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PECM
Global Success Through Innovation Issue 23 2016 ÂŁ3.95 www.pecm.co.uk
EnErgy EfficiEnt Motors - 58
nsK BEarings provE rEliaBlE - 68
clinical Diagnosis BEnEfits - 92
A site upgrade at an historic Thames Water pumping station has given the 90 year old facility a new lease of life, improving performance and efficiency.
Every day Excavator 290 at the Hambach mine moves up to 240,000 tonnes of coal or, using its 130-tonne bucket-wheel.
New dosing unit forms one of the cores of the new BA400 analysis device, which is designed to carry out fully automatic analysis of up to 400 tests per hour.
Man and Machine Training Academy Man and Machine offer an extensive range of "VUPEFTL training courses
Man and Machine specialise in Autodesk training for Manufacturers, Engineers, Architects & Product Designers. All courses are taught with the official Autodesk courseware and includes one month’s free post training support. Autodesk AutoCAD courses include: AutoCAD Essentials AutoCAD Electrical Fundamentals AutoCAD Advanced AutoCAD 3D Drawing & Modelling AutoCAD Mechanical Essentials
E: marketing@manandmachine.co.uk W: www.manandmachine.co.uk T: 01844 263 700
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Sections Editors Choice Advanced Engineering Show Air, Gas & Odour Control Control & Automation Electrical & Electronics Electrical Engineering Energy Efficiency Facilities Management Facilities Fasteners & Fixings Fluid Handling Gears, Drivers and Motors Machining Health & Safety Measurement & Monitoring News & Events Process Technologies Lifting Software & Systems Storage Handling & Distribution Training & Recruitment Valves & Flow Control
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Manufacturing
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Inside...
Inside Issue 23 How To Specify Simple, Reliable And Adaptable Screw Jacks
PP pushes the button on £1m factory extension
The need to raise a load is one of the most common requirements in industry.
One of the West Midlands’s fastest growing manufacturers is dismissing uncertainty surrounding Brexit by investing more than £1m on a new factory extension.
Thirty Years Service To The Water Industry And Still Innovating A&J Fabtech Water Division is celebrating 30 years in the industry and is continuing its history of developing innovative solutions for the treatment of water and wastewater. Clinical Diagnosis Benefits From Design Collaboration Precision and reliability are two critical requirements of testing and analysis for clinical diagnosis; a collaborative project has now combined these with efficiency and cost effectiveness by designing a new modular microfluidic solution.
Spelsberg IBT Enclosures Speed Up Electrical Installation For New PreCast Hospital Build Thanks in part to the use of Spelsberg IBT junction boxes, a project to build a new £89m mental health hospital in South Wales has kept to a rigorous construction programme. Metalock’s Steel Plant Refurbishment Reputation Spreads Worldwide Due to the severe operating conditions in steel plants, regular refurbishment of heavy rolling mills is essential to ensure efficient production and consistent product quality.
Issue 23 PECM
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100 Verlinde Stagemaker Motors Operated By AED Studios Lint, Belgium or their ceiling grid equipment, AED’s audiovisual studios were recently equipped with 100 VERLINDE STAGEMAKER SR10 motors to simplify assembly and disassembly operations for shows.
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AED group caters for the needs of international players in the audiovisual sector and the realm of live performances both by renting out and selling standardized products embracing the techniques of sound, lighting, image projection and the lifting of stage equipment and by the letting of a complex of fully operational studios for cinema, television and event productions.
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PECM Issue 23
A studio complex in the heart of Belgium AED at Lint, near Antwerp, runs one of Europe’s largest audiovisual production complexes. Covering a surface area of 25,000 m2, the company rents out 16,000m2 of studios, 4,000m2 of offices and can supply any postproduction equipment or facilities required by cinema or TV teams. The company is very attached to its industrial heritage. In the entrance hall, for the benefit of customers and visitors, are exhibited audiovisual and stage equipment tracing the history of techniques in the industry. Using state-ofthe-art museography, it displays lamps, cameras, microphones, mixing desks, image projectors and for the lifting section, the display of Verlinde motors used by AED over many decades, like the first manual
screw hoist (1858), the first L104 motor, the LITACHAIN LI5, the STAGEMAKER SM10 range and finally the latest generation of the STAGEMAKER SR line with the SR10. 100 STAGEMAKER SR10 motors at the service of audiovisual productions. Filip Van Vlem, AED Communication Director, declares: “Energy economy is a major concern for us and the integration of photovoltaic panels in our studios’ roof structures goes hand in hand with the use of STAGEMAKER hoist motors for ceiling grids. They replace energy consuming lifting trucks while providing flexibility, efficacy and time savings for our customers. When a TV programme or film is being produced, studios equipped with these motors enable all equipment mounted on arched supports to be rapidly put in place.
VERLINDE: The leading French manufacturer and exporter of lifting and handling equipment with a constantly upgraded range of 30 series of lifting equipment to handle loads from 60 to 250,000 kg. ISO 9001 quality assurance certified and ISO 14001 EMS certified (environment management system). In France, Verlinde operates through a sales network, a distributor network, after sales facilities and with travelling crane manufacturers. The EUROPONT network covers France, Belgium and Holland. A Verlinde advisory service is also available in 92 nations around the world. www.stagemaker.com
STAGEMAKER motors lower the beam on which lighting, microphones, cameras or video projectors used for the performance will be fixed to place them at the right height when required. Using this equipment, adjustments or modifications are fast and easy. Lastly, disassembly by the technical team after performances is very much faster resulting in improved profits for the producer!” STAGEMAKER SR10, a well thought out decision Filip Van Vlem: “We have worked closely with VERLINDE for many, many years, both for our rentals business and for the studio equipment business and from time to time we suggest improvements that are integrated in the development of products. Safety is decisive for us because equipment placed in the arched supports by the motors are just above performers, presenters and the public. We can take no risks whatsoever. Le STAGEMAKER SR10, with its lifting capacity of up to 1 tonne, is the first guarantee, backed by the double lifting brake, the torque limiter and the electric limit switch, safety features we consider indispensable. For our operations, hoist speed is not a decisive factor. On the other hand, motors must run smoothly,
with or without load, to ensure that equipment fixed on the arched support is not subjected to jerking. As for the control of motors, we have standardized the type of control panel, there also for the question of safety. We can control motors individually or by groups just by pressing a single button.” STAGEMAKER above the performance. Collaboration between VERLINDE and AED goes back a long way and is based on a mutual awareness of needs with an ongoing concern for quality and for the provision of reliable equipment. Since STAGEMAKER motors were installed in the Lint studios, they have operated above the filming of “Iron Sky”, “A quiet passion”, “Aéroport” and the following TV series:
“Belgium’s Got Talent”, “So You Think You Can Dance”, “Wouf”. The arched supports of the studios are only their birthplace, that’s for sure! AED Rent and VERLINDE, partners full of confidence. The partnership between the two companies is highlighted by the figures that speak for themselves. Currently, motors SR1 (250kg), SR5 (500kg) and SR10 (1 tonne) are available at AED Rent (delivered in compliance with D8+ requirements) and if VRH/PHD manual hoists are included there are more than 5000 VERLINDE products in stock at AED Rent.
Issue 23 PECM
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Process
The leading source for innovators in Technology, Manufacturing and Maintenance within the Engineering & Processing industry worldwide. Published bimonthly, a subscription to PECM magazine is essential for Process Engineers, Chemical Engineers, Instrumentation Engineers, Mechanical Engineers, Plant Engineers, Precision Engineers, Environmental Engineers & General Engineers, Companies and Organizations in the Food, Dairy, Beverage, Brewing, Semiconductor, Pharmaceutical, Biotechnology, Chemical, Oil & Gas, as well as all UK's major manufacturing units. Every issue of the magazine contains the latest news, in-depth features, together with product innovations and case studies showing how process engineers are implementing new technologies to reduce costs and impact on the environment. With over 300,000 readers worldwide the publication is widely read, recognized, and well respected within the Process, Engineering & maintenance industries. A subscription to PECM magazine is the industry's 'must have' publication.
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Issue 23 PECM
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Bottling Plant Calls for a Cool Breeze from Andrews Chiller Hire
U
nable to maintain a
site managers soon realised that additional
The customer commented that the
constant cool temperature
temporary cooling was required. With
patience of Andrews Sykes engineers
within a number of
the existing temporary chiller solution
overseeing the project was greatly
bottling areas due to lack
performing so well the company turned
appreciated as gaining access to the site
of ventilation during planned staged
once again to Andrews Chiller Hire for the
was both limited and time consuming.
replacement of its air conditioning system,
additional equipment hire. It was decided
a well-known drinks company called on
that duplicating the original hire package
Andrews Sykes Hire Limited
the vast experience of Andrews Chiller
would be the best option, comprising
Chiller Division
Hire. It was required to provide that all
another 100kW chiller plus a 30kW and a
Unit 54 Gravelly Industrial Park
essential temporary solution for cooling
50kW air handler unit.
Tyburn Road Birmingham B24 8TQ
the air within the customers Gloucester production facility, preventing downtime
With more than 35 depots nationwide
Tel: 0800 211 611
and protecting the quality of the end
and a large chiller fleet with individual
E: s.salescentre@andrews-sykes.com
product.
units ranging from 30kW to 750kW the
Web:
Andrews-Sykes Special Hire Division is Part of the problem was caused by minimal
ideally situated to respond promptly
air movement which left the whole
with the best optimal chiller solution
bottling area exposed to temperatures in
when either planned or emergency air
excess of 30°C. Initially Andrews Chillers
temperature control is required.
had supplied a 100kW chiller along with two air-handling units for localised cooling
At the bottling plant, the second chiller
of a bottling area during this planned air-
was located adjacent to the first and as
con upgrade.
close as possible to the outside wall of the building. During installation each
However, as more bottling areas were
air handler was manually skated into
having their air-con disabled at a time
place around conveyor belts within the
Britain began to bask in exceptionally
production area to prevent any disruption
constant, higher summer temperatures,
to the workflow.
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PECM Issue 23
www.andrews-sykes.com
Pressurisation of staircases: the importance of correctly selecting the system class and controlling the degree of overpressure Authors: Santos Bendicho Alonso (Special Projects Director, Sodeca & Member of CEN TC191 SC1 WG 6, WG 5 & WG 9) & Mark Newcombe (Product Engineer, Axair Fans UK Limited)
A
pressurisation system is intended to prevent smoke leaking through closed doors into stairs by injecting clean air into the stairwell. The intent is to have the highest pressure in the stairwell and a reducing pressure in the accommodation area to facilitate pedestrian escape route and firefighting access. ince the publication of the relevant standard, 12101 6, familiarity has increased along with understanding of pressurisation systems. owever, there are some aspects of the standard which are not taken into account. g selecting the correct class of pressurisation and recognising the purpose of the system. What is EN 12101-6? The standard describes six differential pressure systems based on their function, ranging from facilitating a safe evacuation in the fire affected area only through to keeping firefighting access smoke free while evacuation takes place. System Classes: Class A system: For means of escape: The design conditions are based on the assumption that the building will not be evacuated unless it is directly threatened by fire. The level of compartment means that it is normally safe for the occupants to remain inside the building. Class B system For means of escape and firefighting This pressure system may be used to minimise the possibility of serious smoke contamination during evacuation and while fire fighters are extinguishing the fire. Class C system: For means of escape via simultaneous evacuation: These systems are designed for all of the occupants of the building to be evacuated when the fire alarm is activated. Class D system: For means of escape. Risk to personnel that are sleeping: These systems are designed for buildings where the occupants may be sleeping. Class system For means of escape via evacuation in phases These systems are installed in buildings where evacuation is carried out in stages or phases. Class F system: Fire protection system and escape means: These pressure systems are used to minimise the possibility of serious smoke contamination of staircases used by fire fighters at the same time that the building is being evacuated. Current standard 12101 6 is being reviewed by the C TC1 1 C1 W 6 and the next review will only include 2 types of pressurisation systems for evacuation and firefighting. It is not yet known if the revised document will be adopted as a British tandard. What performance is required? For all possible systems, at least two evacuation situations are considered that may occur a With all the doors of the evacuation route closed differential pressure of 0 a must be maintained between the protected route and the non pressurised areas where the fire has broken out. In some cases there is an additional requirement where a differential pressure of 10 a has to be maintained between the protected route and the non pressurised areas when the exit door to the outside of the evacuation route is open. In the latter, the difference between class systems lies in the number of doors that are open inside the staircase whilst the exit door to the outside is also open. b When a door is opened to the fire one In this case a minimum air velocity through the open door must be maintained. This is 0. m s for systems designed for evacuating personnel and 2 m s for systems designed for assisting firefighters. The difference between the class systems is based on the air velocity through the open door to the fire affected area as well as the number of doors that are open inside the staircase. electing the class of the pressurisation system will determine the design flow rate of the installation. This affects all the elements of the pressurisation system. It is essential to determine the correct si e and system class in order to ensure correct operation of the fire protection pressurisation system. The table right lists the airflows required for each situation and the design flow based on the ystem Class. Pressurisation System Control A system must be installed which is capable of automatically and safely supplying the two air flows. t the same time, excessive air flow to the staircase must be prevented so that children or less able occupants can open the access door to the staircase during an evacuation. Although several types of systems are available for controlling excess pressurisation of the staircase, the most commonly used system is the latter. This consists of a fan controlled by a frequency inverter, which takes signals from a differential pressure sensor that measures the pressure difference between the pressurised evacuation route and the non pressurised area. This maintains the desired pressure, normally 0 a, and subsequently controls the pressure during situations where the doors in the evacuation route are closed. In the case where a door is opened, the pressure in the staircase drastically decreases and so the fan speed increases to regulate the pressure. The fan then supplies the maximum design airflow for the installation when an evacuation route door is open or when the exit door to the outside is open. Axair Fans UK Limited www.axair-fans.co.uk
Issue 23 PECM
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Editors Choice FLUX presents the first brushless battery motor to drive pumps.
More than just pumps
With the FBM-B 3100, FLUX UK presents the world’s first brushless battery motor for pumps. The motor is designed for the small sealless COMBIFLUX drum pump. In combination with the pump, the motor provides a delivery rate which is extraordinary for this type of pump and guarantees the highest possible degree of flexibility in operation. Depending on the pump variant, flow rates of 12 to 60 litres per minute can be adjusted with the stepless speed adjustment. For example, at the highest speed, a 200 litre drum can be emptied within just three minutes. Using the lowest speed, even ten 200 litre drums can be emptied with just one battery charge. When the replaceable lithium ion battery has run flat, it can quickly and easily be exchanged and recharged within just 30 minutes. FBM-B 3100 battery motor — for even more mobility and flexibility The COMBIFLUX pump is especially suitable for transferring smaller volumes, e.g. out of narrowopenings and difficult to access containers. It is available in three variants made of the materials polypropylene, polyvinylidene fluoride or stainless steel. Due to the modular design, the FEM 3070 collector motor previously enabled different containers to be emptied one after the other with different COMBIFLUX pumps. The new FBM-B 3100 battery motor now provides even more mobility and enables new applications. Because its independence from mains electrical power supply this makes the FBM-B 3100 especially suitable for applications where cables are problematic or not desired, or mains supply is unstable or not available at all, e.g. outdoors. The new brushless battery motor has no carbon brushes, making it maintenance free. Other features such as the variable speed delivery rate, independence from mains electrical power supply and replaceable battery deliver clear benefits to the user in terms of flexibility and economic efficiency.
Now independent and free. e. The motor FBM-B 3100 is the world‘s first brushless and therefore maintenance-free battery motor for pumps. In combination with the small sealless COMBIFLUX drum pump it is impressive with a highh delivery rate, astonishing for such a small pump. With its replaceable storage battery it is extremely usefull wherever electrical outlets and cables are not desired and ideal for outdoor works – leavingg you independent and free.
Granted the iF Product Design Award The new FBM-B 3100 battery motor has won the world-renowned iF Product Design Award 2014.
! Newfor Also s IBC
Phone: 01202 823304 · sales@flux-pumps.co.uk www.flux-pumps.co.uk
Issue 23 PECM
11
The sky’s the limit From technical problem solving and tool servicing to powder coating and overseas expansion, Star Fasteners is a business keen to push into new areas. Torque speaks with Directors Daniel Starbuck and Nicola Smith for the inside story…
S
tar Fasteners Fasteners tar thrives on on fi finding nding thrives solutions to to the the solutions many challenges challenges many that customers customers send send its its way. way. that Within seconds seconds of of entering entering Within tar ss still still relatively relatively new new tar headquarters in in Pinxton, Pinxton, headquarters near Nottingham, Nottingham, aa clearly clearly near enthused Daniel Daniel tarbuck tarbuck enthused – Director Director of of the the company company – – – takes me me through through one one of of the the takes latest solutions solutions the the fi firm rm has has latest come up up with. with. come The challenge challenge was was using using The strong fastener fastener system system aa strong with lightweight lightweight panels panels – – aa with material increasingly increasingly being being material used in in the the manufacturing manufacturing used sector, including including commercial commercial sector, vehicles. With With less less weight, weight, vehicles. automobiles are are cheaper cheaper to to automobiles run and and require require less less fuel fuel to to run get around, around, but but lightweight lightweight get panels are are less less well well equipped equipped panels to accept accept your your typical typical robust robust to fastener without without incurring incurring fastener
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PECM Issue 23
damage. The The customer customer in in damage. question wanted wanted to to use use question ® Huck® Huck fasteners and and came came fasteners to tar tar the the U U ss largest largest to Huck distributor distributor – – to to see see if if Huck they could could come come up up with with aa they solution. The The team team duly duly did did solution. simple, clever clever fi fixx using using aa simple, shim creating creating aa dead dead stop stop aa shim on the the fastener, fastener, averting averting the the on possibility of of over over tightening tightening possibility and potentially potentially crushing crushing the the and
The firm has grown from quite small beginnings, working out of the family home. lightweight panel. panel. Thanks Thanks lightweight to the the added added shim, shim, Huck Huck to
fasteners can can be be used used on on fasteners those increasingly increasingly popular popular those lightweight panels panels without without lightweight the risk risk of of damage. damage. Another Another the problem solved. solved. problem
“Customers come come to to us us “Customers with aa problem, problem, often often with where aa manufacturer manufacturer where doesn’t have have aa readyreadydoesn’t made solution” solution” made
“Customers come come to to us us with with “Customers problem, often often where where aa aa problem, manufacturer doesn doesn tt have have manufacturer ready-made solution,” solution,” aa ready-made tarbuck tells tells Torque. Torque. We We tarbuck talk to to the the lads lads on on the the shop shop talk floor, oor, to to the the product product designers designers fl and we we aim aim to to come come up up with with and an innovative innovative solution.” solution.” an We work work on on the the small small We pro ects ects too too and and we we re re pro continually coming coming up up with with continually new solutions. solutions. We We are are working working new with new new manufacturers manufacturers and and with trying to to come come up up with with the the trying next thing. thing. It It ss exciting. exciting. next Located ust ust off off unction unction 2 2 Located of the the M1 M1 the the fi firm rm had had the the of internal layout layout of of the the unit unit internal constructed to to their their own own constructed design. It It was was an an empty empty shell shell design. when we we bought bought it, it, tarbuck tarbuck when explains, “so “so we we built built it it to to our our explains, own specifi specifications. cations. ow ow we we ve ve own space to to hold hold an an increased increased space product range range we we don don tt want want product our customers customers to to have have to to wait wait our for product.” product.” for The fi firm rm has has grown grown from from The quite small small beginnings, beginnings, quite working out out of of the the family family working home. tarbuck tarbuck picks picks up up the the home. story It It ust ust started started with with aa story couple of of boxes. boxes. Over Over time time couple we increased increased our our storage storage we from aa shed, shed, to to aa concrete concrete from garage, then then moved moved to to our our garage, first rst commercial commercial warehouse warehouse in in fi Ilkeston. Our Our fi first rst warehouse warehouse Ilkeston. seemed formidably formidably sized sized at at seemed the time time We We thought thought we we dd the never fi fillll it it never
Tools && parts parts are are hot hot Tools washed whilst whilst being being washed repaired // serviced serviced repaired
But But fi fillll it, it, tar tar Fasteners Fasteners did. did. Director Director icola icola mith mith tells tells Torque: Torque: “Moving “Moving here here has has opened opened up up the the possibilities. possibilities. Most Most of of the the staff staff came came with with us us and and we we value value them. them. You You have have to to look look after after them.” them.” Aside Aside from from being being able able to to squeeze squeeze in in more more product, product, the the added added space space has has given given tar tar Fasteners Fasteners room room to to develop develop an an all all new new off offering ering powder powder coating. coating. Coloured Coloured heads heads are are becoming becoming more more popular, popular, with with manufacturers manufacturers increasingly increasingly keen keen to to use use fasteners fasteners with with heads heads that that match match their their livery. livery. mith mith adds adds There There ss aa practical practical benefi benefitt in in terms terms of of corrosion corrosion resistance. resistance. Vehicles Vehicles obviously obviously are are driven driven in in all all weathers weathers and and the the powder powder coating coating is is great great for for longevity longevity and and salt salt spray spray protection.” protection.” The The high high quality quality polyester polyester powder powder coating coating produces produces aa maintenance-free, maintenance-free, hardwearing hardwearing fi finish nish that that is is resistant resistant to to yellowing yellowing and and fading fading over over time. time. reviously, reviously, tar tar contracted contracted out out powder powder coating, coating, but but that that inevitably inevitably had had pitfalls. pitfalls. If If aa big big order order came came through through we we dd inevitably inevitably be be at at the the back back of of the the queue, queue, which which is is understandable, understandable, but but not not ideal ideal for for us,” us,” says says tarbuck. tarbuck. There There were were other other obstacles obstacles too. too. Bringing Bringing it it ininhouse house was was the the only only way way around around it. it. ow ow we we re re in in control control of of our our own own timescales timescales and and can can turn turn an an order order around around for for delivery delivery very very quickly.” quickly.” Not Not that that powder powder coating coating is is aa simple simple matter. matter. Temperature Temperature is is aa key it key consideration consideration it ss as as vulnerable vulnerable as as eggshell eggshell ifif you you get get the the process process wrong. wrong. Because Because it it is is in-house in-house any any issues issues that that we we had had previously previously encountered encountered
have have been been practically practically eliminated eliminated and and 1,000 1,000 is is the the ideal ideal minimum minimum to to work work with, with, but but once once you you ve ve had had an an initial initial order order there there is is room room for for manoeuvre. manoeuvre. We We can can colour colour match match to to our our customers customers requirements requirements and and our our personal personal service service means means that that we we can can supply supply whatever whatever colour colour the the customer customer wants.” wants.”
