PECM - Issue 27 2017 by MH Media Global

Engineering Process

Control &

Manufacturing

PECM

Global Success Through Innovation Issue 27 2017 ÂŁ3.95 www.pecm.co.uk

EEF - 20

Hering with Chocolate - 22

Optimas Solutions - 44

Photographers of all experience levels are being asked to get snappy as the annual EEF manufacturing photography competition opens for entries.

Separated by thick, black curtains, the welding booths line up one next to the other along the large production hall.

The phrase 'global supplier' creates thoughts of shipping containers travelling the world and large multinational corporations.

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Sections Editors Choice Air, Gas & Odour Control Boilers & Maintenance Calibration Solutions Control & Automation Drives, Motors & Gears Electrical & Electronics Energy Efficient Facilities Management Fluid Handling Health & Safety Lifting & Handling Equipment Machining Measurement & Monitoring News & Events Process Technologies Product News Pumps Switches & Sensors Software & Systems Storage, Handling & Distribution Training & Recruitment Tools Valves & Flow Control Waste Treatment

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Control &

Inside...

Inside Issue 27 Sainsbury Management Fellows Helps Engineers to Lead in Business

photography competition opens for entries.

Thirty years ago Lord Sainsbury identified a need for UK businesses to have more engineers in leadership positions to help them grow.

Hering with Chocolate

WHAT EFFECT WILL BREXIT HAVE ON STANDARDS AND COMPLIANCE FOR HAZARDOUS AREA INDUSTRIES? Tim Marks represents the AEMT as a member of BSI, IEC, and IECEx standards committees for Explosive Atmospheres and Rotating Electrical Equipment. Annual photography competition celebrates British manufacturing Photographers of all experience levels are being asked to get snappy as the annual EEF manufacturing

Separated by thick, black curtains, the welding booths line up one next to the other along the large production hall. What does the next generation of SCADA have to offer? Despite all the talk of ‘lights out factories’, there will always be a need for people to interact with machines and processes. OPTIMAS SOLUTIONS SUPPLIES GLOBAL EXPERTISE WITH A LOCAL TOUCH The phrase ‘global supplier’ creates thoughts of shipping containers travelling the world.

Issue 27 PECM

Industry News EEF comment on EU citizens' rights paper Commenting on the Government’s EU citizens’ rights paper, Tim Thomas, Director of Employment and Skills at EEF, the manufacturers’ organisation said: “The frustrations felt by many employers will not be eased with the publication of the Government’s migration offer. “The proposed system seemingly requires two new sets of registration for EU nationals who want to live and work in Britain one leading to permanent status and the other for a work permit. The announcement which ranges from Government ‘wanting to’ to ‘intending to’ will do nothing to ease the uncertainly of EU nationals and their employers. “Employers need clarity and certainty well before the date we officially leave the EU and face a tipping point after which it becomes almost impossible to retain or attract employees from Europe. With most other EU countries already using a registration system, operating in a similar way to that proposed, now is the time to radically rethink our approach to Brexit enabling the UK to enjoy premium access to the single market and the EU workforce when we leave.”

EEF launches new Health, Safety & Environment leadership skills as sentencing guidelines start to have real impact Strategic support aims to increase Board level engagement EEF, the manufacturers’ organisation has launched a unique course to aid health, safety & environment practitioners communicate more effectively at Board level within companies and help them engage the whole of businesses in health & safety issues. The launch of the course comes at a time when the impact of new sentencing guidelines for health & safety offences are beginning to rapidly escalate. In 2016 nineteen companies received fines over £1million (the largest being £5illion). This compares to only three in 2015 and none in 2014. EEF believes that, given fines are based on turnover, the £100million fine will occur in a matter of time. The two day course has been specially developed in conjunction with EEF’s management and professional development experts. As well as helping match high levels of health & safety competence, it will provide practitioners, who often have to work harder to get the attention of business leaders, with leadership and management skills. This will give them the ability to effectively create, influence and clearly communicate health & safety strategy in a pragmatic and commercial way for maximum business impact.

www.eef.org.uk

MTA CEO says that modern manufacturers need to address the ‘archaic’ image of the industry, to attract top talents into engineering careers MTA CEO James Selka used his key note speech at the National Manufacturing Debate (NMB) hosted by Cranfield University to highlight the importance of Industry collaboration in tackling the skills gap.

