1249 651138 sales@rotaval.co.uk www.rotaval.co.uk
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