Star Fasteners offer a comprehensive tool service tar tar Fasteners Fasteners off offer er aa comprehensive comprehensive tool tool service, service, something something it it has has done done virtually virtually since since day day one. one. The The company company stocks stocks new new tools tools and and related related consumables consumables and and also also off offers ers hire, hire, repairs repairs and and servicing. servicing.
Magna-Lok® Magna-Lok® Section XX Section
It It ss generally generally hydro hydro pneumatic pneumatic tools tools that that are are used used to to install install these these fasteners fasteners there there ss aa lot lot of of force force required required so so it it ss important important they they are are maintained maintained and and serviced serviced regularly.” regularly.” The The fi firm rm undertakes undertakes regular regular tool tool servicing servicing for for customers, customers, taking taking care care of of repairs repairs to to keep keep production production lines lines rolling, rolling, fasteners fasteners installed installed correctly correctly and and to to help help them them adhere adhere to to their their health health and and safety safety obligations. obligations. tar tar Fasteners Fasteners like like to to keep keep abreast abreast of of the the latest latest technology technology and and products products so so did did plenty plenty of of research research to to fi find nd an an environmentally environmentally friendly friendly parts parts washer washer We We didn didn tt want want to to be be handling handling drums drums of of harmful harmful chemicals. chemicals. The The unit unit reuses reuses its its cleaning cleaning fl fluid uid and and you you ust ust have have to to top top it it up.” up.”
Hucktainer® Hucktainer® XX Section Section
Companies Companies can can hire hire their their entire entire fl fleet eet of of tools tools from from tar tar Fasteners Fasteners or or can can lease lease out out just just one one If If aa tool tool develops develops aa fault fault or or requires requires servicing, servicing, that that can can be be aa serious serious obstacle obstacle for for aa business business – – we we can can step step in in and and provide provide service service loan loan tools.” tools.” uck uck is is central central to to the the tar tar Fasteners Fasteners business. business. We We are are the the U U ss largest largest uck uck fastener fastener distributor. distributor. We We do do aa lot lot of of business business in in Europe Europe and and worldwide worldwide as as far far afi afield eld as as China.” China.” Huck, Huck, owned owned by by Arconic Arconic Fastening Fastening ystems ystems and and ings ings Ltd, Ltd, has has been been working working with with tar tar on on new new applications applications – – often often in in the the context context of of more more problem problem solving solving for for customers. customers. While While the the design design of of Huck Huck has has evolved, evolved, the the original original products products are are still still available available – – with with all all Huck Huck fasteners fasteners sporting sporting the the trademark branding. trademark la la yy branding.
BobTail® BobTail® Section XX Section Issue 23 PECM
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Less historic uck products include this year s new uck 12. mm diameter Magna Lok® which has been designed as a versatile, hole filling blind fastener. s well as having a wide grip range that can handle wide variations in joint thickness, the Magna Lok has 60 internal locking technology that mechanically locks the pin to the sleeve. The structural blind rivet expands during installation, filling the hole and providing resistance to liquid penetration. Then there is BobTail®, one of uck s latest fasteners. With no pintail to break off there is no wastage, therefore less opportunity for corrosion and no pin tails rolling around the production line. Installation is fast and crucially for the factory floor it s much quieter to install. The BobTail is a permanent, mechanically locked fastener. It is used widely in the rail sector, however the standard flanged, carbon steel 10.9 grade pin and collar enables its use in commercial chassis applications. The BobTail is quick, easy and consistent to install out-performing traditionally used nuts and bolts, we re told. Other key developments for tar Fasteners include a coloured encapsulated Hucktainer®. This again is controlled in house and is produced in a UV stable polymer in a huge variety of colours specified by customers. The firm can also supply a myriad of other fastener brands such as Recoil®, Marson®, Avdel® and cell it® among others, and works with a variety of customers,
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PECM Issue 23
from distributors to manufacturers – particularly in the rail sector and commercial bodybuilding market. tar s product range is always evolving to meet the changing needs of the market. tar Fasteners itself has wasted no time in embracing the latest I O 001 201 uality Management tandard. eeping up with and sometimes ahead of the international standards and expectations is now part and parcel of the distribution sector. mith explains Distribution has changed over the years. The business is constantly evolving and it s not really showing any signs of slowing.” tarbuck adds It s hard to imagine, but we started with hand written delivery notes on carbon paper But we couldn t cope without our system now. “Traceability is a very big deal, some customers require in-depth information about materials right through to the plating process. Customers are looking to hold less stock and so require next day delivery; we hold the stocks for them. You need to look after your customers.” mith says Customers, particularly the large ones, ask that we deliver their orders in an environmentally responsible way – so more bulk orders and fewer small ones to help reduce the environmental impact. “Our customers still like to be able to speak to a person if they need to.
upport, assurance and solutions are part of the tar Fasteners brand we have many years fasteners experience. Aside from the changing distribution game, tar Fasteners clearly thrives on the challenges thrown its way. ou never switch off and we re not too big or too busy to work on smaller pro ects. We ve had all kinds turn up in our car park: Fairground rides, classic cars…we even had an old double decker bus where a customer had pulled the handrail off and they wanted us to supply a fastener to fix it. mall pro ects are ust as exciting to us as the big ones. We re not a one stop shop we are a specialist fastener distributor. We don t do standard nuts and bolts, we don t get into that. But never say never if it s good for our customers and we can make it work for us then you never know what the future holds.” There are fresh challenges ahead for fastener firms to get to grips with, whether it s working with those increasingly popular lightweight panels or working with the burgeoning renewables sector, in solar panels and wind turbines. There are new fixing solutions to be designed it s all moving forward, tarbuck concludes. It s a good business to be in and every day is different. www.starfasteners.co.uk Twitter and Instagram: @StarFasteners .....as first seen in Torque Magazine
Editors Choice
Issue 23 PECM
15
Editors Choice ... /01$
Hinge d e every ap sign for plication
"20 3%"45
$2 6%
# conti nuous # lift-o ff # butt a nd bac kfl # speci al purp ap ose # heavy -duty
Quality hinges for over 200 years
01827 63391
www.goldwassallhinges.co.uk
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NEW PRODUCTS FOR HAZARDOUS AREAS Anamet Europe is the manufacturer of ANACONDA SEALTITEÂŽ conduit systems, Hiprojacket heat protection systems and ANACONDA corrugated metal hose assemblies for the industry. Their ANACONDA SEALTITEÂŽ brand name is recognized and respected worldwide by customers in multiple markets. Founded in 1955, Panduit products are engineered for all aspects of designing, installing and maintaining infrastructures within heavy-duty environments. Optimas Components will be supplying their superior cable management products and will have access to the full Panduit ranges.
OPTIMAS SOLUTIONS - COMPONENTS DIVISION
Tel: +44 (0) 1202 865222 Email: sales@optimascomponents.com Web: optimascomponents.com
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PECM Issue 23
Editors Choice
Talk to the Specialist Test and Calibration System Designers O ver the past 40 years, Chell have designed and built custom test and calibration systems for many of the most demanding and mission-critical applications. Our senior engineers have all experienced the demands of working in a U accredited calibration laboratory and so are able to assess our customer s needs quickly and be ready to work with them to provide test and calibration solutions for your products. Our service encompasses the entire system design including the incorporation and management of calibration standards, any automation needed with its LCs and software, product handling systems and all the support these will need in service. A large part of any installation is the training of your staff and any hand-holding they may need after commissioning, all part of the Chell
service. We will work with your quality team to ensure that the uncertainty budgets associated with the equipment we supply are suitable for your needs and will incorporate their management in the system controlling software.
Many of the bespoke test systems we have supplied over the years have gone on to become products in their own right and it is a measure of the reliability of our systems that many are still giving good service over 30 years after their original plant installation. If you have a need to find test solutions for a product or service involving the measurement of ressure, acuum or as Flow, then give us a call, you ll find that our engineers will be keen to help. Tel 01 00 Email: info@chell.co.uk www.chell.co.uk
Eliminate 52% of bearing failures
Lubrication
Corrosion
11%
4%
Other
5%
Overloading
4% Particle Contamination
48% Misalignment
13% Disassembly
15%
A major study into equipment reliability has shown 52% of all bearing failures are due to particle contamination and corrosion caused by water contamination. The LabTecta®66 bearing protection range can reduce bearing oil contamination from 83% to 0.0003% significantly reducing bearing failure. Visit www.LabTecta.com for a 3-minute video showing statistics and technology www.aesseal.com
Issue 23 PECM
17
Vibracoustics Vibracoustics Ltd Ltd isis proud proud to to be be aa UK UK manufacturer. manufacturer.
ibracoustics have have ibracoustics designed and and marketed marketed designed many products, products, some some of of many which have have now now become become which today ss industry industry standard standard products. products. today
in the the selection selection and and recommendation recommendation in of fl flexible exible suspension suspension systems systems using using of metal, steel steel spring, spring, air air and and rubber rubber metal, mounts for for applications applications in in aa variety variety of of mounts industries and and environments. environments. industries
Founded in in 1979, 1979, Vibracoustics Vibracoustics Founded Ltd specialise specialise in in the the design design and and Ltd manufacture of of high high quality quality antiantimanufacture vibration mounts mounts and and systems. systems. We We are are vibration globally recognised recognised as as an an authority authority globally
Over the the years years we we have have designed, designed, Over manufactured and and supplied supplied vibration, vibration, manufactured noise and and shock shock control control systems systems across across noise many industries industries and and so so have have developed developed many comprehensive product product range range with with aa comprehensive
products manufactured manufactured to to the the highest highest products standards at at our our manufacturing manufacturing facility facility standards in the the U U .. in Our company company provides provides in in depth depth Our technical support support for for all all of of our our products products technical with initial initial application application proposals, proposals, with installation instructions instructions and and service service installation maintenance advice. advice. This This can can range range maintenance from initial initial telephone telephone support support from from from one of of our our sales sales engineers, engineers, choosing choosing one from our our standard standard product product range, range, to to from an in-depth in-depth full full product product analysis analysis with with an onsite investigations investigations and and on on to to project project onsite management with with prototype prototype and and management ongoing product product trials. trials. ongoing We are are always always seeking seeking to to innovate innovate We and develop develop new new solutions solutions using using the the and latest technology technology and and materials materials and and latest adopt aa turnkey turnkey approach approach to to provide provide adopt fast eff effective ective solutions solutions encountered encountered in in fast today ss industry. industry. today our U U manufacturing manufacturing facility facility we we tt our produce our our standard standard and and bespoke bespoke produce products for for which which we we have have an an products extensive range range of of tooling tooling and and extensive equipment. This This enables enables us us to to provide provide equipment. fast, fl flexible exible and and effi efficient cient supply supply aa fast, service for for samples samples and and prototypes, prototypes, service serial production production and and special special projects. projects. serial All products products are are fully fully tested tested for for quality quality All and specifi specification cation in in line line with with our our and quality procedures. procedures. quality We also also provide provide aa full full refurbishment refurbishment We and replacement replacement service service as as there there are are and many instances instances of of products products which which many are no no longer longer available available and and occasions occasions are
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PECM Issue 23
where there there are are no no readily readily available available substitutes. substitutes. where ibracoustics Ltd Ltd is is proud proud to to be be aa U U manufacturer. manufacturer. We We ibracoustics are accredited accredited to to II O O 001 001 and and by by following following best best practice practice are we continue continue to to improve improve the the products, products, process process and and services services we we provide provide giving giving increased increased customer customer satisfaction. satisfaction. Our Our we commitment to to you you is is to to provide provide high high quality quality solutions solutions and and commitment products to to meet meet your your delivery delivery deadlines deadlines at at competitive competitive products prices. prices. For more more informative informative about about our our extensive extensive range range of of products products For and services services please please visit visit our our website website at at and www.vibracoustics.com www.vibracoustics.com
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Camberley Rubber is pioneering the way forward in the precision moulding of Natural Rubbers and Synthetic Elastomers. Moulding the future, today!
C
amberley Rubber Rubber has has amberley grown into into its its dominating dominating grown position by by working working closely closely position with emergent emergent engineering engineering with and hi hi tech tech industries industries off offering ering and otherwise unavailable unavailable solutions solutions for for otherwise rubber mouldings mouldings capable capable of of meeting meeting rubber the stringent stringent demands demands of of modern modern the technology. technology. Their pioneering pioneering approach approach to to their their Their solutions has has gained gained Camberley Camberley Rubber Rubber solutions recognition for for producing producing high high quality quality recognition precision rubber rubber mouldings mouldings in in many many precision varied industries. industries. The The industries industries they they varied are involved involved in in include include Aerospace, Aerospace, are
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PECM Issue 23
lectronics, harmaceutical, harmaceutical, Industrial, Industrial, lectronics, utomotive, Oil Oil as, griculture, griculture, utomotive, as, Marine and and Military Military to to name name but but aa few few Marine The impressive impressive 0,000 0,000 qq ft ft modern modern The factory in in Hampshire Hampshire houses houses “state “state factory of the the art art machines machines for for In In ection, ection, of Compression and and Transfer Transfer moulding moulding Compression which enables enables Camberley Camberley Rubber Rubber to to which mould the the parts parts that that others others can can tt mould The work work force force of of skilled, skilled, experienced experienced The Engineers gives gives Camberley Camberley Rubber Rubber Engineers the capacity capacity to to off offer er fl flexible exible solutions, solutions, the optimising materials, materials, tooling tooling and and optimising process to to deliver deliver cost cost eff effective ective process
solutions. Camberley Camberley Rubber Rubber work work solutions. with their their Customers Customers to to assist assist them them in in with processing their their projects projects from from protoprotoprocessing types to to production. production. At At Camberley Camberley types Rubber they they are are involved involved in in projects projects Rubber from large/complex large/complex assemblies assemblies to to high high from volume components components from from multi-cavity multi-cavity volume tooling. tooling. As dedicated dedicated leaders leaders in in Rubber Rubber As Moulding Camberley Camberley Rubber’s Rubber’s Moulding continued focus focus is is always always on on continued maintaining and and developing developing maintaining technical excellence, excellence, effi efficiency, ciency, on on technical time manufacturing, manufacturing, delivery delivery and and time above all…QUALITY! all…QUALITY! above
8IBU NPSF DPVME ZPV XBOU GSPN B 3VCCFS 4VQQMJFS Technical competence competence Technical Camberley Rubber Rubber have have succeeded succeeded where where others others have have failed. failed. Camberley They have have genuinely genuinely achieved achieved remarkable remarkable things things for for their their They customers customers ngineering support support ngineering Engineering experts experts work work with with you you to to achieve achieve your your objective objective Engineering – be be it it aa very very straightforward straightforward part part or or aa complex complex feat feat of of rubber rubber – engineering engineering Capacity & & equipment equipment Capacity Camberley Rubber Rubber know know what what their their customers customers want want and and they they Camberley consistently deliver deliver it it consistently Quality accreditation accreditation Quality Camberley Rubber Rubber have have stringent stringent quality quality procedures procedures and and are are Camberley O 001 001 200 200 certifi certified ed II O Industry experience experience Industry Four decades decades in in the the rubber rubber manufacturing manufacturing industry industry doesn doesn tt Four happen by by accident. accident. happen Capability Capability With aa team team of of experienced experienced experts experts and and aa facility facility to to be be proud proud of, of, With Camberley Rubber Rubber Mouldings Mouldings has has the the capability capability to to achieve achieve your your Camberley objective objective Trustworthy Trustworthy Accustomed to to working working on on sensitive sensitive projects projects they they understand understand Accustomed the importance importance of of discretion discretion and and would would never never disclose disclose the confidential dential information information confi
The work work force force of of skilled, skilled, experienced experienced The Engineers gives gives Camberley Camberley Rubber Rubber Engineers the capacity capacity to to off offer er flflexible exible solutions, solutions, the optimising materials, materials, tooling tooling and and process process optimising to deliver deliver cost cost eff effective ective solutions. solutions. to
A ordability ordability A Cheap doesn doesn tt mean mean good. good. Camberley Camberley ubber ubber concentrate concentrate Cheap on delivering delivering top top quality quality rubber rubber mouldings mouldings at at aa price price that that is is on affordable ordable and and fair fair aff Recommended Recommended Approved suppliers suppliers for for numerous numerous famous famous brands brands and and market market Approved leading blue blue chip chip companies companies from from around around the the world world leading If you you have have a a new new pro pro ect, ect, or or need need reliable reliable and and cost cost If e ective ective sources sources for for a a current current product, product, please please contact contact e Camberley ubber ubber Mouldings Mouldings Ltd. Ltd. Camberley Tel 0 1 1 330 00 00 Tel 0 330 mail sales sales camberleyrubber.com camberleyrubber.com mail www.camberleyrubber.com www.camberleyrubber.com Issue 23 PECM
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Editors Choice Battery Powered Universal RTU & IoT Terminal From within its compact & robust case the NanoULTRA™ packs a big punch! Huge connectivity [Analogue, Digital, Serial, Modbus, CANbus, I2c, SPI, etc] Autonomous Operation [ Low power for battery use and GSM connectivity] On Board D card flight recorder for granular data Instant SmartHub access for Internet of Things! Small footprint [109 x 29 x 95mm] Over 4 years battery life possible due to its world beating low power consumption. PDF data sheet Caption Data staff will help at every stage throughout the selection and testing process to ensure the best outcome for your trials. Why not give us a call to discuss your application?
Email: Sales@captiondata.com
www.captiondata.com
Datalogic is a global leader in Automatic Data Capture and Industrial Automation markets. s a world class producer of bar code readers, mobile computers, sensors, vision systems and laser marking systems, Datalogic offers innovative solutions for a vast range of applications within all types of manufacturing environments including automotive, food & beverage, electronics and healthcare. From inventory management and real time tracking of work in progress across the production line, to facilitating quality assurance inspections that ensure product safety is upheld at all times; manufacturing organisations across the globe rely on Datalogic solutions to improve traceability and enhance operational efficiency. www.datalogic.com +44 (0)1582 790020 Datalogic House, Dunstable Road, Redbourn, Herts, AL3 7PR
Filterserve are the UK’s leading independent distributor of Industrial Filtration. We offer a vast range of filters catering for all applications within oil gas, aerospace, engineering, power generation, food & beverage industries. We have our own manufacturing facility producing basket strainers and filter silencers. Other bespoke filters can be manufactured. Additionally we have a nonwoven conversion factory where we roll and slit filter rolls or sheets for filtering coolant or edible oils. We distribute for all ma or filter manufacturers offering their proprietary filters. Whether it is consumable spares or complete filtration systems our technical experience will ensure we offer you the complete filtration service.
Tel 01 0 1 mail salessupport filterserve.com www.filterserve.com
A New Website for SeaShield Marine Protection Systems Winn & Coales International are pleased to announce the launch of a newly redesigned website for their SeaShield marine protection systems, which can now be found at www.seashield.com. The new website features a modern, streamlined design that showcases the solutions available to customers, details for each of the product systems available and real world case studies highlighting SeaShield’s protective capabilities. A comprehensive questionnaire allows enquirers to outline their own unique requirements in order to receive tailored advice or make contact with more general enquiries, all of which are available in an easily navigable, mobile optimised format. SeaShield systems provide protection to structures that are vulnerable to corrosion in marine environments. Offering long term corrosion prevention to etty piles, offshore structures and sheet piles, multiple grades of defense can be employed to achieve cost effective protection irrespective of section structure design.