PECM Issue 27

The course includes expertise on: What are the characteristics of a commercially aware person and how does this relate to the role of a health, safety & environment practitioner? Understanding the wider internal and external environment within which businesses operate including customers, market-dynamics, competitors, suppliers, financial drivers Developing your business case for health, safety & environment investment and demonstrating the return on profits, growth, productivity Identifying the impact health, safety & environment advice and recommendations may have on the bottom line. Commenting, Steve Jackson, Health, Safety & Sustainability Director at EEF, said: “As the impact of new sentencing guidelines begin to have a real impact, the price for failing to adhere to health, safety & environmental regulation is becoming an ever great business risk, not to mention ever more cost with senior individuals being held more to account. “In today’s challenging business environment being an expert on health, safety & environment is not enough. If those professionals are going engage at board level and with the wider workforce then a much more rounded package of business skills and competencies is required.” www.eef.org.uk

The NMB is an annual event hosted by Cranfield University and took place on 24th May. The event brings together manufacturing professionals from a range of sectors to discuss and debate current challenges in the industry as well as encourage networking and collaboration across manufacturing to enable continued and long-term growth. The theme for the 2017 debate was Leadership and Investment for Manufacturing Skills. The MTA CEO highlighted that the image of manufacturing is still a barrier for recruiting new talent. Selka said, “The default portrayal of manufacturing features images of dirty factories, on run down industrial estates and a declining industry as a whole. www.mta.org.uk

Industry News Academy Fellows recognised in Queen’s Birthday Honours Congratulations to the following Fellows of the Royal Academy of Engineering who have been recognised in The Queen’s Birthday Honours 2017 for a range of accomplishments in the engineering industry and their services to wider society.

Order of the Companions of Honour

Knights Bachelor Knighthoods •

Members of the Order of the Companions of Honour (CH) •

Dame Vera Stephanie Shirley DBE FREng Entrepreneur and Philanthropist. For services to the IT Industry and Philanthropy.

Professor Mir Saeed Zahedi OBE FREng Technical Director, Chas A Blatchford & Sons. For services to Engineering and Innovation.

www.raeng.org.uk

Engineering CEOs commit to tackling gender crisis To mark International Women in Engineering Day, CEOs and senior leaders from some of the UK’s top engineering companies are joining the Institution of Engineering and Technology (IET) in calling for urgent action from the top to address the shortage of women in UK engineering. Women currently account for only 9% of the UK’s engineering workforce, yet 63% of UK engineering employers do not have gender diversity initiatives in place*. The call comes from engineering leaders during a panel discussion at the start of the IET’s #9percentisnotenough conference, which takes place today in Birmingham and is named after the IET’s multi-award winning social media campaign to highlight the gender diversity issue in UK engineering. Engineering industry leaders will be joined at the event by senior HR professionals, as well as other representatives from industry, academia and the professional engineering institutions. www.theiet.org

SSE Hydro Arena recognised with Major Project Award The engineers behind Scotland’s largest entertainment venue are to receive the Royal Academy of Engineering’s Major Project Award in recognition of nearly a decade of work turning a vision into iconic reality. Since being selected for the project in 2004, the team from Arup combined their structural, civil, mechanical, electrical, lighting and fire engineering expertise to help deliver the 12,500-seater SSE Hydro Arena in Glasgow. During that period, the engineers had to overcome a number of significant challenges to create the building situated on the bank of the River Clyde, including difficult ground conditions in the city’s old docks and a design to withstand a one in 200-year flood event, including allowing for climate change. The team, based in Arup Scotland’s offices in Edinburgh and Glasgow, consists of Project Manager Ian Lumsden, Project Director Martin Surridge, Lead Mechanical Engineer David Brodie, and Senior Structural Engineer Graeme Moncur.

Warwick students to compete to build best locomotive at Railway Challenge A team of seven student engineers from WMG at the University of Warwick, is gearing up to compete in the Institution of Mechanical Engineers’ Railway Challenge, taking place on 29 June-2 July 2017 at the Stapleford Miniature Railway near Melton Mowbray, Leicestershire. The competition will see 12 teams compete against each other to design and manufacture the best, most innovative, efficient and quietest small-scale locomotive. The competition comprises a series of track based and presentation challenges, including a design report and an ‘Innovation Challenge’ which involves the production of an academic paper on the innovations in the loco. The track based challenges include: energy storage, traction, ride comfort, noise, maintainability and energy efficiency. Louise Jackson, Team Leader for WMG’s team said: “Taking part in the Railway Challenge gives us the opportunity to put our imagination and resourcefulness to the test. The locomotives that will be competing are designed to work on 10¼” gauge railway line and must be powerful enough to transport a 600 kg load – including one of the Railway Challenge judges. www.imeche.org

www.raeng.org.uk Issue 27 PECM

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Engineering Process

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

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Issue 27 PECM

Sainsbury Management Fellows Helps Engineers to Lead in Business hirty years ago Lord Sainsbury identified a need for UK businesses to have more engineers in leadership positions to help them grow. He established the SMF Scholarship Scheme which has produced 330 engineers with business skills – known as SMFs. SMFs have used their combined technical and business skills to create successful businesses and jobs, or they work in senior decision-making roles in major corporations and non-profit organisations.