Email: mail@denso.net
www.denso.net
ůĞĂĚĞƌƐ ĂŶĚ ƐƉĞĐŝĂůŝƐĞĚ ƐƵƌĨĂĐĞ ĐŽĂƟŶŐƐ ĞdžƉĞƌŝĞŶĐĞ ďƌĂƐŝǀĞ ůĂƐƟŶŐ ^ƉƌĂLJ ƉĂŝŶƟŶŐ ƌLJ &ŝůŵ ŽĂƟŶŐƐ dŚĞƌŵĂů DĞƚĂů ^ƉƌĂLJ ŝŶĐ WŚŽƐƉŚĂƟŶŐ ZĞĨƵƌďŝƐŚŵĞŶƚ /ŶƐƉĞĐƟŽŶ DĂƐŬŝŶŐ Θ ^ƚĞŶĐŝůůŝŶŐ ƐƐĞŵďůLJ Θ <ŝƫŶŐ
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PECM Issue 23
The UKâ&#x20AC;&#x2122;s largest meeting place for advanced engineering professionals
With less than two months to go, REGISTER NOW and join us where the familiar and the unfamiliar collide to provide new opportunities across the engineering supply chain.
REGISTER NOW
Advanced Engineering is the industry event where high-technology manufacturing sectors converge under one roof to meet and do business. Join other companies who have already registered to attend including: Rolls-Royce, BAE Systems, Bombardier Aerospace, Airbus, Thales, British Airways, Babcock, and many moreâ&#x20AC;Ś REGISTER FOR FREE at www.advancedengineeringuk.com
Contact us to find out more gg +44 (0)20 8843 8800 or visit www.advancedengineeringuk.com
Advanced Engineering Hosts the Largest Open Conference of Its kind Advanced Engineering, the UK’s largest meeting place for engineering professionals, returns to Birmingham’s NEC on 2 & 3 November 2016. The show, which has become the hub for the high performance engineering sector, brings together engineering professionals and decision-makers to source new ideas, technologies and suppliers all under one roof. Open Conference
Throughout the two-day conference there will be a number of insightful and educational sessions from leading industry experts. Sessions confirmed so far include the likes of Jaguar Land Rover, Innovate UK, Magna International, SMMT, BOC, KTN, National Instruments, Women’s Engineering Society and many more.
Automotive Engineering Show With 2.6 million new cars registered in 2015, and this number expected to rise in 2016, it is no wonder there is a need for an event like the Automotive Engineering Show. It brings together the best and brightest from the UK’s auto community, offering numerous opportunities to do business and find the very latest technologies from leading automotive suppliers. Visitors will be able to see sessions from the likes of Jaguar Land
Advanced Engineering will host the
Rover and Magna International, plus have
most comprehensive Open Conference
access to big name exhibitors such as
programme of its kind. Visitors will gain
SMMT, High Value Manufacturing Catapult
access to all conference forums which
(HVM), North East Automotive Alliance,
will span key industry sectors, including
MIA (Motorsport Industry Association) and
aerospace, automotive, motorsport,
National Instruments.
marine, civil engineering.
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PECM Issue 23
Composites Engineering Show For those interested in the everchanging world of advanced materials, the Composites Engineering Show will highlight the latest breakthroughs in composite materials, the most upto-date equipment used to produce the composites and the research & Aero Engineering Show The UK aerospace industry has been tasked to deliver new technologies to ensure that the next generation of civil aircraft is cleaner, quieter and more efficient than ever.
development that takes place at every level of the industry. The UK’s only dedicated composite materials, design and processing event will host an array of exhibitors, many of whom will be using the show to present their latest technologies to the UK market, including Composites
With this in mind, the Aero Engineering
UK, PREA Ltd, Swift Composites
Show will feature a plethora of key
Ltd, NetComposites, Irish Centre for
industry suppliers and research institutes,
Composites Research (IComp), epm
many of whom are committed to finding
Technology, Scott Bader and Gazechim
new developments and innovations within
Composites UK.
the aerospace industry, including aero structures; power plants; R&D; materials and production. Sessions taking place at its dedicated conference include: ‘Manufacturing Confidence through Product Verification’ from Phil Cooper, National Product Verification Programme Leader at National Physical Laboratory and ‘Inclusive Engineering’ by Dawn Bonfield, Chief Executive of the Women's Engineering Society.
Performance Metals Engineering The performance metals industry is worth £2.6 billion a year to the UK economy. It is
Sessions that will take place at its conference include: ‘Simulation and virtual design for manufacturing technology of high performance metal parts’ by Dr Nikolay Biba, Technical Manager at MICAS Simulations Ltd.
Dave MacLellan, Executive Secretary at the Association of Industrial Laser Users, will then explore ‘Better by laser: Saving weight, money and time with lasers in manufacturing’. Exhibitors More than just a conference, the UK’s largest annual engineering trade show brings together OEMs and tier 1 manufacturers to meet and do business with all levels of the engineering supply chain. Visitors will have access to leading international suppliers who will showcase their latest products and innovations to the UK market.
therefore no wonder that the Performance Metals Engineering show is one of the fastest-growing areas of Advanced Engineering UK. The show provides the latest information and trends for those involved in casting, extrusion, stamping and forging processes. It also caters to the areas of powder metallurgy, friction drilling, sheet forming processes, metal surface engineering and many more.
It features four ‘shows within a show’ – Automotive Engineering Show, Aero Engineering Show, Composites Engineering Show and Performance Metals Engineering.
With over 700 companies anticipated to
The other conference, ‘Brakes 2016’ will
exhibit, it is set to have its largest exhibitor
provide attendees an opportunity to keep
base yet.
abreast with the latest developments being made and challenges being
Show Support Easyfairs, the organiser of Advanced Engineering, reports that interest has never been stronger, with more than 80 show supporters on board, including most recently the Institution of Mechanical Engineers (IMECHE) and the Manufacturer. The IMECHE, will be running two one-day technical conferences co-located with Advanced Engineering 2016, focusing on the aerospace and automotive sectors. ‘Aviation Aerodynamics’ will provide the latest developments across the aerospace
overcome in the automotive industry.
The Manufacturer will run its Smart Factory Expo in partnership with Advanced Engineering, as part of a series of events to examine Britain’s response to Industry 4.0. The Manufacturer Live events include the two-day exhibition, The Manufacturer Top 100, The Manufacturer Annual Leaders Conference and The Manufacturer MX Awards.
industry for increasing efficiency, covering
For further information about Advanced
additionally external aerodynamic
Engineering 2016, please visit
engineering, and innovation in internal
www.advancedengineeringuk.com or
aerodynamics.
contact one of the Easyfairs team on +44 (0)20 8843 8800.
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PECM Issue 23
DJJ Precision Engineering Ltd
Specialists in Stainless Steel Production Specialist in Stainless Steel, Nimonics, Brass, Duplex, Aluminium, Exotics, Super Alloys, Titanium, Inconel, Copper, Hastelloy, Bronze, Advanced Engineering Plastics, most Ferrous and None Ferrous materials and many more... 14 Pontyfelin Ave Ind Estate Pontypool, South Wales, NP4 0DQ, UK
0044 (0)1495 760561
sales@djjengineering.com www.djjengineering.com
Connect 2 Cleanrooms Exhibiting at Advanced Engineering UK 2016
C
onnect 2 Cleanrooms will be exhibiting its clean air solutions at Advanced Engineering UK 2016 (STAND: B50). Visitors to the exhibition will be able to discover how Connect 2 Cleanrooms’ unique and scalable modular cleanroom systems can reduce failure rates and improve consistency, adding value and improving efficiency for their process.
such as hardwall, softwall and panel system wall construction. Also on display will be the award winning UD Flow, an innovative laminar flow booth creates a clean environment for critical processes, creating a clean room work bench to suit many processes.
Each modular cleanroom from Connect 2 Cleanrooms is bespoke - designed specifically around organisation s production environments, to protect their processes from airborne contamination.
With 14 years’ experience delivering contamination control solutions for mission critical environments in the precision technology sector, Connect 2 Cleanrooms has innovation at its core.
isitors can find out about Connect 2 Cleanrooms’ array of design options;
To find out more about any of Connect 2 Cleanrooms’ products and services,
visit them on Stand B50 at the NEC Birmingham from 2nd – 3rd November 2016 or visit www. connect2cleanrooms.com/events to register for free.
Cleanroomshop Launches Redeveloped Responsive Website
C
onnect 2 Cleanrooms has redeveloped its Cleanroomshop.com website, using the latest trends in e-commerce for its specialist range of cleaning products, equipment and furniture. Today’s purchasing departments have high expectations of the technology they use for their purchasing and this drives a culture of constant improvement for websites, with a focus on user experience. Connect 2 Cleanrooms wanted to harness this trend for its clients and so the newly re-launched Cleanroomshop. com allows visitors to navigate smoothly through its extensive range through the use of filters, product comparisons and smart search allowing them to easily find the right product for them.
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PECM Issue 23
This is particularly important considering the highly technical nature of the products in Cleanroomshop.com’s range – its clients require specialist products with efficacy and performance data and certification behind them. With a global client base, the new and improved Cleanroomshop.com website is now even easier to use for international purchasing – with updates including tailored international content, as well as enhanced shipping and currency options now offering purchasing in GBP, EUR and USD). Further features include a one-step checkout, quote builder, product
videos, reviews and questions, along with increased security from wellknown payment gateways, PayPal and SagePay. To find out more about the all new Cleanroomshop website, visit www.cleanroomshop.com.
Metalock's Global Steel Reputation Metalockâ&#x20AC;&#x2122;s steel plant refurbishment reputation spreads worldwide
In addition to the milling machines for surface work Metalock has developed a range of drilling equipment to redrill and tap all the holes.
Port Talbot
equipment specially designed in-house for
Due to the severe operating conditions in steel plants, regular refurbishment of heavy rolling mills is essential to ensure efficient production and consistent product quality. Window areas on roughing and subsequent finishing mill stands suffer erosion and corrosion due to the very nature of the steel rolling process and once resultant wear reaches a certain point, it becomes necessary to remove old wear plates, remachine the surface behind them to restore original manufacturing tolerances for squareness, straightness and dimensional accuracy. New oversize wear plates are then fitted.
steel mill refurbishment.
Drilling & tapping
Orbital turning
The shear size of the mill housings means that the remachining needs to be carried out in-situ. For this reason Metalock Engineering UK has built up an extensive range of precision on site machining
As well machining the wear areas, before new wear plates can be fitted, many of the tapped holes for the plate bolts often need to be refurbished. The constant pounding of rollers on hot steel and the vibration cause the threads to gradually deteriorate.
One of the latest pieces of equipment to be developed is an orbital turning machine which was designed for machining and reprofiling 0.5 metre diameter X 1.5 metre long stub shafts for a beam straightening/ finishing machine at Corus, Teesside.
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These machines, together with the companyâ&#x20AC;&#x2122;s team of highly skilled engineers and technicians, all of whom have many years of experience with steel projects both large and small all over the world, are enabling Metalock Engineering to establish a global reputation as the market leader in this type of machining work.
Not only is the Metalock mill housing equipment suitable for machining vertical surfaces it is also used to remachine the housing bases flat and level with each other and square to the housings themselves. Increasingly, Metalock is carrying out reboring for upgrades of mill screwdown systems and like the drilling procedures this work is performed using an adaptation to the mill housing remachining system. This means that the range of Metalock equipment available for steel plant work encompasses milling, drilling and tapping, boring and facing.
Spelsberg is one of the largest manufacturers of electrical enclosures in the world. With over 4,000 enclosures available as standard and further customisation possible, it offers solutions for almost any application.
To speed the orbital turning operation and ensure that all seven shafts matched, Metalock fixed a template of the stepped profile to the orbital turning device. The tools followed this profile, as in a copying lathe. Global operation Metalock Engineeringâ&#x20AC;&#x2122;s reputation is growing apace and as well as roughing mill stand refurbishments at Corus, Llanwern; the reversing roughing mill at Corus, Port Talbot and the orbital turning project on the seven beam straightening machine shafts at Corus, Teesside, the company has carried out projects in Spain, at Aviles for Aceralia refurbishing eight screwdown bores; refurbished four mill stands for Sollac in Marseilles and done similar work for Iran Steel in Esfahan. Such is the companyâ&#x20AC;&#x2122;s experience in this type of work that all the contracts were accomplished within the time and budgets allocated by the client to the satisfaction of all concerned. In past years Metalock has carried out works in steel plants in Poland, Turkey, Chile, Norway, Sweden, Belgium, South Africa, India, Romania, China, Canada and the USA.
Cast iron repairs In addition to the machining work Metalock Engineering UK is the largest and most successful company in the world specialising in cold repairs to cast iron using the Metalock process. This technique was developed over 70 years ago for the repair of castings in iron, bronze, aluminium and steel that have been cracked or broken. Because it is a cold repair it avoids the normal stress problems associated with welding. The Metalock process is the accepted repair technique for all cracked, broken and damaged castings in a wide range of industries, for a multitude of applications. The repair consists of peening layers of Metalock special nickel alloy multi-dumbbell shaped keys into prepared apertures.
These keys are highly ductile and can be peened into a metal-tometal condition to become almost integral with the componentâ&#x20AC;&#x2122;s parent metal. Metalock keys are manufactured in a variety of sizes to suit each individual job.
Their high strength ensures the return of a high percentage of the original strength. The essential advantages of the Metalock repair are that no heat stresses are introduced, no distortion occurs and in many instances machining is unnecessary. The process is invaluable in emergency situations and in many cases where the component is accessible, it can be done in-situ to avoid costly dismantling and re-assembly. When it comes to providing specialist services to the world steel industry, Metalock is one of the leaders by offering its skills in In-Situ Machining, Cold Repairs to Cast Iron and Cast Iron Fusion Welding, For those who require it, the company provides alignment services and has a comprehensive in house machining facility at its headquarters in Coventry, England. www.metalock.co.uk
Issue 23 PECM
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Centre for Process Analytics and Control Technology (CPACT)
he Centre for Process Analytics and Control Technology (CPACT) is the leading network for companies seeking advice and research on all areas of process performance monitoring, process analysis and control.
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It provides expertise in R&D technology transfer in process analytics, multivariate analysis, industrial statistics, PAT and process control technologies. CPACT is a collaboration between companies, universities and research institutes with five strategic themes: Research and Development; Conferences and Networking; Technology Transfer; International Collaborations; Expert Training. Member companies enjoy the benefits of: t
Free short-term feasibility studies into process analysis and control applications
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PECM Issue 23
t
R&D and Technology Transfer projects
t
A talent pool of multidisciplinary researchers
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Access to software developed by CPACT including unique highly visual multivariate data pre-processing, analysis, modelling and calibration transfer toolboxes
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Networking, Training and Skills Development
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Webinars
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Courses and workshops
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Research days
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Conferences
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â&#x20AC;&#x2DC;Members onlyâ&#x20AC;&#x2122; website containing free CPACT software, the CPACT research archive, CPACT webinars and presentations
t
Reduced rates at the annual Advances in Process Analytics and Control Technology (APACT) three-day conference
Established in July 1997, CPACT has continued to develop and grow.
It currently has over 30 company members together with 8 universities and 3 research institutes. Uniquely for a consortium of this type, CPACT will celebrate its 20th anniversary next year. New members are always welcome and any interest can be directed to the admin team in the first instance: admin@cpact.com CENTRE FOR PROCESS ANALYTICS AND CONTROL TECHNOLOGY www.cpact.com +44 (0)141 548 4836
The portable and reliable fans and blowers are both safe and suitable for use in confined spaces.
Tough fans for tough jobs VAF
Air, together with their sister company, Miniveyor Products Ltd M L , are specialist suppliers of conďŹ ned space equipment to a diverse industry base globally and has been involved in the supply of vane axial fans to the European market since the mid 1 0 s. ow the Miniveyor ir and VAF Air range of blowers, fans and ventilators has been established as a leading brand worldwide. Designed with a twin wall, rotationally moulded fan body, made from high density polythene, means the products can absorb bangs frequently experienced with industrial use, eliminating costly maintenance procedures. Conventional metal bodied fans ding and dent easily, and typically don t last very long in the workplace. The plastic moulded fans from VAF Air are highly resistant so they can last a much longer time. Additionally, all of the parts are replaceable so if anything does get damaged then they can be changed easily.â&#x20AC;? The portable and reliable fans and blowers are both safe and suitable for use in conďŹ ned
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spaces. Where fumes, smells or dust occur, the axial fans can extract contaminated air out of the building, and blow fresh, clean air into a workspace. The VAF series range has recently been extended with the introduction of the VAF-200C Canister blower. Based on F ir s popular VAF-200, the compact VAF-200C is ideal for conďŹ ned space ventilation and fume extraction and beneďŹ ts from a, simple to attach, Duct Canister that neatly clips onto the fan body and houses 7.5 metres of ďŹ&#x201A;exible duct. Designed for manhole work, it is great for telecoms or utilities contractors that have limited storage space in service vehicles and can be carried to the job site with ease. For work areas where an intrinsically safe solution is required then the air driven, VAF-300P pneumatic fan is the answer, coupled with tatic Conductive ďŹ&#x201A;exible ducting, can provide , 00m per hour air ďŹ&#x201A;ow. The F 00 is supplied with a mounted ďŹ lter, regulator and lubricator unit. The oďŹ&#x20AC;ering from F ir is increasing over the coming months with new product introductions that will provide greater capacity and airďŹ&#x201A;ows as well as personnel cooling solutions. The specialist ventilator company have recently obtained a bigger presence in the U , after the establishment of a new warehouse and oďŹ&#x192;ce in Miami. This expansion is a testament to their prominence in the industry, and the company are set to continue with this incredible growth through the advancement of product lines and the acquirement of new associations across the globe. For more information on F ir s innovative equipment, contact the company today. Visit us online at www.vaf-air.com Or call 0 330 01 000 Issue 23 PECM
33
Safe supply to equipment in the panel Klippon® Connect for optimum control voltage distribution our panel panel building building our processes have have to to processes be fast fast and and effi efficient. cient. be That ss the the only only That way you you can can become become more more way productive and and connectivity connectivity productive plays aa decisive decisive role role in in this this plays regard, as as the the eff effort ort required required regard, for wiring wiring is is aa considerable considerable for time factor. factor. As As your your partner partner time in Industrial Industrial Connectivity, Connectivity, in Weidmuller considers considers panel panel Weidmuller building to to be be an an integrated integrated building process – – from from the the planning planning process stage all all the the way way to to stage installation and and operation. operation. installation The latest latest example example of of this this is is The ® lippon® Connect. The The off offer er lippon Connect. – which which consists consists of of tailored tailored – application products, products, universal universal application terminal blocks blocks and and process process terminal supporting services services – – provides provides supporting you with with productivity productivity benefi benefits ts you at all all stages stages of of the the panel panel at building process. process. building
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PECM Issue 23
saving potential potential is is obvious, obvious, saving oďŹ&#x20AC;ering ering up up to to 0 0 more more oďŹ&#x20AC; compact control control voltage voltage compact distribution. distribution. Utilising U U technology, Utilising II technology, the maximum maximum time time saving saving the during the the wiring wiring process process during is achieved, achieved, as as well well as as is guaranteeing vibrationvibrationguaranteeing resistant and and gas-tight gas-tight resistant connections. Coloured Coloured pushers pushers connections. provide clear clear identiďŹ identiďŹ cation cation of of provide each potential potential and and dual dual cross cross each connection channels channels allow allow for for connection ďŹ&#x201A;exible exible potential potential distribution. distribution. ďŹ&#x201A;
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Issue 23 PECM
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SMALLER JUST GOT STRONGER PFC100 Controller: High performance packed into a smaller footprint
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PECM Issue 23
Control & Automation New tension nut from Heico eliminates need for specialist tooling eico Fasteners, manufacturers of the ICO LOC ® anti-vibration wedge lock washers, will be launching their new ICO T C tension nut at the upcoming ngineering Design how D that promises to eliminate the need for specialist tooling for large bolted joints.
time consuming and potentially expensive options and indeed is so fast that ICO T C nuts are often tightened in the same time it takes to set up such tooling. With ICO T C the nut body is screwed onto the main thread just like a conventional nut – but it is not tightened. everal pressure bolts with associated pressure pins are arranged around the main thread inside the nut body. When the pressure bolts are tightened they push the pressure pins against the part to be tensioned and at the same time the bolts elongate. The pre-tension force created in this way is purely axial and therefore free from harmful torsion or bending. The ICO T C nut also includes an incorporated hardened washer that protects the tensioned parts from high pressure loads caused by the pressure pins.
The ICO T C tension nut is unique in the fact that the pre-tension force of the large main thread is distributed to many smaller pressure bolts. Because these pressure bolts are smaller a conventional torque wrench is all that is needed to achieve the correct pretension force, eliminating the need for complex, bulky or heavy tools and makes securing large bolted joints more convenient and easy. Working with large bolted oints usually means an engineer having to arrange specialist electric, hydraulic or pneumatic bolt tensioning services. ICO T C does away with these
www.heico-tec.com
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Issue 23 PECM
39
PP pushes the button on £1m factory extension O ne of the West Midlands’s fastest growing manufacturers is dismissing uncertainty surrounding Brexit by investing more than £1m on a new factory extension.
PP Control & Automation has pressed the button on ambitious expansion plans that will see it add 1,000 sq metres of production space to its existing site in Cheslyn Hay, including PP Control & Automation, a new logistics department and clean which holds ISO assembly area.
9001:2015 and UL 508A accreditations, is targeting growth in Germany, the US and North America as part of its push for £40m sales.
Construction work has already started on the building in a move that will give the company the additional capacity it requires to achieve its
target of doubling sales turnover to £40m by 2021. New staff are in the process of being recruited for the first phase of expansion, with the control and automation specialist keen to invest in six new apprentices as part of this recruitment drive.
“There was a lot of talk about uncertainty holding back industry after the Brexit vote, but we have confidence - in the medium term - that UK manufacturing in general will be strong and the growth plans of ourselves and our customers remain unchanged,” explained Tony Hague, Managing Director. “In the short term with Sterling weakening against the euro and the US dollar, we have actually seen growth in export markets as UK competitiveness has improved.”
He continued: “The additional 1,000 sq metres will be used for additional manufacturing space, a just-in-time logistics operation and new clean assembly area that we’ll need for new opportunities in the more specialist industry sectors, such as scientific equipment and semiconductor processing markets. “Importantly, it gives us the manufacturing footprint required to increase sales by 100% and is a real show of intent when talking with potential clients.” PP Control & Automation, which is a member of the Manufacturing Assembly Network (MAN), has become one of the world’s most respected suppliers of electrical control systems, cable harnesses and sub-contract manufacturing solutions.
Employing nearly 200 people, the company has benefitted significantly from the ‘outsourcing’ trend being employed by machinery builders keen to reduce production lead times, secure greater manufacturing flexibility and ultimately reduce overall manufacturing costs. “Companies have realised that strategic outsourcing in areas of non-core activities offers many significant commercial and operational benefits, but they have to make sure they fully investigate their choice of outsourcing partner. Get it wrong and the consequence can be devastating,” explained David Fox, Chairman of PP Control & Automation. “Manufacturers are more aware of the processes that they wish to keep in house, these are a core activity and key to
their success and the areas they wish to invest in. “Equally they observe non-core activities as being unnecessary and often a cost burden. This awareness is something we’re now looking to capitalise on through our involvement with the Manufacturing Assembly Network.” He concluded: “Working in partnership with electronics experts SMT Developments and fabrication specialist Mec Com, we have launched the OEM Outsourcing Cluster and will be promoting this through a new brochure, digital marketing campaign and by attending carefully identified trade shows.” For further information, please visit www.ppcanda.com or follow @ppcanda on twitter Issue 23 PECM
41
Electrolytic weld cleaners like Fusion Clean pass an electric current through a cleaning fluid which has been applied to the metal.
How to save time B and money on stainless steel weld cleaning
ecause welds are more susceptible to corrosion if they are left uncleaned, it’s good practice to always clean your welds. There are several techniques, but the relatively new boy on the block, electrolytic weld cleaning, is by far the most effective.
There are many ways to save time and money for your business without compromising on quality. But did you realise you could be wasting precious resources on weld-cleaning techniques that are both inefficient and poor quality?
The traditional method for post-weld cleaning uses pickling paste. This corrosive substance erodes the top layer of the weld, leaving a completely clean surface below. Get the timings right, and it s fine. But get the timings wrong and you could weaken your weld, or even worse, end up with thin patches or holes in the metal. And not that, but pickling paste takes several hours to work and can be very dangerous. In contrast, electrolytic cleaning works immediately on cooled stainless steel welds, providing instantaneous results. And there’s no chance of weakening your weld. Why Because it works in a completely different way. Unlike pickling paste, which strips away the top layer, electrolytic weld cleaning actually restores stainless steel to its original shiny state. Electrolytic weld cleaners like Fusion Clean pass an electric current through a cleaning fluid which has been applied to the metal. The fluid, which is a mild electrolyte, allows
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PECM Issue 23
the the current to dissolve any non-metallic substance, completely removing rust, blemishes and weld burn. And because Inverter Fusion’s cleaning fluid will not affect the steel without a current, you can be secure knowing that you have complete control over the process. Not only does the electrolytic cleaning process restore the steel to its original state, it also significantly decreases the likelihood of future corrosion. Electrolytic processes are also much safer and more environmentally friendly. Pickling paste is a combination of hydrofluoric acid and nitric acid and can not only cause serious burns, but also serious lung problems, dangers which are often overlooked. If you’re looking for a reliable, high-quality cleaning machine, look no further than Inverter Fusion’s Fusion Clean. Designed and manufactured in the UK, the machine comes with a comprehensive three year warranty. ‘The Fusion Clean is the most sturdy, well built machine we have come across. Nothing compares to the price, quality and ease of use,’ commented Dom at Water Blades Us. ‘We found ourselves using less fluid, fewer passes over the welds and found over a batch of parts a saving on time.’ For more information visit www.inverterfusion.co.uk, or call 01404 549791.
Cembre
Ever experienced a problem with a failed connection? ‘It’s a fact that, however hi-tech the equipment, the integrity of its seemingly ‘simple’ electrical connections is fundamental to its operation. Reliability, Safety, Reputation and Livelihood are at risk when insufficient attention is paid at this basic level. Even experienced Electrical Engineers familiar with the requirements of codes of practice BS7609 and BS7727 look for guidance when deciding whether to trust the provenance of many of the myriad of connectors available today. These standards govern the use of Copper tube and Insulated compression connectors and advise that best practice for good electrical connections is to use a matched system of terminations, crimping tools and die sets.
Whatever size, type and material the connector to be crimped - insulated Red, Blue or Yellow (pic1) commonly used in control circuits or 800sqmm 4-hole Transformer lug (pic2) - the OEM/Contractor should willingly provide their Customer with the Cembre assurances that: - The current carrying capacity (related to the Copper cross sectional area) of the termination at least equals that of the cable being connected. Low price alternatives may be only ‘thin wall’ connectors having too little Copper to carry the designated full load current without over-heating.
Pic 1 Insulated Red, Blue and Yellow connectors
Pic 2 800sqmm Transformer lug
Pic 3 Crimpstar crimping tools
- Terminations are fully annealed post-forming to optimise electrical contact and remove residual stresses thereby improving mechanical performance over their operating life. Again price may be the enemy of integrity. - Crimping tools and die sets are matched with the termina tions to ensure consistent, high-integrity connections.
Pic 4 - Smartool reporting feature on 18v crimping tools.
Cembre is one of few manufacturers to offer a truly matched system...by design. (pic3) In addition, Cembre’s new generation of 18v crimping tools for 10-400sqmm lugs has Smartool software (pic4) that enables the user to view, instantaneously, the force applied to each crimp as it is completed. And the data for up to 200,000 cycles is easily downloaded, printed and provided to the customer to verify accordance with BS7609 and BS7727. No surprise then that Cembre’s Best Practice Crimping Workshops have become the must-have on-site Tool Box Talks for those involved, particularly, in Electrical Design, Installation and Maintenance.
Never experienced a problem with a failed connection? You must already be a Cembre customer. If not please call us to arrange for our local engineer to visit. Cembre Ltd - +44 1675 470 440 - sales@cembre.co.uk - www.cembre.co.uk
Issue 23 PECM
45
Electrical & Electronics INNOVATIVE CONNECTIVITY SOLUTIONS Discover more at: EDS, 19 - 20 Oct, Stand K42 ELECTRONICA, 8 - 11 Nov, Hall B2 Booth 219 or call +44 (0)23 9245 9600
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
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www.fischerconnectors.com Issue 23 PECM
47
Spelsberg IBT Enclosures Speed Up Electrical Installation For New Pre-Cast Hospital Build
hanks in part to the use of Spelsberg IBT junction boxes, a project to build a new ÂŁ89m mental health hospital in South Wales has kept to a rigorous construction programme. The IBT enclosure range provides quick and robust electrical installations for pre-cast concrete construction, a proven method of building fast-track projects.
T
The 20,000sq m centre replaces several separate facilities spread around Cardiff and the surrounding area. It will provide adult inpatient accommodation in 135 single-bed en-suite rooms, and also bring together all the area's general adult
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PECM Issue 23
mental health inpatient services including low security, addiction, neuropsychiatry, intensive care and supportive recovery services. The design incorporates sitting rooms, garden areas, therapeutic spaces and consulting rooms. Despite being a large and complex project, topping out of the main buildings was completed within a year. This was achieved through a highly sophisticated technique to prefabricate seven separate plant rooms off-site. These were then installed in a matter of days. Each plant room contains all the building services equipment required, including pumps, fans, Building Management System (BMS) panels, control equipment and complete wiring.
The use of precast concrete panels, rather than poured concrete or other construction methods also helped ensure the rigorous building programme was maintained. The panels are bespoke designs and incorporate the electrical services, which reduced the amount of installation and wiring needed on-site.
Historically, this method of electrical installation has been difficult, due to the lack of specially designed electrical products. But Spelsberg's ITB range of junction boxes and related products has been specifically designed for the precast construction industry.
Spelsberg is one of the largest manufacturers of electrical enclosures in the world. With over 4,000 enclosures available as standard and further customisation possible, it offers solutions for almost any application. www.spelsberg.co.uk
The IBT system allows enclosures, junction boxes, lighting outlets and other installation components to be fixed into the formwork into which the liquid concrete will be poured. They are secured in place either by magnetic couplings for metal formwork, or by patented support spars for timber formwork. Conduit is fitted as required to accommodate the wiring and then the concrete is poured in. Once set, the formwork is removed and the panels are ready for shipment to site. A key element of the IBT system is the integral sealing, which prevents concrete fines from getting inside the electrical components. This uses a patented diaphragm system which, after the conduit is inserted, returns to its original position and provides strain relief and sealing without the need for special grommets.
Conventional housings do not have such a seal, so if used in a precast panel, a sealing arrangement would have to be fitted in-situ, a difficult and costly process. The IBT products are made from halogenfree, high-temperature resistant material which is designed for a long, trouble-free life. The range available in a wide range of sizes. With more and more projects now requiring extra low voltage (ELV) transformers for LED lighting, loudspeakers and network communications cables, Spelsberg has also developed the complementary IBTronic range.
“Space for you” Spelsberg’s company philosophy is based around the idea of providing flexibility and freedom to its customers. The space provided within each junction box; the large distribution and warehousing space; and the freedom to customise almost any product, irrespective of quantity, all equates to “Space for you”.
The IBT system has already been used in a wide range of buildings including prisons, schools, hotels, offices and residential buildings. It is now increasingly recognised for its potential to reduce installation time and save overall build costs. Issue 23 PECM
49
Electrical & Electronics
Guhring Drill Is The Top Prize For Robot War Warriors Over the summer months obot Wars has been back on our TV screens with 40 distinct combat robots battling it out for the prestigious accolade of being crowned the 2016 champion. elf built by the competitors and fighting in a purpose built arena, the six-episode series has been watched by over 2 million people each week. The rand Final was won by pollo, a robot captained and driven by Dave Young. As one of the ouse obots that featured in the eries, ir illalot is a 0kg robot with a 2. tonne pincer grip and a top speed of 10mph. On one arm is a 300kg arm lift that outweighs all competitors and on the other arm is a 2inch taper shank drill from
uhring. The uhring 2 eries Taper hank Drill has been used throughout the series as a tactical feature in battles with contestants. Manufactured by Robo Challenge, a Birmingham based company of enthusiastic, creative and downright whacky engineers, ir illalot is ust one of many prestigious projects that Robo Challenge has delivered. As well as featuring heavily in the hit TV show with ir illalot, obo Challenge was also tasked with designing and manufacturing the coveted trophy. A trophy that has another iconic masterpiece at its centre, the uhring 2 eries Drill.
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Issue 23 PECM
51
Electrical & Electronics New ETA Enclosures 2016 Product Overview Brochure ot o the press for 01 is a new page product overview brochure from TA Enclosures UK Limited. This new, easy to navigate publication shows T s range of ex-stock enclosure products and thermal management solutions and it is the ideal user friendly tool from which to select in stock products for quick no delay delivery. Products featured are: Boxes in Mild teel, tainless teel and olyester Cabinets in Mild and tainless teel Desks Consoles in Mild and tainless teel C Cabinets in Mild teel Outdoor Cabinets in Mild teel and luminium
Including new products M tainless nclosure ystems boxes
tainless
teel
uspension
teel Terminal and
rms and ush button
Die-cast Aluminium Boxes All products are available in standard format to a comprehensive range of sizes but custom modifications to the customer s specific requirements are also available on a quick turn round basis. For further information or to request your free copy of T s new 2016 roduct Overview Brochure call our sales office on 01 0 3 30, E-mail info@eta-enclosures.co.uk or log onto www.eta-enclosures.co.uk
Silicone Gaskets now standard on all ETA Stainless Steel Enclosures. Continual investment in product development and improvement now sees the complete line up of T nclosures tainless teel range of free standing cabinets and boxes fitted with ilicone askets as tandard. Most competitors only offer this type of gasket protection on a limited number of their product range. leader in enclosure development and manufacture T is one of the first manufacturers to comprehensively offer this improved sealing gasket which ensures protection to I 6 providing high resistance to various chemicals and extreme weather conditions. This new ilicone asket offers a closed cell structure that is less water absorbing thus providing the very best in protection for critical internal components. For further information request your free copy of our tainless teel solutions brochure by calling 01 0 3 30 or log on to www.eta-enlosures.co.uk
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PECM Issue 23
Product Overview - 2016 Mild Steel
Stainless Steel
Polyester
Aluminium
Boxes
Boxes
Boxes
Out Door Cabinets
Cabinets
Cabinets
Junction Boxes
Desks/Consoles
Desks/Consoles
Suspension Arms
PC Cabinets
Suspension Arms
Out Door Cabinets
Standard | Modified | Special
www.eta-enclosures.co.uk
New auto-apply label improves electronics production continuity
Brady’s new, high performing and highly reliable polyimide label for auto-apply traceability applications offers great accuracy and pick up rate to improve production continuity.
H
ighly reliable
Brady’s B-7727 polyimide auto-apply label has been developed to reduce adhesive bleed risk, a common issue in auto-apply systems. Adhesive bleed may occur in extreme conditions, and can reduce the reliability of an autoapply labelling system to the point of an unplanned production stop. The new auto-apply traceablity label offers a highly reduced adhesive bleed risk and, as a consequence, increased label accuracy and pick-up rate which improves production continuity.
Print and apply on-site
Applications
The B-7727 auto-apply traceability label works seamlessly with the BSPTM61 Print and Apply System, the ALF Label Feeder and other auto-apply systems.
The new B-7727 auto-apply traceability label is great for PCB and pre-process identification in electronics manufacturing.
Together they provide a reliable and flexible on-site traceability solution for high heat applications in manufacturing.
The label resists high temperature applications with extreme washing processes and aggressive cleaning agents and works well with auto-apply systems in both surface mount and through-hole assembly processes. Both top and bottom circuit board placement are possible with the B-7727 white glossy polyimide label.
The B-7727 label is part of Brady’s UltraTempTM Series which now includes 10 polyimide traceability labels with a strong heat resistance. Email Brady at emea_request@bradycorp.com for a sample or product specifications. www.brady.co.uk
Issue 23 PECM
53
SHINE A LIGHT ON SAFE MAINTENANCE E
lectricity at Work egulations , require maintenance of electrical plant and equipment to be carried out with circuits de-energised and locked off. Locking off the circuit which the equipment is connected to, is just one part of the procedure. Before carrying out any work, you must verify that the circuit is dead. Circuits are frequently mislabelled so there is no certainty that the correct circuit is locked off. In some instances where neutrals are borrowed they can become live if an energised load on another circuit is connected to it. To prove dead, it s essential to use a dedicated voltage indicator and a proving unit. The Drummond test lamp from Martindale has been established for many years as one of the easiest ways to prove dead. igh intensity L Ds have now transformed the humble test lamp into one of the most dependable voltage indicators available. uitable for use in bright sunlight and ideal for measurements where access is restricted, the latest Drummond Test Lamps from Martindale lectric, leaders in safe isolation, are the perfect solution for proving dead and ensuring compliance with the lectricity at Work Regulations.
The new generation retain all the existing benefits of the original test lamp with none of the drawbacks. The lighter and tougher designs operate without batteries, ranges or switches, making the Drummond MTL10 the most flexible and simplest way to prove dead before carrying out electrical maintenance.
result of an unwanted inter connection between circuits, or is a potentially harmless phantom voltage due to capacitive coupling. The MTL20 has the capability to simply dissipate induced phantom voltages by presenting a low impedance to the circuit when needed. This achieved by simply pressing the button on each probe. In order to prevent this from being done accidently, both buttons must be depressed at the same time. Clearly if there is any doubt as to whether a voltage indication is hazardous live or interference / phantom after using a low impedance tester then alternative tests should also be performed.
360o indication over 4 voltage levels from 50V to 400V With distinctive bands of L D illumination, gone are the days of using lamp brightness as an indication of voltage level. The latest Drummond Test Lamps provide safe indication for voltages above 50, 100, 200 and 400 volts. The voltage levels allow accurate identification of potentially lethal voltages and enable electrical professionals to distinguish between 110V, 230V and phase to phase voltages in a 3 phase system.
A wide range of its and loc ing o devices available Available separately, or as part of a kit, the MTL10 D and MTL20 D include a proving unit and a combination carry case, ensuring the essential equipment for safe maintenance is always to hand. In addition Martindale lectric offer a complete range of locking off devices for miniature circuit breakers (MCB & RCBOs) and fuse carriers to prevents circuits from being reenergised whilst maintenance is in progress.
The insulated probes are detachable and can be replaced with right angled or straight probes from 3cm to 13cm long which can be rotated and locked in place to improve access in hard to reach measurement locations in crowded cabinets.
Range of detachable probes improve access igh Intensity L D’s transform the test lamp robably the most significant development in test lamp design has been the move to high intensity L Ds, enabling the display of discrete voltages over a 360o viewing angle, even in bright sunlight for the most difficult of applications. The visibility from all angles is unique when compared to conventional two pole testers and makes for safer and easier voltage indication when carrying out safe isolation procedures.
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PECM Issue 23
As a further precautionary measure, the two layer double insulated cable with white inner insulation provides a clear warning of abrasion that might compromise user safety. uitable for use in a variety of applications, the cable is also heat and oil resistant. Troubleshooting phantom voltages For troubleshooting demanding applications, for example, when live voltage indications appear to be present after isolating a circuit, the additional dual impedance functionality of the MTL20 can help get to the bottom of the problem quickly and safely. It s essential to identify if the voltage is hazardous, possibly back-fed, the
MTL20PD safe isolation includes proving unit and carry essential kit for Electricity at Work compliance Find out more: bit.ly safe-isolation-article bit.ly safe-isolation-video
http://martindale-electric.co.uk/
Safe Isolation saves lives Stay safe, prove dead and lock off with Martindale VIPDLOK kits
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Brand Engineering: Your brand is your everything. In a noisy complex world, we need clarity more than ever. With ever shorter attention spans, your business needs to cut through with a succinct, compelling, and unique brand promise: a simple statement of what your brand stands for. Applying lean principles to branding we deliver real commercial value that pervades the organisation from the inside out.
your brand. Everyone involved needs to understand what your brand stands for and what it means to their role. Your brand will bring your people together and help build belief right through the organisation. Engaged employees can often mean the difference between success and failure. STARTING WITH THE RIGHT REASONS LET’S BE CLEAR Branding can have a significant impact on your people, sales, growth and business performance. B2B branding in the engineering space is no different from any other when it comes to communicating effectively. The traditional definition of a brand is a name, sign, or symbol used to identify products or services of the seller(s) and to differentiate them from goods of competitors. It’s clearly not enough anymore to operate with this narrow viewpoint. Your brand is your everything, from your people, products, place of work, your culture through to your tone of voice. All have a cumulative effect on how your customers perceive and experience your brand. It is through these touch points that they build a relationship with you rather just conduct a transaction. BRANDS ARE BUILT FROM THE INSIDE OUT Brands are built on relationships and trust: between your leaders and your people, and between your people, your customers and partners. Your people are
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PECM Issue 23
Starting a branding project includes finding the right reason, commitment, and strategy; analysing brand equity; and uncovering insights and opportunities. Fundamentally, there are two reasons a business needs branding. Either a new product or company has been created or there is a desire to change an existing brand to better reflect new business objectives (most often called a “rebrand”). There must be a solid business reason to change, or refresh, a brand and a brand idea. Without a solid business objective and brand idea, the judging of brand change becomes purely subjective. Suffice it to say, when you embark on a rebrand it is critical to ensure that you are rebranding for the right business reason, and if there is a desire to alter some visual or verbal elements, a clearly defined brand idea is essential for guiding this change.
making tough decisions about the market you are in. Get this clear and your nearly there. Who is it intended for? The more specific and targeted the answer to this question, the better. What is the benefit to customers? A company should be able to articulate clearly, in a few words, the unique aspect that differentiates its product from the competition and provides a benefit to its customers. Start with the right focus: Customers One of the most important first steps in a branding project is to create a framework that identifies and compares all possible interaction points where a customer experiences the brand. Uncover insights and identify opportunities As an agency, the process of creating a new brand or a rebrand always starts with a situation analysis or brand audit. This process can uncover issues that you can exploit to your business advantage. NAMING IS CRUCIAL
Follow these signposts and you won’t go wrong:
Naming is increasingly an important element to a brand’s success. Ideally, a name should be the pure encapsulation of the brand idea and, along with this audacious goal, should meet other key criteria:
Start with the right business strategy
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Good branding cannot save a poor product or business.