The SMF Scholarship Scheme has awarded over £8.5 million worth of MBA scholarships to engineers with leadership potential and each year they award up to 10 new scholarships valued at £300,000, allowing the awardees to attend the top international business schools. SMF MBA Scholarship awardees gain business skills (strategic thinking, finance, economics, marketing) that complement their engineering skills. This enables them to secure strategic leadership roles in blue-chip organisations and to create innovative startups. SMFs have founded 275 new companies which are thriving and 153 of them founded/cofounded businesses valued at £4.6 billion, creating 18,000 jobs. Traditionally company directors have not been trained to identify and manage the risk of failure positively. By contrast, risk analysis skills are an integral part of the skills set of engineers. By drawing on both areas of expertise, the MBA-qualified engineer, helps organisations to identify and manage risks

PECM Issue 27

and create new strategies to achieve challenging goals, be they around finance, technology, security, sales and marketing, health and safety, or legislative frameworks. With the world changing at an unprecedented rate, creating new challenges for UK businesses (eg globalisation, cross-culturalism, rise of the Asian markets, flux in the international politics, the economy, technology, cyber security and environmentalism), the need for multiskilled engineers is increasing.

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The SMF Scholarship Scheme has played an important role in increasing the number of business leaders with an engineering background and skills working across all sectors of the UK and global economy. SMFs use their mix of technical and commercial skills to bring new approaches and solutions to challenges in both the private and public sectors. In addition to the scholarship, several SMFs teach business and innovation as visiting professors at universities, and the charity is working to promote business skills and entrepreneurship through its Engineers in Business competition. The SMF MBA Scholarship interview panels and awards are administered by the Royal Academy of Engineering with Sainsbury Management Fellows. If you are interested in making an application, please visit the RAEng’s website. www.raeng.org.uk/grants-and-prizes/ schemes-for-people-in-industry/ sainsbury-management-fellowship

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Gas detectors are commonly included as part of a health and safety system within the workplace, with portable instruments designed for protecting personnel when working in potentially hazardous areas. Fixed gas detection systems comprise of individual gas detectors connected to a central alarm panel, providing constant monitoring of gas detection within the designated area. Health and safety regulations stipulate the use of such devices across a wide range of industries including; mining, oil & gas, manufacturing, laboratory research, and agriculture. Used as an essential part of safety equipment, gas detectors can detect oxygen deficiency, explosive atmospheres and multiple poisonous gases, thus removing threats from hazardous and potentially lethal environments. The online gas detection shop from Cambridge Sensotec offers a wide range of gas detection and monitoring equipment with exclusive website discount applied to a number of products, providing customers with our lowest possible prices. Regular calibration of gas detectors is vital to verify the sensor accuracy and system integrity, enabling reliable and continuous safety for your workforce. Cambridge Sensotec provides calibration and servicing as well as installation service for fixed gas detectors. For more information, please visit our shop, or contact our sales team for further advice on +44 (0)1480 462142 or email sales@cambridge-sensotec.co.uk

PECM Issue 27

Designed with you in mind, the Rapidox 2100 oxygen gas analyser has recently undergone a facelift with exciting enhancements! An accurate and reliable gas analyser originally created in the year 2000 with many still in service today! Enhanced with a five-point calibration option, this ensures accuracy and repeatability. Additionally, the updated zirconia oxygen sensor connected via a 2m cable, provides an improved sensor heater design with a faster response time and superior service life. Additional features on the new Rapidox 2100 include: • • • • • • • • • • • •

A new OLED (organic light-emitting diode) screen with four lines of information New simplified menu system and measurement scale/unit readings Pressure and humidity measurement parameters Enhanced air calibration with auto pressure and relative humidity correction Updated and enhanced alarms with new latching and hysteresis functions Simplified menu system with redesigned data entry system Full diagnosis menu including sensor lifetime monitoring New live R-squared monitoring to indicate calibration quality Modbus RTU digital communication Updated password menu allowing partial/full protection of critical menu features Date and time with new formats including ISO standard formats Superior sensor clean function allowing enable and disable by the user

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12/06/2017 11:18:39

What Effect Will Brexit Have On Standards And Compliance For Hazardous Area Industries? im Marks represents the AEMT as a member of BSI, IEC, and IECEx standards committees for Explosive Atmospheres and Rotating Electrical Equipment. He looks at some of the issues facing the Hazardous Area industry now that the UK Parliament has agreed to Brexit.