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What are we selling? In a very practical sense, selling involves
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We deliver global brand, rebranding and naming projects specifically within the engineering sector. 4P XIFO ZPV OFFE IFMQ UP EFmOF BOE DPNNVOJDBUF ZPVS CSBOE MPDBMMZ PS HMPCBMMZ XF SF IFSF UP UBML ZPVS MBOHVBHF
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www.engineeringclarity.com Issue 23 PECM
57
Energy Efficient Motors Drive Up The Savings At Water Pumping Station To Almost £1/2 Million In Award Winning Project site upgrade at an historic Thames Water pumping station has given the 90 year old facility a new lease of life, improving performance and efficiency. Central to the success of the upgrade were the systems design and implementation capabilities of Boulting Pump Management, using energy efficient motors from WEG. Energy savings expected from the project are close to five million kilowatthours per annum – with a correspondingly spectacular annual energy cost reduction of £500,000.
A
The Littleton facility was designed in the 1920s with four steam powered, 900mm discharge horizontal, double suction, axially split case pumps, together delivering 3.6m at the duty point and each capable of supplying 340 megalitres of water per day. In the 1950s, three pumps were modified with electric motor drives, but very little had been upgraded since.
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PECM Issue 23
Thames Water was keen to implement a project that would improve the efficiency of the station and reduce the energy costs. This long term project uses the financial savings made from improved efficiency to fund more work on other stations. In addition to the improved efficiency, Thames Water also wanted to increase average pump capacity up to 750 megalitres per day, simplify start-up, maintenance and control procedures and reduce operational costs. Remote facility operation To meet these objectives, Thames Water turned to long-standing project upgrade partner the Boulting Group. Along with improved performance, some of the specific project requirements
included remote operation through an automated control system – minimising on-site personnel time which was making operation of the facility time consuming and costly. The Pump Management division of Boulting took a holistic approach to the project, looking at upgrades to the pumps, motors, gearboxes, drives and switchgear. A new control system would also be developed to simplify operation as well as reduce energy consumption and enable remote operation. A key aspect of the project identified by Boulting was the upgrade of the existing motors and to address this aspect of the upgrade the company turned to WEG. Boulting has an excellent working relationship with WEG, having worked with the company for two years on various projects to replace older, less efficient motors with newer high efficiency models.
In that time, WEG has supplied Boulting with over 100 motors, rated from 55 kW up to 900 kW. Many of these have been from the W22 range, which covers frame sizes from IEC 63 to 355A/B and can deliver between 0.12 and 500 kW; offering high levels of productivity and reliability in an industry that requires minimal downtime. For more specialist applications, the W22 range can supplied with increased levels of ingress protection, up to IP66, as well as being specified for operation in potentially explosive atmospheres. For this particular project, WEG supplied three W50 IE4 super premium efficiency motors as the most efficient solution for the pump drives. Operating at 96.9% efficiency, they can play a key role in significantly reducing energy costs at water pumping facilities. At the same time, the robust, reliable design also helps to reduce operational costs, minimise downtime and drive up operational reliability.
Improved pump station performance With new pump impellers, gearboxes, drives and the WEG motors – all being 900 kW motors with IP55 protection – the facility has been upgraded from its existing 400 megalitres per day capacity to 750 megalitres per day, with an efficiency increase from 80% to 86%. Suction lift capacity has also been increased from 3.6m to 3.9m. Control of the plant is facilitated by new Boulting-designed pump system operation (PSOp) software, implemented on a SCADA system and local PLCs. The PSOp software continuously monitors and optimises pump speed to achieve the required performance and greatest energy efficiency, running the number of pumps that are required at any given time and at the optimum speed. The control software has improved operation of the plant significantly. For example, in conjunction with some mechanical modifications, the priming time has been reduced from a stately four hours to a significantly swifter five minutes. At the same time, the capability for remote operation means there is no longer the requirement to start up the system and operate the facility on site, eliminating a number of time consuming operations. Innovative solution With its improved efficiency and reliability, Littleton pumping station has been transformed into one of the most modern and innovative in the UK. At the same time, Boulting Pump Management was keen to
address the aesthetics of the project, so that as much of the original character of the facility as possible was retained. This approach and the resulting improvements led to the company being awarded the Pump Centre Project of the Year award 2015.
Boulting was able to complete the upgrade in almost half the anticipated time scale, delivering what Thames Water had expected to be a two year upgrade in just 13 months. Most importantly, thanks to Boulting's innovative design and WEG's energy efficient motors, the upgrade has delivered on all of the performance objectives, driving energy savings in excess of 4.9 million kilowatt hours with associated cost savings in the order of £½ million, which will go towards the next round of refurbishment projects.
A global major in the power distribution, automation and control sectors, WEG has just celebrated its 50th birthday. www.weg.net
Facilities Management
Highly Chemically Resistant Lining for Ineos Salt Owner: Ineos Salt, Runcorn Specialist Contractor: Thelwell Flooring Limited Materials Consultants: NCC Products Used: Atako ATB-300 RC System Contact: David Mackay Tel: 01257 266696 Website: www.bundlining.co.uk
I
neos Salt is the UK’s largest manufacturer of vacuum salt based products, which are all produced at their dedicated plant in Runcorn, Cheshire. These salt products include domestic and catering food salts, water softening salts, animal feed salts, de-icing salts, and salts for use in many other different industrial and chemical processes. The plant engineers were building a new reinforced concrete chemical storage tank farm as a secure secondary containment and ground water protection area. They wanted a highly chemically resistant lining system to protect all of the horizontal and vertical concrete surfaces from any possible salt penetration and also to resist all of the many other different chemicals that could be stored in the tanks for use in the wide range of Ineos production processes.
Applying ATB-300 Vinyl Ester Resin Flooring System for Chemical Containment Areas at Inneos Salt
NCC also work with many different Process Engineering industries every day, all around the UK and ROI, enabling our customers to obtain solutions to complex problems in bund and containment area lining (primary and secondary), resin flooring, tanking and concrete repairs on both new and refurbishment projects.
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NCC working as Materials Consultant and Distributors to the specialist contractors, Thelwell Flooring Limited was able to define and then successfully and durably meet all of the project requirements using the Atako ATB-300 RC System. This extremely resistant vinyl ester resin based coating system was applied to all of the prepared horizontal and vertical concrete surfaces, including the floor and walls, plus all of the plinths and upstands in the whole of the new bunded secondary containment area for the tank farm. The special vinyl ester resins that are used for the ATB-300 RC System provide extremely high resistance to a wide range of aggressive materials, and also provide very good mechanical resistance to abrasion and wear, including at both high and low temperatures.
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PECM Issue 23
Quick installation | Flexible product ranges | Spot cooling | Mobile products available | Retrofit to existing AHU intake |
Proven Technology Over 3500 installations worldwide | Case studies online | Clients include: Cummins Diesel, Decathalon, Diageo, Premier Foods, Nestle, Borg Warner Turbo Systems, Rolls Royce, Net-a Porter |
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ALCA Fasteners have been at the forefront of the European, Scandinavian and Global Fastener Industry since our foundation in 1977.
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C asteners supply high integrity bolting to the oil & gas industry, along with the ind Power, Nuclear, Construction and Renewable and many more industries throughout the world.
e are also fully e perienced in independent certiďŹ cation to N , loyds, etc
e have continued to draw on our e periences and evolve the company with continual improvement programmes to meet the increased demands for quality and inspection levels that have been implemented by the various industries.
Tel: +44 (0)121 526 6010 Fax: +44 (0)121 526 6397 Email: sales@alcafasteners.co.uk www.alcafasteners.co.uk
Over the last 5 years we have invested heavily in new machinery to allow C to take control over many processes in house, this enables C to machine components from M2 up to M120. Our next major project is the installation of a real time scanning process system- this will give us the ability to pinpoint any order at any stage of production. C asteners are in an e tremely strong position to supply the demanding and fast moving fastener market stocking all grades of material, including steels, stainless and exotic grades enabling us to supply high integrity products in all head formations and to help us meet your delivery times C ENE carry over , tonnes of either ďŹ nished or semi-ďŹ nished blank stock in either e agon, ocket or Countersunk along with studding and bar of our stock is certiďŹ ed to EN102043.1
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C are also conscious of moving further towards supplying predominantly European teel
With ALCA FASTENERS Itâ&#x20AC;&#x2122;s Guaranteed ed With ALCA FASTENERS Itâ&#x20AC;&#x2122;s Guaranteed ed
+44 +44 (0) (0) 121 121 526 526 6010 6010
Stockists Stockists of of over over 2000 2000 tonnes tonnes of of high high grade grade fasteners fasteners in in ... ... 4 4
LARGE diameter finished bolts and LARGE diameter finished bolts and semi-finished hexagon and socket blanks semi-finished hexagon and socket blanks
4 4 4 4
Grades 8.8,10.9,12.9 and B7/L7 Grades 8.8,10.9,12.9 and B7/L7
4 4 4 4 4 4 4 4
Suppliers to a wide range of global sectors Suppliers to a wide range of global sectors
Manufacturers in all exotic materials Manufacturers in all exotic materials in all diameters in all diameters
Full in house testing facility including 100% MPI Full in house testing facility including 100% MPI All plating finishes carried out All plating finishes carried out Can be certified to BE EN 10204 3.1 and 3.2 2 Can be certified to BE EN 10204 3.1 and 3.2 2
Visit our new website Visit our new website
www.alcafasteners.co.uk www.alcafasteners.co.uk to see what to see FASTENERS what ALCA ALCA FASTENERS can supply to you ... can supply to you ... E-mail sales@alcafasteners.co.uk E-mail sales@alcafasteners.co.uk
New Innovation from Colex International Limited
NeuVend SI Tap Tail
NeuVend SI
C
80% of Colex product is bespoke, so they have a wealth of experience in designing and manufacturing hose to meet your specific requirements.
olex International Ltd. is a UK company with over 20 years’ experience in the manufacture of high quality hoses and tubes. With an excellent reputation for forward thinking, innovation & new product development, Colex has added a number of new lines to their portfolio to meet the ever increasing demands of the market. e a ex is the next generation dual containment hose system, offering all the benefits of existing products but in a smaller, lighter and more manageable format. The durable PU outer is stable and offers excellent clarity for visual inspection. Inner hoses are available in reinforced PVC, Vendhose and NeuVend™. e e is a triple layer hose with added antimicrobial protection. It has been designed for critical applications where there is an enhanced risk to human health from microbial organisms within
Protectaflex
the potable water supply system.
these Tap Tails to exactly suit your requirement.
e e is suitable for use in all potable water supply applications especially where the additional Biomaster Antimicrobial Protection properties are critical, such as, hospitals, dental clinics, nursing and care homes, HVAC, aviation & leisure.
al l e T e offers all of the benefits of standard silicone, with added antimicrobial protection. pecifically engineered for applications where bacteria control is required, antimicrobial silicone provides prolonged and effective protection against bacteria such as MRSA and E.coli.
e e e Flex le Ta Tails are comprised of NeuVend SI™ Liner overbraided with stainless steel and fi ed on both ends with the re uired fitting he NeuVend SI™ liner itself is manufactured from a blend of polyolefin based materials lined with smooth polyethylene internal surface all containing a Biomaster antimicrobial additive. The NeuVend SI™ liner combined with stainless steel over braiding results in a Tap Tail that has e cellent fle ural and working pressure properties. Available in a variety of lengths with a number of different fittings, Cole can make
In addition Colex also manufactures a range of stock products including, nylon, PVC and polyurethane hoses & tubes plus a range of PTFE and Silicone. 80% of Colex product is bespoke, so they have a wealth of experience in designing and manufacturing hose to meet your specific requirements. Please visit lex for more information about all of Colex Internationals products and services or email ale lex to enquire about products.
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Need an innovative solution to knock out your level control problems? M
agnetrol® offers best-in-class radar instrumentation that packs a powerful punch Eclipse® uided ave adar and Pulsar® odel Non Contact adar transmitters provide measurement performance that far e ceeds traditional level control technologies rom very light hydrocarbons to water based media, NE radar instrumentation is versatile enough to handle a wide range of processing applications adar technology has revolutioni ed level measurement in a variety of process industries since the introduction of - m loop powered, radar-based transmitters in the s oth guided wave radar and non-contact radar have numerous advantages over older, more established level measurement technologies oth guided wave radar and non-contact radar have the same general principle of operation microwave time of flight and no moving parts ecause of this, users can retrofit these radar transmitters into various process applications and see improvement in e ciency and accuracy, including applications that use these technologies Ps, due to shifts, installation cost, and leak points uoyancy, due to shifts, moving parts, calibration issues, and cost Capacitance, due to cumbersome calibration, dielectric shifts, and coating issues ltrasonics, due to vapor effects, turbulence, and foam uided wave radar and non-contact radar are related technologies, and together they are a powerful combination that can cover the ma ority of your continuous level control needs very similar user interface and uick disconnect electronics means that, if you know how to use one, you ll know how to use the other or more information on both guided wave radar and non-contact radar level control technologies, check out radar.magnetrol.com
The Radar Punch
Magnetrol
ÂŽ
Total Radar Solutions Count on best-in-class Guided Wave Radar and Non-Contact Radar performance â&#x20AC;&#x201C; to knock out all of your level control application challenges.
radar.magnetrol.com
k
Š 2016 Magnetrol International, Incorporated
NSK bearings prove reliable in bucket-wheel excavator
he selection of NSK spherical rolling bearings in one of the world’s largest bucket-wheel excavators has proven to be an astute decision. Despite six years of heavy duty operation at RWE Power’s opencast mine in Hambach, Germany, the bearings are still going strong – without any relubrication.
The idea of using NSK bearings was driven by the need to reduce maintenance costs on the mine’s largest machines. Excavator 290, which is 240m long, 40m wide, 100m high and 14,000 tonnes in weight, has been in service since the end of the 1970s.
NSK spherical rolling bearings have been operating for six years in Excavator 290 without relubrication
With this in mind, the RWE Power product managers responsible for the conveyor belt drums set up a pilot project that involved installing a sealed, dual row NSK spherical roller bearing with tapered bore inside the drive drum of belt 2 on Excavator 290.
T
Every day, ‘Excavator 290‘ at the Hambach mine moves up to 240,000 tonnes of coal or, using its 130-tonne bucket-wheel, excavates large volumes of overburden which is then transported to a spreader on conveyor belts in its upper structure. The four central conveyor belts located here have to work hard, not only due to the volume of material transported, but because they operate 24/7 in an adverse environment heavy with dust and moisture. This is where two NSK spherical rolling bearings are helping the mine operator maximise the operational uptime of Excavator 290.
Sealed, dual row NSK spherical roller bearing with tapered bores are fitted to RWE Power’s excavator conveyors The bearing, which has an external diameter of 500mm and a shaft diameter of 300mm, was then replaced at the scheduled time. Inspection of the removed bearing revealed that it was in excellent condition despite having been subject to continuous, intensive use. This provided RWE Power with the confidence to adopt NSK’s spherical rolling bearing technology, a move that has been rewarded with excellent service – with zero maintenance – for the past six years. Among the reasons for this high level of performance is the efficiency of the seals, the high quality grease used by NSK, plus the Super-TF (STF) raw material used for the bearing. STF is a carbonitrate steel that is subjected to a specific heat treatment that helps retain optimum levels of austenite content. STF bearings have twice the service life in comparison with conventional roller bearing steels with clean lubricant, and where there are contaminants in the grease, bearing life can be increased as much as ten-fold. www.nskeurope.com
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Gears, Drives & Motors
Machining Chain Company Triples Capacity to Meet Demand onghua imited announces their relocation to a new building three and a half times the size of their previous facilities, to meet the growing demand for their products.
Manufacturer of High Quality
he arm of one of the world s largest chain manufacturers has been established in the since 2009, doubling its turnover year on year to establish itself as one of the leading chain suppliers in the country ocated in olverhampton in the heart of the idland s historic chain industry, Donghua has moved to a larger building on the same industrial park which has minimised disruption for their customers. ob ellsbury, managing director, of onghua imited e plained his move heralds a new chapter for the team and is a direct response to the continued interest from customers in our range of quality chain products. One of our biggest strengths is we only sell to Distribution and OEMs and do not supply direct to end-users, unlike other manufacturers.â&#x20AC;? n additional, larger arde storage shuttle unit which holds half a tonne per tray has been installed alongside two existing vertical shuttle units, enabling Donghua to improve the storage and retrieval of small chain components.
Anti Vibration Products
Email: sales@fibet.co.uk Visit: www.fibet.co.uk | Tel: 01282 878200
he technical orkshop, where Universal Attachment Chain and Bespoke Chain is assembled, is housed in a dedicated area of the building which has been further enhanced with the addition of e uipment to wash old lubrication oďŹ&#x20AC; chain before re-lubrication or inspection, plus an etching machine for sprockets. Further developments are planned for 2017. For more information visit a or call 01902
66 200
a
, email sales@
Issue 23 PECM
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iwis – Specialist Industrial Chain Applications iwis has has many many years years experience experience in in development development and and manumanuiwis facturing of of high high precision precision chains chains for for automotive, automotive, agricultural agricultural facturing and specialist specialist equipment equipment producers, producers, with with many many respected respected and “blue chip” chip” manufacturers manufacturers using using our our products. products. “blue
Our excellence excellence in in quality, quality, innovation innovation and and resource resource lies lies unparunparOur alleled within within the the industry industry and and many many manufacturers manufacturers rely rely on on alleled our products products to to surpass surpass expectation expectation and and fulfil fulfil arduous arduous and and our precise operations. operations. precise
iwis Product range
å SSimplex implex & & Duplex Duplex Spike Spike Chains Chains for for å thermoform equipment. equipment. thermoform å SSimplex implex & & Duplex Duplex Grip Grip chains chains for for film film å and tray tray sealing sealing equipment. equipment. and å EExtended xtended pin pin chains chains for for packaging packaging å and carton carton erecting erecting machinery. machinery. and
å LLubrication ubrication free free chains chains (Megalife) (Megalife) å for high high speed speed applications applications giving giving for additional service service life. life. additional
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For more more information, information, contact contact us: us: For
iwis drive drive systems systems Ltd. Ltd. // Unit Unit 8c 8c Bloomfield Bloomfield Park Park // Bloomfield Bloomfield Road, Road, Tipton Tipton // West West Midlands, Midlands, DY4 DY4 9AP 9AP iwis Tel. +44 +44 121 121 5213600 5213600 // Fax Fax +44 +44 121 121 5200822 5200822 // salesuk@iwis.com salesuk@iwis.com Tel.
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PECM Issue 23
www.iwis.com
ESG Water Treatment Services n the food and drink industry, one of the most important responsibilities is to maintain high levels of sanitation throughout the production process. For organisations that bottle beverages, water treatment is a fundamental part of any effective hygiene regime and there are stringent health and safety standards which need to be met.
I
Historically, organisations have used biocidal products which are based on chemicals such as chlorine, bromine or iodine, to disinfect water systems. However, concerns over their impact on product quality and the environment have led to the development of sanitation methods that donâ&#x20AC;&#x2122;t rely on halogen-based chemical disinfectants. These are being increasingly utilised by the worldâ&#x20AC;&#x2122;s leading drink producers. Cleaner technologies One such treatment method, which holds a number of benefits for bottlers, involves the use of ozone as a disinfection agent. When dissolved in water, ozone produces an extremely powerful and environmentally friendly biocide through
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oxidisation, capable of eliminating bacteria, viruses and microbial cysts.
Unlike other disinfectants, ozone does not combine with organic materials to create chemical by-products or residues during the sanitation process. In addition, the substance naturally breaks down into oxygen once contaminants have been removed, resulting in minimal product interference. Resource efficiency is another key advantage that comes with the ozonated water as, instead of being flushed away, it can be reclaimed and used countless times. Despite this, the substance is over 50 times more reactive than chlorine, the more traditional alternative, making it a highly efficient disinfection agent. Leading the way One major company, currently making the most of this advanced, non-conventional water treatment technology, is Coca-Cola HBC Ireland and Northern Ireland.
As one of the largest bottlers in Ireland, the business produces a range of beverages for the island of Ireland from its production plant in Lisburn, County Antrim. With a heavy focus on sustainability, Coca-Cola HBC was recently named global beverage industry in sustainability for the 3rd consecutive year according to Dow Jones Sustainability Indices (DJSI). The local business contributes to these results, with ambitious local targets across water, carbon and waste to help the Group achieve these global accreditations. Coca-Cola HBC places a high importance on water stewardship in its operations, making use of local fresh water for its production and cleaning processes. Regular risk assessments are conducted at the plant, and the business aims to ensure that all water is returned to the natural environment in a condition that supports aquatic life. In addition to its environmentally friendly focus, CocaCola HBC commits itself to high internal efficiency standards, incorporating water saving technologies into its production lines and setting its teams stringent targets to meet.
Before they are filled, all receptacles going through the plant are washed in line with international food safety management standards, such as ISO 22000. With this in mind, Coca-Cola HBC needed a water treatment system that did not rely on the use of halogen-based disinfectants and was specifically designed to ensure minimal disruption to operations. Bringing ESG on board Over the last 15 years, ESG, the UK’s leading testing, inspection and compliance company, has been working with CocaCola HBC Ireland and Northern Ireland, maintaining a range of ozone water treatment equipment at its production plant in County Antrim. Two OCS 100 water disinfection units installed in the plant currently provide Coca-Cola HBC with ozonised, reclaimable water on two bottle washing lines. These highly reliable devices use state of the art technology which results in minimal oxygen demand and energy consumption. Since the contract began in 2002, ESG’s water treatment team, which specialises
in non-chemical disinfection methods, has been carrying out regular, quarterly maintenance of the ozone systems, helping ensure uninterrupted operations within the plant. Having been impressed by ESG’s maintenance services over the years, Coca-Cola HBC has made several advancements on its original contract, the most recent of which being the purchase of a remote monitoring and control option. The new upgrade to the ozone equipment allows ESG to remotely access the system from any location and make alterations to the programming from offsite. By using the machines, the company is also able to save around 50 litres of cooling water for every minute of operation. Mick Pratt, commercial director, ESG, commented: “Over the last 15 years, ESG has worked with Coca-Cola HBC Ireland and Northern Ireland to ensure a smooth and reliable service. The recent upgrade means the Water Treatment Team can login to the units from ESG’s office in Thame, Oxfordshire, and monitor the system in real time, making any changes instantly and remotely if required. “Due to the highly dependable nature of the equipment, ESG hasn’t had a call out to conduct emergency maintenance on
the system in over two years. Even so, its service engineers are always at the end of a phone if any issues need to be resolved and can be on site to provide support within hours of a call. Jim McCambley, engineering services manager, Coca-Cola HBC, added: “We were very proud to be recently named beverage leader in sustainability for a third consecutive year, and locally we are pleased to say that our efforts have contributed to these results. “In our Lisburn plant, we have reduced water usage by 13% over the last five years and are on track to achieve our 2020 commitments in this area. With our advanced water treatment system, we have complete assurance that products are sanitised in the most efficient and effective manner, without the need to use any halogen-based biocides. As the machines use reclaimable water for their cooling systems, this helps us to minimise consumption and continually achieve these internal targets.” For more information about ESG’s water treatment services, visit www.esg.co.uk/ our-services/built-environment/ water-management www.esg.co.uk
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VERSADRIVETM IMPACTA-DRILLTAPS M5-M12
VERSADRIVETM CARBIDEMAX TCT HOLESAWS WITH COUNTERSINK
VERSADRIVETM CARBIDEMAX TCT HOLESAW
“CUTTING TOOL INNOVATION SPEED UP METALWORKING”
Holemaker Technology HoleMaker Technology (HMT) manufacture and distribute cutting tools for improved metal working and fabrication. The revolutionary HMT product range is creating a buzz in the market with innovative design plus endurance and speed advantages over traditional methods.HMT was founded in late 2013 by brothers, Piers, and Hugh Crane and now has a network of over 100 resellers in the UK and Europe. Director Piers Crane said... “My brother and I have been involved in the metalworking and industrial supply marketplace for a combined 18 years, and we kept being asked for products that simply were not available. Overwhelmingly, these requests were about making or modifying the holes that connect metal components together. Following intensive market research, we launched HMT dedicated to this area, with the vision to be the leading brand of fabricators cutting tools”.
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“Agencies like Growthaccelerator and MAS (Manufacturing Advisory Service) have really helped us in practical areas like CAD tool design as well as grant funding for the R&D projects.”
In addition to the new Versadrive products, the HMT product range also has three main pillars which are Fabrication Reamers, CarbideMax TCT Broaching Cutters, and Impact Tapping products.
Latest HMT products include the groundbreaking VersaDrive Cutting tool range optimised for use with both portable site tools as well as workshop equipment. Versadrive tools are specially hardened and coated to give up to 6X the working life of traditional cutting tools and are designed to work with the linear torque of a standard impact wrench, as well as rotary power tools.
Business Development Manager Hugh Crane explains – “the great thing about the Versadrive cutting tools is, the guy on site or in the workshop, can use this product in any drill with a chuck, or quickly slot it into an impact wrench, magnet drill, or pillar drill when the job changes.”
This gives increased safety as well as speed, resulting in better value for the customer. For dealers, the Versadrive system allows them to sell one stock item for multiple applications, allowing a lower overall stockholding. For example, the Versadrive ImpactaTap can be used as a hand tap or machine tap as well as an Impact Tap.
support is very important “ Technical to HMT; we believe in helping the end user optimise the tool’s performance. So we’re actively promoting best practice and safe working with video demonstrations, digital user instructions, and training visits.
”
“It’s brilliant to be working with some of the great names of British industry like BAE Systems, Cammell Laird, and Portakabin.” www.holemaker-technology.com
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Sulzer is the leading worldwide, independent service provider for large rotating equipment.
Only The Best For Colombian Generator Repair esigning and manufacturing high voltage coils for large generators and motors requires precision, experience and sometimes, a little assistance from a similarly skilled company. So, when a Colombian coil manufacturer needed to outsource a complete set of new windings it approached Sulzer. The redesigned coils received the greatest compliment and the customer stated that they were the best quality coils they had ever seen and installed.
D
M&M Bobinados Industriales has over 45 years' experience in providing a complete refurbishment service for generators and electric motors, including the replacement and subsequent testing of new windings.
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PECM Issue 23
Based in Valle del Cauca, Colombia, the company offers a complete service for generator and motor repairs including balancing and electrical testing.
As part of a recent project, M&M called on the design and manufacturing expertise of Sulzer's Service Center in Birmingham, UK, to produce 160 new, large coils for an 11,000 kVA generator. Benny Hinchliffe, Head of International Operations at Sulzer UK, explains: "Our coil shop is supported by an expert design team that can analyze the original coil design and apply the latest insulation
technology to produce a much more efficient coil. In this case M&M completed one of our datasheets and also sent one of the original coils to the UK so we could double-check every dimension." Having ascertained the required dimensions of the finished coil, Sulzer's designers created a 3D computer model of the coil and, by introducing the latest insulation materials, were able to redesign the coil while increasing the volume of copper by 12%. This increase in copper effectively improved the efficiency of the generator by a similar figure. The new design was also created for a 'best-fit' which would eliminate the need for side packers in the stator slots, making installation quicker and easier.
The coil shop uses its own in-house facilities to draw and anneal the base copper before manufacturing the insulated copper strips. This enables very short production schedules, especially since the shop runs 24 hour shifts, if necessary, and new coils are air-freighted to the customer after passing all of the inspections and electrical tests. Danny Fox, Business Manager, Formed Coil Manufacturing at Sulzer, explains: "The new coils for M&M were created by looping the copper strip to form a full size coil. It was then carefully shaped to the exact dimensions of the stator. Our looping machines have the capacity to produce 5 meter long diamond coils and we also have the capacity to press slot sections of up to 6 meters in length on our half bars, meaning the entire bar length
can be anything up to 7-8 meters including their overhangs." "A high degree of automation and the continuous quality control checks throughout the processes ensure that each and every coil is formed to exactly the right size and shape. The design also includes a precision-built mock-up of a section of the stator, which is used to double-check the final fit of every coil before it is shipped to the client." Ulises Osuna, Technical Manager for M&M Bobinados Industriales, commented: "We have been involved with the manufacture and installation of high voltage coils for over 45 years and the coils we received from Sulzer were the best coils we have ever installed. The improvements in the design have certainly reduced the installation time as well as improving the
efficiency of the generator, which makes the coils very cost effective for the client."
Following this project, Sulzer is hoping to work closely with M&M and provide technical expertise as well as manufacturing capacity to the Colombian market. At last year's ACOLGEN exhibition, which was organized by the Colombian Association of Electric Power Generators, Sulzer and M&M shared a stand in order to promote the benefits of this partnership. In this way, it is anticipated that other clients can also benefit from the turnkey services offered by both Sulzer and M&M, including faster delivery times. www.sulzer.com
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Machining New Double Pulse MIG Welder from Jasic New from Global Welding Manufacturer Jasic, the Pro MIG 350P Multi Process Separate is an IGBT inverter designed for industrial use in MIG/MAG, pulse, double pulse and DC MMA processes. DSP digital technology provides optimum welding performance as well as featuring easy parameter settings for the operator. This model offers an abundance of features; synergic control with pre-programming of common materials and wire diameters for time saving as well as self-diagnostic protection systems for extreme reliability. This 3 phase inverter offers 350 Amps at 60% duty cycle. The package includes power source, wire feed unit, 2m interconnecting cable, trolley, water cooler, MIG torch, earth return & gas regulator. Free product demonstrations are available through authorised Jasic Distributors Readily available through Jasic UK equipment distributors, this machine is supported by a 5 year warranty when registered at jasic.co.uk. Wilkinson Star Limited is the Sole UK Importer of Jasic Welding and Industrial equipment. Tel: 0161 793 8127
Simple belt conveyors becoming obsolete Roy Fowler and his international company UPM Conveyors have updated their conveyor technology and processes to suit the changing market. According to the company’s MD, simpler, traditional belt conveyors are becoming more and more obsolete as bespoke engineered solutions become necessary due to shifts in the industry. The conveyor expert has witnessed the change where processors require more integration of belt conveyors into fully automatic cells incorporating product orientation; singulation and counting prior to presentation to assembly machines. “The days of offering a simple belt conveyor to transfer parts from the moulding machine to a stillage have virtually disappeared,” claims Fowler. As a result, UPM have established a product testing area in conjunction with 3D software to simulate the customer’s production environment. This advancement works to prove the viability of a solution and allows UPM to offer a Performance Guarantee based on equipment performing to the agreed specification. In the event of any issues arising, UPM then supply labour and parts to remedy the situation free of charge.
www.upmconveyors.co.uk
Demand for off-site construction continues to increase in the UK’s manufacturing sector
Plastic vs Metal – 5 reasons to switch to Plastic
The Portakabin Group is seeing a significant rise in demand for buildings in the manufacturing sector as more organisations look to expand their facilities using off-site construction. The Group’s latest project constructed using its Yorkon off-site solutions is for Totally Wicked – the first purpose-designed fluid production and technical facility for electronic cigarettes to be built in the UK.
5 REASONS TO SWITCH TO PLASTIC
The scheme has increased the company’s capacity to over 10 million bottles of premium quality e-liquid every year for the UK, USA and worldwide markets. The facility was constructed off site to radically shorten the programme time and reduce disruption to the local community and to the company’s existing operations on the Totally Wicked site in Blackburn. Finished in anthracite grey with striking chilli red stripes to reflect Totally Wicked’s strong corporae image, the scheme accommodates a new production facility on the ground floor, complete with test room, fluid mixing area, bottling plant and a highly insulated cold room. New offices are located on the upper floor.
Email: info@yorkon.co.uk
www.yorkon.co.uk
More OEM’s are looking to reduce the weight of components but still maintain their performance. This combined with a reduction in cost means plastic can be an attractive alternative to metal… 1. Weight reduction 2. Cost reduction 3. Additives can be built into the plastic, from anti-microbial agents, colour pigments, flame retardants, to fluorescent additives. 4. Meeting the political and economic demand for better fuel economy and lower emission levels on automotive parts 5. 100% Recycled material moulding options
Tel: 0121 520 8387 Email: mbrazier@counterplas.co.uk www.counterplas.co.uk
Health & Safety BPE opens new office in the North
Leading chemical and biochemical engineering design company BPE has opened a new office in the North West. The Cheshire office, headed up by regional operations manager Jon McGeehan, brings BPE closer to some of its existing clients in the North, which include Fujifilm Diosynth, Kerry Foods and Sanofi. Managing director Mike Brown said the area’s thriving manufacturing sector, particularly its specialisms in pharmaceutical and chemical production, was a factor in BPE’s decision to open up at the Sci-Tech campus in Daresbury. BPE has been helping manufacturers make their processes safer and more efficient since 1997. It offers a full range of process engineering services, including process modelling, process safety, project management and process development/scale-up support.
Tel: 01962 717070 Email: enquiries@bpe-ds.com www.bpe-ds.com
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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
TRENDS IN MICROSCOPY
GT
ision is the UK’s largest independent microscope supplier and manufacturer with over 20,000 microscope installations across the UK alone. With this experience of products from all major manufacturers and a program of rigorous microscope and camera testing, we have a unique insight into the latest trends in microscopy and camera technology. There are two optical methods of obtaining images of features at high magnification, one is to use a conventional microscope and add a camera to it and the other is to use a digital microscope which is a microscope with the camera built-in. Both methods have their advantages and disadvantages a few of which are outlined below. d anta es o addin
a camera to a microscope:
1) All the features of the microscope are preserved. For example, the 3D visual image delivered by a stereo microscope, essential for many inspection, assembly and repair tasks. 2) You can select the best camera for the job and one that fits your budget. Example important choices are a. Image output eg USB, HDMI, WiFi or SD. b. Image resolution to 1.3- 0 MP. c. You can select a camera that is supplied or compatible with the best software for your job. d. You can select a camera with the best quality sensor (incredibly important for image quality and often overlooked). e. You may want to attach a camera with a built-in screen, SD card storage and optionally a USB output to the computer. (These cameras, once seen, are by far, the camera of choice in our experience. 0% of all cameras GT ision have supplied in the last 1 months have been this type, the image quality is simply stunning). 3) You can change the camera when the technology is outdated, without having to change the entire microscope. i ital microscopes ad anta es:
a e a di erent set o
1) Many basic types are very low cost. Some are semi-portable i.e. handheld but nearly all are still tethered’ by the USB lead. 3 They are all-in-one’ and therefore appealing and simple to use. With good manufacturers this is an advantage because the quality of the optics is maintained and
High Speed USB3 Microscopy Camera
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PECM Issue 23
A Portable Digital Microscope
Monozoom Microscope with WiFi camera
the quality of the built-in camera is also reasonable – for cheaper makes this absolutely is not the case 4) Very few are truly portable, untethered and with batteries. T e reatest disad anta es o di ital microscopes are: 1) Unable to upgrade the camera when out of date or unsupported. 2) The quality and functionality of the optics often can be rather limiting. 3) The choice of stands and illumination, in many cases is a choice of one stand and one type of illumination. ut or: ob Town ana in irector T www. t ision.co.uk
ision td
Camera with built-in display & measurement software ‘GXCAM HiCHrome MET’
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The VEGA Controls team just after completing their 40 miles. From left: Doug Anderson, Ray Tregale, Agnieszka Sielaszuk, Tom Foreman, Matt Westgate and Peter Lewis
VEGA team steps up to the Plod Challenge! O
n the 16th July, staďŹ&#x20AC; from EGA Controls took part in T e out owns lod a 0 mile 6 m ni t and day hike across The South Downs of England, from Devils Dyke, North West of Brighton to Beachy Head, Eastbourne. It involved a team of 6 navigating and walking through the night and ďŹ nishing the following day on Sunday 17th July, via a series of check points along the way. The event was to raise funds for Action Medical Research, a childrenâ&#x20AC;&#x2122;s medical charity.
The Plodâ&#x20AC;&#x2122; started at midnight on a (thankfully) warm and dry summers evening, the EGA team Challenge 6 â&#x20AC;&#x2122; set oďŹ&#x20AC; amongst a tide of head-
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torch lights with almost 300 walkers involved. However, along with the 6 walkers from EGA participating in the event, there was also an indispensable EGA support crew who worked in shifts through the night to rendezvous at the check points all along the route. They were the unsung heroesâ&#x20AC;&#x2122;, providing sustenance, support and plasters The hike went very well, with team Challenge 6 â&#x20AC;&#x2122; completing the course in a very respectable14 ž hours. There were a few blisters and a bit of sunburn, especially from the last stages across Seven Sisters and Burling Gap â&#x20AC;&#x153;It was a great achievement, experience and team building event, not just for the team doing the walk and their support crew, the whole company got behind usâ&#x20AC;?. Said Ray Tregale, Managing Director of EGA Controls. The challenge was in aid of Action Medical Research for children, you can ďŹ nd out more about their fantastic work on their website. Fundraising donations came from all areas of the company, staďŹ&#x20AC;, family and friends, suppliers and customers, fundraising events - including a cream tea day where 200 cream teas were distributed on behalf of EGA by AMR, enjoyed
across the country in oďŹ&#x192;ces and homes on special EGA yellow picnic cloths You can still donate, www.action. or .uk sponsor e acontrols t e pa e will be open until t e 15t ctober. ter w ic one luck donator will be drawn to win a 2 t i addin ton ear w o is currentl celebratin 0 ears o bein t e mascot o ction Medical Research! Ray concluded, â&#x20AC;&#x153;On behalf of the EGA team and company, we would like to express our deepest thanks to all those who donated and supported us, and with a total currently approaching ÂŁ4000, all the money raised has gone to a great cause.â&#x20AC;?
Dust and buildup on the antenna? No problem! The future is 80 GHz: a new generation of radar level sensors
VEGAPULSÂ 69 is designed specifically for level measurement of bulk solids. Even in dusty conditions, it always provides precise readings. Dust in the silo or buildup on the antenna have no effect. This radar sensor also features unrivalled focusing at a frequency of 80Â GHz. Simply world-class! www.vega.com/radar
Improving Process Accuracy with Metrohm Process Analytics
Metrohm Process Analytics offers a range of off the shelf and bespoke Process Analysers that automatically sample and analyse direct from your process.
M
etrohm Process Analytics offers a range of off the shelf and bespoke Process Analysers that automatically sample and analyse direct from your process. Many processes operate within tightly defined limits for parameters such as weight, temperature, pH, or more unique parameters; as examples, Acid concentration in an etching solution, Nickel concentration in a plating bath, moisture levels in reactive drawing oils… Often control of these parameters is critical to maintain product and process specifications to achieve optimal product quality and consistency. Deviation of these parameters from target can negatively impact on product quality and/or lead to excessive operating costs, e.g excess chemical consumption, reduced throughput, lower yield….. Processes that rely on any analytical measurement to maintain the process near to an operating target and within an operating window will be accurate dependant on: The analytical instrument employed SEP Error of sampling from the process and any manual manipulations of the sample Frequency of analysis Process variation error
Moving from the laboratory to a process analyser allows you to run production much closer to your operating target giving increased yield, improved final product quality and consistency. All this leads to increased profit margins and less out of conformance product. Also by reducing the process/product variation can mean product specification can be tightened giving a competitive advantage and/or higher value product versus the competition. Because process analysers remove the manual sampling from a process, there is a clear safety advantage. Moving to a process analyser fully removes the risk associated with taking samples that are: under pressure, at elevated temperature, toxic, corrosive, sensitising, noxious, carcinogenic, harmful, and unpleasant. Metrohm Process Analytics has experience designing and integrating Process analysers for many industries and applications. Metrohm Process Analysers operate on the methods of Titration, Liquid Chromatography, Photometry, near-infrared spectroscopy, voltammetry and TOC.
Figure 1. Process Accuracy depends on multiple sources of error
Normal laboratory analysis “off-line can have detrimental impact on process accuracy by introducing sampling error and limiting analysis frequency due to manual limitations and differences between analysts. Introducing “on-line process analysers reduces the sampling error and increases the sampling frequency as well as improving the prediction error for the analysis. Improving all these steps leads to significant improvements in process accuracy narrowing the normal operating window to ensure the process is operating at its most efficient.
Figure 3. Difference in Process Accuracy for laboratory analysis (1) and continuous analysis (2) , highlighting how the process can be shifted closer to specification (3) to increase profit.
Figure 2. Operating window for continuous process analysis versus “at-line” laboratory analysis is significantly improved
Figure 4. Metrohm Analysers have major application in the surface finishing industry.
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www.metrohm.co.uk
MetrohmProcess ProcessAnalytics Analytics Metrohm
youcan cando doitit in in the the lab, lab, you you can IfIfyou can do do itit on-line! on-line! Imagine processunder underfull fullcontrol, control,operating operating within within defined Imagine a aprocess defined limits, limits,performing performing to exact specifications and standards. Saving money, increasing throughput, to exact specifications and standards. Saving money, increasing throughput, improving quality, consistency and safety. As a leader in analytical solutions, we improving quality, consistency and safety. As a leader in analytical solutions, we have the products to fit most industries and processes. Fully automated analytical have the products to fit most industries and processes. Fully automated analytical control of your critical parameters can be realised with Metrohm Process control of your critical parameters can be realised with Metrohm Process Analytics. Analytics. ' ! inishing Processes ' ! inishing Processes ' ocessing ' ocessing ' ood processing and products ' ood processing and products ' ! & ocesses ' ! & ocesses ' "% ! % ' "% ! ' % aste water ' aste water
www.metrohm.co.uk www.metrohm.co.uk
Measurement & Monitoring Acsoft establishes Acoustic Calibration Laboratory Reinforcing its position at the forefront of sound and vibration instrumentation and sensors for aerospace, defence, automotive and telecommunications, AcSoft 01 3 639550; www.acsoft.co.uk has established an Acoustic Calibration Laboratory at its new stateof-the-art office in Bedford.
Cirrus Research launch new App for doseBadge5 Noise monitoring specialists Cirrus Research has launched a new wireless App to enhance the features of its latest personal dosimeter, the doseBadge5. Already boasting a host of new advances, the doseBadge5 has now enhanced wireless technology to allow the instrument to communicate remotely with the doseBadge5 Wand and the dBLink App.
With the first phase of the facility fully operational, the company is now able to offer on-site calibration of its G.R.A.S measurement microphones and pre-amplifiers, as well as perform diagnostics and repairs.
The doseBadge5 Wand allows instruments to be started and stopped without disturbing the wearer and view measurement information via a mobile phone or IOS or Android controlled device.
AcSoft has appointed acoustics specialist Alejandro Alex Santana to head up the new calibration laboratory.
If the doseBadge5 is running, the current measurement information can be display, allowing mid-shift readings to be obtained. If stopped, the doseBadge5, any stored measurements can still be reviewed.
Paul Rubens, General Manager at AcSoft comments “Calibrating microphones at regular intervals is a way to safeguard the quality of measurements and eliminate the costs caused by unreliable equipment.
The dBLink App for Android allows the doseBadge5 units to be configured, measurement information viewed and measurements started and stopped.
Tel: 0123
www.cirrusresearch.co.uk
639550
www.acso t.co.uk
Japanese approval for intrinsically safe EE300Ex humidity and temperature transmitter The intrinsically safe EE300Ex humidity and temperature transmitter from E+E Elektronik has been certified according to TIIS. The device, which already meets the relevant requirements for Europe and North America ATE , IECEx, FM , may now be employed in Japan as well. TIIS-certified EE300Ex devices can be obtained from the Japanese E E sales partner TEKHNE Trading Co., Ltd. EE300Ex is dedicated for use in potentially explosive environments and can be installed directly in both gas and dust hazardous areas of zone 0 / 20. The device accurately measures relative humidity and temperature in the range from 0 to 100% RH and - 0 to 1 0 C - 0...356 F with pressure rating up to 300 bar (4351 psi). The EE300Ex is also available for moisture measurement in oil as well as for temperature measurement only.
www.intrinsically-safe-measurement.com
ProLine P50000 from Knick: Innovative High-Voltage Transducers for Railway Applications Transducers of the new ProLine P50000 series from Knick Elektronische Messger te were specially developed for voltage and current measurement in main and auxiliary power circuits of locomotives and multiple units. They are used, for example, for short circuit detection as well as for monitoring of traction motors and inverters, auxiliary inverters and accumulator batteries. The devices comply with all applicable railway standards and thus meet the high demands of fire protection HL3 according to EN 55 5016 , electrical safety, mechanical robustness as well as insensitivity to extreme environmental conditions and electromagnetic interferences. Compared to conventional sensors used in railway vehicles, ProLine P50000 transducers stand out due to their calibrated range selection feature and integrated universal power supply unit. Calibrated range selection allows different input ranges up to 00 to be selected quickly and flexibly.
Tel:
9 30 80 191-0
www.knick.de
Nadcap and CQI-9-compliant process validation
Fluke Process Instruments will be at the Advanced Engineering exhibition in Birmingham at booth K11, showcasing temperature measurement and validation systems such as the new Datapaq TP3 data logger. This 0-channel logger performs temperature uniformity surveys TUS and system accuracy tests SAT compliant with C I-9 and Nadcap AMS 2750E. Featuring a large memory for 3.6 million data points, it records detailed temperature profiles with an accuracy of 0.3 C. The channels can be flexibly specified for different thermocouple types and for up to four analog sensors. The Datapaq TP3 provides full connectivity options, including Bluetooth and USB download as well as real-time data transfer via radio. Users can perform ten consecutive profiling runs before downloading to a computer via USB or Bluetooth. The manufacturer also offers an unparalleled range of industry-specific pyrometers, infrared linescanners, and thermal imagers. Raytek MP150 infrared linescanners ensure correct thermal treatment and 100% quality control and documentation of processed parts such as light-weight pillars. They achieve a superior frequency of up to 150 lines per second and a high optical resolution of up to 150:1, enabling detailed thermal images from a longer distance.
Email: sales-info@datapaq.com www. ukeprocessinstruments.com Issue 23 PECM
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Measurement & Monitoring
LumaSense’s new Ratio Pyrometer with Automatic Transition between 1-color and 2-color Measurement The IGAR 6 Advanced employs a unique switchover technology that transitions between modes, creating a very long temperature measurement range.
L
umaSense Technologies officially introduced the IMPAC® IGAR 6 Advanced, a digital, compact pyrometer with 1-color, 2-color, and Smart operating modes for noncontact temperature measurement in ranges between 100 to 000 C. This product is unique not only because of the wide temperature range, but because of the seamless switchover’ technology,” This technology, known as Smart Mode, allows the pyrometer to measure temperature in 1- color mode at low temperatures (100 to 50 C and then transition to -color mode to provide the advantages of measurements in ratio mode at higher temperatures 0 to 000 C . The automatic, smooth transition from
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1-color to 2-color measurement occurs between 50 and 0 C. In addition, the pyrometer can operate in 1-color mode 100 to 000 C and -color mode 50 to 000 C . The large temperature range, compact si e, and new Smart Mode make the IGAR 6 Advanced pyrometer ideally suited for many different industrial manufacturing applications such as induction heating, hardening, tempering/annealing, brazing, sintering, vacuum processes, coating, and laser heat treatment. Presented at various events in Europe and USA, show visitors previewed the instrument last month and raved about the large temperature range, the different operating modes, and other features such as the automatic
emissivity determination and optional line optics. These additional features make this instrument unique and create opportunities to measure processes not considered previously and those not measured with appropriate accuracy. Contact: uma ense Tec nolo ies Frankfurt/M. Germany www.Lumasenseinc.com info@lumaseneinc.com
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Spelsberg IBT Enclosures Speed Up Electrical Installation For New Pre-Cast Hospital Build hanks in part to the use of Spelsberg IBT junction boxes, a project to build a new ÂŁ89m mental health hospital in South Wales has kept to a rigorous construction programme. The IBT enclosure range provides quick and robust electrical installations for pre-cast concrete construction, a proven method of building fast-track projects.
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The 20,000sq m centre replaces several separate facilities spread around Cardiff and the surrounding area. It will provide adult inpatient accommodation in 135 single-bed en-suite rooms, and also bring together all the area's general adult mental health inpatient services including
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low security, addiction, neuropsychiatry, intensive care and supportive recovery services. The design incorporates sitting rooms, garden areas, therapeutic spaces and consulting rooms. Despite being a large and complex project, topping out of the main buildings was completed within a year. This was achieved through a highly sophisticated technique to prefabricate seven separate plant rooms off-site. These were then installed in a matter of days. Each plant room contains all the building services equipment required, including pumps, fans, Building Management System (BMS) panels, control equipment and complete wiring. The use of precast concrete panels, rather than poured concrete or other construction
methods also helped ensure the rigorous building programme was maintained. The panels are bespoke designs and incorporate the electrical services, which reduced the amount of installation and wiring needed on-site.
Historically, this method of electrical installation has been difficult, due to the lack of specially designed electrical products. But Spelsberg's ITB range of junction boxes and related products has been specifically designed for the precast construction industry.
The IBT system allows enclosures, junction boxes, lighting outlets and other installation components to be fixed into the formwork into which the liquid concrete will be poured. They are secured in place either by magnetic couplings for metal formwork, or by patented support spars for timber formwork. Conduit is fitted as required to accommodate the wiring and then the concrete is poured in. Once set, the formwork is removed and the panels are ready for shipment to site. A key element of the IBT system is the integral sealing, which prevents concrete fines from getting inside the electrical components. This uses a patented diaphragm system which, after the conduit is inserted, returns to its original position and provides strain relief and sealing without the need for special grommets. Conventional housings do not have such a seal, so if used in a precast panel, a sealing
arrangement would have to be fitted insitu, a difficult and costly process. The IBT products are made from halogenfree, high-temperature resistant material which is designed for a long, trouble-free life. The range available in a wide range of sizes. With more and more projects now requiring extra low voltage (ELV) transformers for LED lighting, loudspeakers and network communications cables, Spelsberg has also developed the complementary IBTronic range.
The IBT system has already been used in a wide range of buildings including prisons, schools, hotels, offices and residential buildings. It is now increasingly recognised for its potential to reduce installation time and save overall build costs.
“Space for you” Spelsberg’s company philosophy is based around the idea of providing flexibility and freedom to its customers. The space provided within each junction box; the large distribution and warehousing space; and the freedom to customise almost any product, irrespective of quantity, all equates to “Space for you”.
A&J Fabtech Water Division offers a dedicated team of experienced individuals who provide the capability to design, manufacture and install a wide range of standardised and bespoke products for the water treatment industry. www.spelsberg.co.uk
Clinical Diagnosis Benefits From Design Collaboration
recision and reliability are two critical requirements of testing and analysis for clinical diagnosis; a collaborative project has now combined these with efficiency and cost effectiveness by designing a new modular microfluidic solution.
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Integrating the design expertise of BĂźrkert Fluid Control Systems with the long-standing experience of Biosystems a prominent manufacturer of analysis equipment has resulted in the design of a new dosing unit that significantly reduces running costs for analysis instrumentation. The new dosing unit forms one of the cores of the new BA400 analysis device, which is designed to carry out fully automatic analysis of up to 400 tests per hour. The operator prepares the device with the corresponding samples and reagents before starting the analysis process.
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The design of the new dosing unit has also reduced water and material consumption, which allows the analyser to operate continuously for eight hours without intervention to replace or refill containers.
The work of clinical analysis equipment as used in human medicine is hugely important but the pressure to reduce both capital expenditure and running costs is increasing on a daily basis. The ultimate solution then requires innovation that, at the same time, is accepted as proven technology and so is suitable for operation on a device used in a context, where a pedigree for reliability is essential. Biosystems is a Spanish manufacturer of clinical diagnostics products that aims to streamline workflow and enhance operational efficiency and improve patient treatment. To that end, the company has developed a new analysis
device that is to be used for in-vitro diagnostics (IVD), through collaboration with BĂźrkert, which has provided significant design and manufacturing expertise for the control and monitoring of the fluids. The aim of the project was to develop a modular dosing unit that would be suitable not only for use on the new system, but also for existing analysis devices available from Biosystems. This posed a considerable design challenge that would need to integrate the various components such as the injection unit, two or three valves, a pressure sensor and a filter, all of which would be mounted onto a transparent, injection-moulded structure. The solution required considerable design skill and expertise in fluid control in order to deliver very high dosing precision in an extremely compact space. The engineers at Biosystems decided to take advantage of the BĂźrkert Systemhaus facilities that
offer bespoke design solutions that can be manufactured and assembled in-house. One of the crucial aspects of the design was the detection and prevention of air bubbles which can substantially corrupt the analysis results. Coupled with the client's requirement for a transparent inspection window, it was essential that the BĂźrkert designers avoid any rough surfaces, dead zones and sharp edges while creating the new dosing unit. The engineers developed an injection moulded component that would house the control elements and machined it in such a way that all of the internal passages had a very high quality surface finish. The control valves, based on the Type 0127 solenoid valve and the Type 6628 Twin Power rocker solenoid valve, were positioned to minimise dead zones and deliver maximum flexibility of control.
The BĂźrkert solenoid valves have been specifically designed to deliver complete back pressure tightness, excellent flushability and a low internal volumewhile offering precision switching of micro volumes. In addition, the basic design of these solenoid valves ensures complete fluid separation that enables them to be used with aggressive fluids, which is essential for applications using specific cleaning chemicals as part of the process. The cooperative approach to the design and manufacture of the new dosing unit has brought together technological innovation and a desire to overcome the technical challenges associated with the development of a unique solution.
BĂźrkert Fluid Control Systems is one of the leading manufacturers of control and measuring systems for fluids and gases. The final design can be used in a number of analysis devices, thanks to its flexibility, which means that the overall demand for the product increases. This increases the demand for components and reduces manufacturing costs, making the new dosing unit a very cost effective project for the client. www.burket.co.uk
News & Events AHT supporting Quicksilver water-speed project Alloy Heat Treatment (AHT) are delighted to be involved in the Quicksilver World Water Speed Record project. The project is a collaborative venture uniting highly-skilled people and firms from across the broad span of British industry, drawn together by the man who founded the project, author Nigel Macknight.
Looking for advice on process analysis and process performance monitoring and control?
AHT are the UK’s first and only specialist in the heat treatment of aluminium alloys. With over 0 years experience as a subcontractor focused solely on the heat treatment of aluminium alloys, they are the preferred destination for companies within all sectors of the light metal industry. AHT Director, Ian Perks explained “We are extremely proud to sponsor the uicksilver project in its aim to bring the World Water Speed Record back to Great Britain, and it would be great to be a part of that. It is brilliant that there is a concentration of local companies that are also supporting the project. AHT’s support of the uicksilver project will be highlighted when they exhibit between 11-17th July at MAA stand 1/ B90 Hall 1, UK Pavilion at the Farnborough International Airshow.
Tel: +44 (0)1384 456777
Join our network of companies, universities and research institutes for expertise in R&D technology transfer in process analytics, multivariate analysis, industrial statistics, PAT and process control technologies.
Snickers Advice on ‘What To Wear On Site’ This Winter
Enjoy benefits of access to: free feasibility studies, research projects, talent pool of skilled researchers, specialised software downloads, networking; training and skills development, ‘members only’ website with free resources.
Introducing the NEWEST Working Clothes that will fit your winter workdays - in Snickers’ latest page FREE maga ine. You’ll find all need to know about the world’s most innovative range of working clothes, the only one that will your fit your workday on site - all winter long.
For more information: www.cpact.com
There’s advice on choosing the right Work Trousers and Jackets to suit your trade – RUFFWork, LITEWork, FLE IWork and ALLROUND workwear. They’re working clothes that deliver superb functionality, comfort, protection and are equipped for any task at hand.
If interested, please contact us at: admin@cpact.com +44 (0)141 548 4836
To get the catalogue visit the website at www.snickersworkwear.com alternatively, call the Snickers Helpline on 01484 854788.
German Electronic Component Distribution: Remaining stable in Q2/2016
Kasto automated warehouse forms core of new distribution centre
Electronic Components Market Germany (FBDi e.V.) in Million Euro 1.000 900 800 700 600 500 400 300 200 100 0 CY10
The member companies of the German electronic component distribution association FBDi e. . report sales growth of 5.6% for the second quarter 016; revenues totalled 16 million. In summary, the first six months of the year recorded an increase in turn-over of 7.7%. Orders did not rise as strongly, increasing by 3.3% to 09 Million in the second quarter 016. The order increase across the first half of the year was still 5. %.
CY11
CY12
CY13
Q1
Q2
Q3
CY14
CY15
CY16
Source: FBDi e.V., August 2016
Q4
Electronic Components Market Germany (FBDi e.V.) in Million Euro 1,20 1.000
1,03 0,96
0,99
1,00
1,01
1,01
1,04 0,99
0,97
0,99
1,00
800 0,80 600 0,60
400
0,40
200
0,20
0
0,00 1Q14
2Q14
3Q14
4Q14 Billings
1Q15
2Q15
Bookings
3Q15
4Q15
1Q16
2Q16
Book-to-Bill-Ratio Source: FBDi e.V., August 2016
The breakdown across the various technology fields remained stable. Semiconductors accounted for 70% of sales, rising by 5.3% to 56 million. Next came passive components, which achieved sales of 119 million, accounting for 15% of total revenues. With a 9. % increase, passive components performed well above average. Electromechanical component sales totalled 7 million, achieving a growth of 1. %. The power supply segment grew most strongly, increasing by 13. %. Its sales revenues of 1.0 million represented .6% of the total.
Tel. +49 8563 - 9788 908
Email: w.ziehfuss@fbdi.de
New lighting rental scheme aids cash flow Using LED lighting with the latest in lighting management systems, it is now relatively easy to achieve 50% to 0% energy savings on most projects with these energy savings paying for the systems and installation. With this in mind, Aura Light has launched a Rent Your Lighting’ scheme which eliminates investment in equipment and reduces an organisation’s energy costs from day one. Simon Taylor, Aura Light UK’s Managing Director comments, “This is an exciting development with big benefits for UK commerce and industry. The concept is likely to appeal to all business directors and accountants as the scheme aids cash flow keeping costs off the balance sheet and also takes advantage of the tax benefits.
Email: simon.taylor@aura-light.co.uk www.aura-light.co.uk
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www.alloyheat.co.uk
Pipe Center has opened a new distribution centre DC in Measham, Derbyshire, the newest and most technologically advanced distribution operation in the supply chain of parent company, Wolseley UK. The 1 ,000 sq ft facility, which went live in December 01 , has given Pipe Center the ability to provide next-day delivery across its entire network and has created over 50 new jobs. At its heart is a bespoke, 3,33 -location KASTOunicompact .0 automated warehouse, built in Germany and supplied through KASTO Ltd, Milton Keynes. The cassette-type tube storage system provides dynamic goods-to-man presentation for efficient picking, which reduces the amount of manual handling required. The KASTO system has reduced the distance warehouse operatives have to move when picking, speeding the consolidation of orders. The warehouse design also increases the height used for storage of Pipe Center’s SKUs stock keeping units . The consequently reduced footprint represented significant cost savings.
Email: sales@kasto.uk.com
www.kasto.uk.com
Tergo™ Chlorine-Free Cleaning Fluid Now Available in EU MicroCare Europe has introduced a new precision cleaning chemistry, Tergo™ Chlorine-Free Cleaning Fluid. It is a totally new product which enables faster, better and less expensive cleaning while meeting stringent environmental regulations. This new product is suitable as a degreaser and flux remover and handles even the most difficult contamination. It is highly effective for quickly and gently cleaning complex shapes and delicate substrates. It avoids the expense of aqueous technologies and the environmental challenges of chlorinated fluids. It can be used anywhere in Europe, in any standard vapour degreaser, without hardware changes. In today’s world of ever-more demanding requirements, Tergo™ Chlorine-Free Cleaning Fluid offers a better, faster and greener option.
www.microcareprecisioncleaners.com Tergo, The Tergo logo, MicroCare and the MicroCare logo are trademarks or registered trademarks of MicroCare Corporation
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meriflex, Inc.ÂŽ provides flexible solutions from conceptual design, prototypes to mainstream production and operates on a simple philosophy based on Integrity, Service, and uality. Our commitment to this philosophy is put into practice on a daily basis in the manufacture of our precision bellows, flanges, and other quality products. With the latest in technologies we supply a wide range of industries ranging from Semi Conductor, Medical, Oil/Gas, Food and Beverage and Automotive. Our bellows and expansion joints are designed to absorb and reduce
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vibration and relieve structural stress from working under pressure, extreme temperatures, and other variables. We speciali e in thinwall bellows. We also offer the highest quality metal braided flex hose in the industry. Our braided hose is designed for high pressure applications. It provides the protection needed for the inner convoluted hose to withstand high pressure and for vacuum or partial pressure applications requiring protection from hazards. Our stainless steel braided hose can be found on NASAâ&#x20AC;&#x2122;s Curiosity Mars Rover, on still-in-development commercial spacecraft, and in countless other applications.
Also produced is a full line of bellows assemblies to complement our metal bellows. We manufacture bolt-style and clamp-style bellows assemblies, flanges, valve assemblies, and expansion joints. Every bellows assembly we make is ultrasonically cleaned prior to welding, and helium leak tested after to ensure weld integrity and defect-free construction.
2390 ailroad treet orona Tel: 951 737-5557 www.ameri e .net
92880
Process Technologies Serving all steam industries, CERTUSS TC Model Steam Generators with touch screen control offer output ranges from 0- 000kg/hr and full modulation from 50-100% firing on output ranges 5002000kg/hr.
“EXCELLENCE IN APPLIED CHEMICAL ENGINEERING” ualit
Process Engineering International, LLC PROCESS speciali es in providing applied chemical process engineering skills to industry. PROCESS’ projects routinely include process design services, simulation and troubleshooting, debottlenecking, safety relief device sizing, process optimization, process installation oversight, process safety services, and many other chemical engineering related duties. We serve the oil and gas industries (upstream, midstream, and downstream), chemical production industries, petrochemical industries, pharmaceutical industries, food & beverage industries, and all other process industries. Our personnel are world-class, experienced, highly-motivated chemical engineers with work histories that have significant achievements in the process engineering field. Our engineering services range from large projects that involve complete plant process design package preparation, all the way through startup, and optimization, to small projects that may only require a few hours of consulting. Contact us for additional qualifications or to discuss your needs for process engineering services.
www.processen r-intl.com or www.processen r.com irect
one:
1 865 813 1607
Fuel types offered are Gas, Light Oil, LPG and Bio Fuel, with combination burners offered on all units from 500kg/hr upwards. Also available are CERTUSS Electric Steam Generators from 6kW to 1 0kW.
Tel: 0121 327 5362 Email: sales@certuss.co.uk www.certuss.co.uk
T e i est e el in rocess En ineerin er ices
Email: in o@processen r-intl.com
All CERTUSS Steam Generators are type tested according to European Pressure Equipment Guideline DGRL 97/ 3/EG.
Heraeus Tests Show New MAX Oven Is Five Times Faster for Glass Tempering Recent extensive tests in the Heraeus Noblelight Applications Centre have demonstrated that the tempering of glass, heatformed packaging products used in the medical and pharmaceutical sectors is five times faster and significantly more energy efficient with the new MA oven than tempering carried out using conventional electric heating techniques. In addition, the compact oven requires much less floor space than a conventional oven and individually-controlled oven elements can be arranged one behind the other in a modular fashion to allow very fast product change-over. Unlike conventional ovens, which use fireclay as the insulating material, the inside of a MA infra-red oven is comprised exclusively of quart glass, including QRC® nanoreflectors.
www.heraeus-infraredsolutions.co.uk
! Oil-water separators ! Service kits ! Condensate solutions
Quality
that goes on and on
To sustain the quality that you have come to expect from Sepura, our products can now only be obtained through our selected distributors.
Remember, if it doesn’t say SEPURA on the label its not SEPURA
SILEXA™ filtration media inside
To find your nearest distributor please visit our website
www.sepura-technologies.com
t:
+44 (0)1543 379212
e: sales@sepura-technologies.com
Issue 23 PECM
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We are an independent, privatelyowned company representing a number of manufacturers from across the world within the mechanical power transmission and processing industry in Great Britain and Ireland.
How To Specify Simple, Reliable And Adaptable Screw Jacks he need to raise a load is one of the most common requirements in industry. This is often achieved with a screw jack, but these need to be used in conjunction with other drive components and possibly in a system of several synchronised screw jacks. Ian Carr of Drive Lines Technologies explains how lifting systems are typically designed.
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In Drive Lines' thirty-plus years of service to the British machine building and design engineering communities we have helped with the development of innumerable
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screw jack lifting systems, and built up our expertise to the point where we are now probably the nation's 'go-to guys' for help with such projects.
We find that most of our clients have a good idea of the system they need to build, so most of our input is directed to helping them refine their design and selecting the best components for the job in hand. However, a few need help with the basics and we are happy to get stuck in at this level too.
So, let's start with a quick run through the basics, then move onto more detailed ideas. Screw jacks provide linear motion so are used to lift, lower, position, align and hold loads. In this they are similar to hydraulic and pneumatic cylinders, their advantage being they don't need an expensive power pack or compressor, just a simple motor drive system. Other attributes of screw jacks include that they are simple and therefore reliable, accurate in use, numbers of them can
be synchronised to work together, and that their screw operation can be used to amplify force. Essentially there are two types of screw jack: translating, in which the lifting spindle is driven axially through the gearbox, and rotating (or travelling nut), where the spindle is axially fixed and rotates to drive a travelling nut fixed to the load. The former is generally the more economic option, although with longer strokes the spindle may protrude through the bottom of the gearbox when retracted which can be a disadvantage. Unless fixed securely to the load, the spindle may rotate under friction when lifting, therefore an anti-rotation measure may be necessary. The latter, rotating type, ensures there is no protrusion below the gearbox - though the free end of the spindle will normally need securing by means of a flanged bearing. Depending on the duty cycle or lifting speed required, a trapezoidal spindle or ball screw spindle can be selected. Trapezoidal spindles have the great advantages of being simple, robust,
reliable, low cost and inherently selflocking. However, the greater expense of a ball screw can be justified.
Because frictional losses are reduced significantly, they can operate at greater speeds and are highly efficient, so will require smaller motor drives. Ball screw jacks tend to be specified when frequent actuation is expected while trapezoidal screw jacks are favoured for systems that will be used less often. However as ball screws are not normally self-locking, a brake motor must be used in all cases to prevent back driving. Selection of a screw jack for a given application may require some thought and Drive Lines will help identify the best choice. We will also help calculate the optimum size, typically a unit that is big enough to cope with likely shock loads but not so big that it requires excessive power. We will often sit down with the client and discuss the optimum solution â&#x20AC;&#x201C; for example if travel speed is not important
then a smaller motor may be specified, saving cost for the client. Screw jacks are usually driven by a standard industrial AC motor, to which it is coupled by a shaft, couplings and gearheads, as appropriate. However, other types of motors could also be used, such as: DC in remote locations where an alternating current supply is unavailable; compact servo in spacelimited applications; air or hydraulic motor in potentially explosive atmospheres. The configuration of the mechanical drive elements is often dictated by the physical layout of the system. Drive Lines always likes to carefully scrutinise this element of the design project; noting that simplicity is always better than complexity because it aids efficiency and reliability. It also looks for ways to design out possible failure modes: for instance an overhead system that pulls the load up is preferable to one that pushes from below because it is in tension rather than compression, therefore preventing buckling of the spindle if overloaded. Issue 23 PECM
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For this reason smaller spindle sizes can often be used for expanding loads. Beyond this, component selection is defined by power and efficiency requirements and may include right angled gearboxes, and line shafts of appropriate length. Drive Lines can consider the duty cycle, working environment etc. and help with specifying the best components for a long, reliable and safe working life. The simplest lifting systems will be designed around a single screw jack, but many loads will benefit from having multiple lifting points â&#x20AC;&#x201C; typically four, one at each corner of a square or rectangular load.
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Six or even eight screw jacks may be used for long loads, while particularly large or irregularly shaped loads may have any number of screw jacks. In most cases a lifting system consisting of more than one screw jack will use a single motor, driving through the necessary configuration of line shafts and distribution gearboxes. This is the simplest and best way to ensure synchronicity of movement between the screw jacks. Alternative multi-motor designs would be possible, but they would have to be synchronised using encoder feedback or other means. Another factor that must be considered is the guidance of the load, especially in compressive lifts.
As already mentioned, the spindle buckling factor must be accounted for in our calculations; this factor is influenced by how rigidly the load is guided. It is important that screw jacks are not side loaded, as this can damage the spindle and bearings. Again, a smaller spindle may be possible if the load is very rigidly guided. We will help the client specify a suitable guidance system, consisting of combined bearings and profile rail, or linear shafts and bushes. www.drivelines.co.uk
Mobile Drill Rig Uses Electric Drive For Fume-Free Operation Redevelopment of city centre locations can require drilling of deep bore holes to check the suitability of the soil and bed rock for supporting new buildings. If a site requires a comprehensive geological survey it may be necessary to drill inside existing buildings. However, most drills are diesel driven, meaning the exhaust fumes have to be extracted to the outside, a task that is difficult, time consuming, expensive and often not entirely successful.
commercial accommodation. There are several equally ambitious building projects nearby, including the new US Embassy and the long-awaited redevelopment of the redundant Battersea Power Station into a cutting edge mixed use facility.
A new type of drilling rig, developed with the help of electric motor company Exico, can be used indoors without the risk of filling the building with diesel exhaust fumes.
“Normally the drilling rigs used by geological surveyors are driven by diesel engines,” he says. “This is fine if you are working out of doors and the exhaust fumes can dissipate on the wind. “However, if you attempt to use such equipment indoors the fumes quickly cause problems. It becomes necessary to use ducting and fans to extract the fumes. This can cause delays to the schedule, add costs and is often difficult to achieve.
Planning the redevelopment of London’s New Covent Garden fruit, vegetable and flower market has required a comprehensive geological survey to be commissioned, right down to a depth of 50m. So a specialist drilling company was brought in to collect soil and rock samples from multiple deep drillings across the 57 acre site. New Covent Garden market, in Nine Elms on the south side of the River Thames, has been in operation since 1974 when the old site was closed to make way for retail and leisure businesses. It is home to the 200-plus independent traders that supply London with nearly all of its fruit, vegetables and flowers. The redevelopment of New Covent Garden is scheduled to take 10 years and cost £2bn. It will see the market facilities modernised to make them more efficient and free up 20 acres of land for nearly 3,000 homes and 115,000 sq ft of
Jerry Hodek of Exico explains that the geological survey has to be thorough and requires many of the exploratory bores to be drilled inside existing buildings.
With so many holes to be drilled across the New Covent Garden site a solution was required that would effectively overcome the fume problem yet be quick to set up and easy to operate, and an electric motor drive provided the answer.
Kostal’s Inveor inverters are designed to be mounted directly onto the motors they are controlling, in place of the motor’s usual terminal box. Normally inverters are located in a separate, remote control cabinet, but this would be an impractical configuration for portable equipment such as on-site drilling rigs. “Motor mounted inverters are subjected to significant levels of vibration and heat,” says Jerry. “The Kostal units are built to be so robust that they can cope with the vibration and also have a large heat sink, which in this case we have augmented with a cooling fan to provide a constant airflow over the unit.” The variable speed, electrically driven drilling rig is proving its worth on the New Covent Garden project, reliably drilling bores to precise depths and helping the surveyors keep to a strict schedule. www.exico.co.uk
“The electric motor is fitted onto the rig in place of the diesel engine,” explains Jerry. “This can be driven from a three phase mains supply or a mobile diesel generator located outside the building, where fume build up is not a problem.” In fact the motor that Exico supplied is a four pole 18.5kW 400/690V 50Hz machine, fitted with an integral inverter to turn it into a variable speed unit. The inverter, made by Kostal was also supplied by Exico. Issue 23 PECM
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Pumps
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PECM Issue 23
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Productivity in manufacturing has always been an area of concern and by bringing in automation, Man and Machine hopes the industry would benefit in terms of efficiency, helping to lower production costs and being more commercially competitive.
The Future of Automated Manufacturing
A simple web form can be used to create models, quotes, manufacturing drawings, bills of material and even generate NC machine code at the touch of a button.
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utomating the manufacturing process is about increasing capacity without increasing headcount, by taking labour cycles our of the design or production processes. Using a combination of software integration skills and unique software platforms, li e product con gurators ustom and on gurator , cloud based solutions usion and integrated so tware ypermill and utodes we have a power ul solutions set the can increase eďŹ&#x192;ciency throughout the manu acturing wor ďŹ&#x201A;ow. simple web orm can be used to create models, quotes, manufacturing drawings, bills o material and even generate machine code at the touch of a button. In some instances, through the use of feature recognition in the rules based engineer and integrated pac ages it is even possible to generate machine code to drive, . , axis and axis machines to automatically manufacture the products. his can dramatically reduce the level o
technical s ills needed to drive the machines, o ten a prohibitive actor in manufacturing companies being able to scale the use o expensive machinery or expand the capacity in their wor shops. roductivity in manu acturing has always been an area of concern and by bringing in automation, an and achine hopes the industry would bene t in terms o eďŹ&#x192;ciency, helping to lower production costs and being more commercially competitive. manu acturing contributes to and improvements in automation, use of information technology and investment in are critical to continuous production improvements or the industry. or more in ormation on automated manu acturing and how an and achine can help please get in touch on 01844 263700, email marketing@manandmachine.co.uk or visit www.manandmachine.co.uk
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SG Transmission secures five year deal with TGW Logistics Group Transmission has signed a renewed five year contract with TGW Logistics Group to provide an innovative clutch brake solution for a conveyor application that will be employed in some of the world’s largest distribution networks.
SG
TGW Logistics Group, a global systems provider of automated logistic solutions, has been working with the experts at SG Transmission to find a solution for a mechanical roller conveyor system, which needed to be custom designed to fit within the existing system’s space envelope.
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The solution is a combination of a clutch and brake developed with a design brief to withstand five million cycles with maximum load, in a 24/7 environment, with an extended life cycle. SG Transmission has the in-house capability to work with the customer to provide a solution which developed the client’s previous product further. Paul Short, technical manager at SG Transmission, said: “This project was very challenging but we managed to provide an improved technical solution for TGW’s requirements.
SG Transmission was one of only a few suppliers in Europe that was able to cater for the customer to solve the issue.” SG Transmission is based in the north east of England, where it operates a state of the art manufacturing facility and in-house design office. It manufactures a wide range of electromagnetic clutches and brakes for a global customer portfolio. www.britishengines.co.uk
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Thirty Years Service To The Water Industry And Still Innovating &J Fabtech Water Division is celebrating 30 years in the industry and is continuing its history of developing innovative solutions for the treatment of water and wastewater.
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Over the years the company has built an unrivalled ability to understand the individual needs of each project and to design installations that meet these using a mixture of standard and bespoke plant and equipment.
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A&J Fabtech is headquartered in Dewsbury, West Yorkshire and has large scale UK manufacturing capabilities. Indeed it is one of a rare breed of British companies that not only designs and manufactures a wide range of water treatment equipment in-house, including half-bridge, three-quarter bridge and full bridge rotary scrapers and thickeners for both dirty and clean water applications, but it can also supply fixed bridge scrapers, skimmers, thickeners, tanks and vessels and all necessary pipework.
The company is equally committed to supporting water treatment plants with comprehensive capabilities for maintenance, repair and servicing, as well as being able to assist with development and modernisation plans. Founded in 1974, originally to build concrete moulding machines, it grew rapidly, regularly developing new capabilities and entering new markets such as rail, power and wind power. By the turn of the century it was well established internationally, with operations in Europe and Asia. All of these activities are linked through a core competence for precision, high-quality design and manufacture.
The Water Division was formed in 1994 and as its reputation in the field grew, larger contracts and framework agreements were secured with some of the UK's leading water treatment companies.
Its manufacturing systems conform to BS EN 1090, Execution of Steel and Aluminium Structures, and it is registered on the Utilities Vendor Database (UVDB) with Verify accreditation. "A&J Fabtech Water Division brings together a dedicated professional team of engineers whose years of experience in the water industry and understanding of plant and equipment design is unsurpassed," says Managing Director Mark Wright. "We work closely with our customers to assess
existing plant and develop solutions that address both current and future needs. Naturally we are very aware of the industry's special requirements, such as the need to always maintain operations yet be cost effective and efficient at every stage of a project." The Division has long-standing framework agreements in place with a number of key water companies and also manufactures proprietary scrapers for other companies. Its core product range encompasses settlement tank equipment and accessories to suit any site or customer requirement, designed and built to the highest standards and installed by the inhouse installation team. "We have a work ethic of continuous improvement," says Mark Wright, "so are
A&J Fabtech Water Division offers a dedicated team of experienced individuals who provide the capability to design, manufacture and install a wide range of standardised and bespoke products for the water treatment industry. always seeking ways to develop our products and to create the best value service for our customers. We only deliver high quality engineered products for our customers, based on our close-knit supply chain. The skills and expertise of our in-house site services and installation teams ensure a first class approach to customer care."
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Old, Tired, Troublesome Valves?
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O LI LIDS I DS HANDLING H AN ANDL D I COMPONENTS FOR BULK SOLIDS
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TELEPHONE
Handling Adhesive Products Handling Adhesive with Rotary Valves
Products with Rotary Valves
Adhesion is the tendency of dissimilar particles or surfaces to cling to one another. prevent the product from plugging. dhesive products tend to than drop through style rotary valves (Note: Under positive pneumatic come from the food and because the rotor conveys directly in conveying conditions two rotor vanes chemical industries. Fatty, to the conveying line. This is especially should be sealing at all times to dhesion is the tendency of dissimilar particles or oily products with high pertinent if the connection pipes have prevent excess leakage air). Product surfaces cling to one another. Adhesive products moisture can tobe stic y as been designed to efficiently purge contact surfaces should be polished or tendstarches, to come fromwax the food are milk powders, - and chemical theindustries. rotor pockets. Valves designed have a non-stick coating applied and Fatty, oily products with high moisture (+20%) can gelatine powder, lactose, soap noodles, to provide a smooth ull flow o avoid narrow or multi-vane rotors, be sticky as are milk powders, starches, wax gelatine maltodextrine powders. conveying air through the convey line even with polished surfaces and nonpowder, lactose, soap noodles, maltodextrine powders. pipe connection with minimal pressure stick coatings because highly adhesive Adhesive products will stick to the drop will also aid product discharge, A larger valve running slowly with less rotor vanes and scalloped rotor pockets will Adhesive products will stick to the valve internals causing the running products can still adhere to them. valve internals causing the running preventing the possibility of line also provide a wider rotor pocket that will aid product discharge and prevent the clearance to block, which can lead to the valve seizing up. The product can plug in product from plugging. (Note: Under positive pneumatic conveying conditions clearance to block, which can lead blockage / lodgement and thus product the bottom of the rotor pockets causing reduced throughput, line blockage and Do not specify replaceable bladed two rotorhygiene vanes should to later theproduct valve degradation. seizing up. The product is be sealing at all times to prevent excess leakage air). Highly adhesive products can contamination, be very poor flowing vital where rotors for sticky because Product contact surfaces should be polished or have aproducts non-stick coating applied can plug in the bottom of the rotorthe desired throughput a factor. difficult to which makes the sizing of a valve to achieve product will stick to the ledge at the and avoid narrow or multi-vane rotors, even with polished surfaces and non-stick pockets causing reduced calculate.The solution is to makethroughput, sure you choose the correct valve. Blowing Seal bottom ofcan the the route of the coatings because highly adhesive products stillblade adhere in to them. line blockage androtary latervalves product A larger valve with reduced capacity (Blow through) style with scalloped rotor pockets are usually better rotor pocket and do not use closed degradation. rotor will provide a wide suited to adhesive products than drop through style rotary valvespockets because the rotors product will hold upproduct on the Do not specify replaceable bladed rotors–for sticky products because will rotor conveys directly in to the conveying line. shallow poc et con guration. his stick to the ledge at the bottomclosed of the blade in the route of the rotor and rotor end disc and it pocket can also Highly adhesive products can be very is proven to aid discharge of sticky do not use closed rotors – product hold upthe on the closed rotor discdisc and it getwill behind closed rotorend end This fl isowing especially pertinent if the pipes have been designedand to also prevents poor which ma esconnection the si ing products thebehind product can also get the closedand rotor end discup anduntil build up until the valve seizes. build the valve seizes. the rotor pockets. Valves designed to provide a smooth flow of efficiently a valvepurge to achieve the desired plugging in full the bottom of the rotor of conveying air through thecalculate. convey line pipe connectionpocket, with minimal throughput diffi cult to as pressure there is noOn narrow bottom drop through rotary valves,On rotordrop pocketthrough purge ports can be drilled to aid rotary valves, rotor drop will also aid product discharge, preventing the possibility of line blockage section for product topocket adhere to. and finally a product sample can be useful to determine the discharge pocket purge ports can be drilled to aid / lodgement and thus product contamination, vital where hygiene is a factor. The solution is to make sure you level of adhesion and product flow prior to the supplier quoting. A larger valve with reduced capacity rotor pockets will provide a wide shallow poc et discharge and nally a product choose the correct valve. lowing eal A larger valve running slowly with less pocket configuration. This is proven to aid discharge of sticky products and also sample can be useful to determine the Email: sales@rotaval.co.uk Tel: +44 (0) 1249 651138 (Blow through) style rotary valves with rotor vanes and scalloped rotor pockets prevents the product plugging in the bottom of the rotor pocket, as there is no level o adhesion and product flow prior scalloped rotor pockets are to usually will also provide a wider rotor pocket Web: www.rotaval.co.uk narrow bottom section for product adhere to. to the supplier quoting. better suited to adhesive products that will aid product discharge and
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Tiny temperature probe for fast response The TA-series of miniature temperature transmitters features a fast response with built-in IO-Link for setting, PT1000 element and class A accuracy for precise measurement. 4 to 20mA output, available lengths from 25 to 150mm. Up to 400 bar pressure.
www.ifm.com / uk/ ta ifm Telephone 020 8213 2222