There are currently a lot of blank faces, particularly in Whitehall when it comes to the subject of standards, directives, and compliance in the wake of Brexit, but what does it mean for the Hazardous Area industries and will it cause problems for companies doing business in the UK? The main message here is a sense check; first one needs to understand the difference between standards and Directives: Technical standards embody the best practice put together by technical experts to create a uniform engineering or technical criteria. They are becoming more and more international, are not mandatory, and will not be affected by Brexit. European directives, may have technical input, but emanate from the European Parliament. They must be embodied into

the laws of each EU member and are mandatory. The two however are often interlinked and standards can be used to support and help meet European directive requirements. The European Directives are designed to create a level playing field for trade within the EU. They may also form a technical barrier to goods emanating from outside the EU. They cover all angles of trade, from machinery and transport to eco-design, health, safety etc. Hazardous Areas are covered by the ATEX Directives for potentially explosive atmospheres (ATEX emanates from the French: ATmosphĂ¨res EXplosibles). There are two ATEX directives: ATEX 95, originally ATEX 94/9/EC, but superseded by ATEX 2014/34/EU on April 20, 2016. ATEX 137, workplace directive 99/92/EC covering Health and Safety on site. There is then the legislation that embodies the ATEX directives into the UK legal system. DSEAR (The Dangerous Substances and Explosive Atmospheres Regulations). To a large degree these directives create an invisible barrier to trade with Europe, and are items that will still need to be conformed to after Brexit. Every item manufactured in Europe or manufactured outside the EU for use in an EU zoned hazardous area has to have a valid certificate of compliance to the ATEX directives. The certificate gives information on the results of testing for compliance with the ATEX directive and named standards, as well as safety issues, labelling details, etc. The certificate is only issued after three samples of each item have been extensively

tested in an accredited laboratory by a Notified Body in the EU. This can be a very expensive hurdle for a company wishing to sell its product range into Europe, however, ATEX is no different to the barriers that EU companies meet if they wish to export to the US where they have to meet UL or FM standards, or the Canadian CSA standards, Japan, China, Russia etc. So what are the top seven problems that may affect the UK Hazardous Area Industry after Brexit? Will Brexit affect UK manufacturers and importers - who already ensure that their products have the required ATEX certificates? If the UK continues to ensure that products manufactured, or imported, into the UK, abide by the ATEX Directives, discussions over ease of access to the EU countries by the Customs Union Committee should be more straightforward. The existing ATEX certificates will ensure ease of access into the European market. Will Brexit affect the users - from international oil and chemical companies to local flourmills? There would be no advantage in the UK deciding not to comply with the ATEX Directives and many advantages in keeping the status quo. Users of Hazardous area equipment will still specify, buy and conform to the ATEX directives as long as DSEAR in the UK continues to embody the ATEX Directives. Will the government alter DSEAR if it no longer needs to comply with Europe? DSEAR ensures that everything manufactured or imported to the UK still complies with the European Directive. ATEX works well and is well respected internationally. Its requirement in the UK protects our markets from a flood of non ATEX compliant equipment, and should continue to facilitate the free movement of Hazardous Area Equipment from the UK to Europe, and vice versa. Will UK companies still be able to manufacture to European standards and Directives? Standards are becoming more and more international and most

of the developed countries are signed into adopting the ISO (International Organisation for Standardisation) or IEC (International Electrotechnical Commission) standards. Both are now based in Switzerland and produce international standards for adoption by member countries. The majority of these are harmonised into the European CEN or CENELEC standards systems, and most EU members are also members of ISO and IEC. Occasionally CEN or CENELEC will produce a standard as a result of a new directive, and this can go the other way and stimulate the production of a corresponding ISO or IEC document. All standards are readily available for anyone or any manufacturer to purchase and comply with.Will the UK be able to have input into the ATEX Directives; Fortunately ATEX directives are quite mature now and after 20 years have just had some minor updates. The UK took part in the consultation process and provided technical and procedural input during the review to produce the updated ATEX 2014/34/EU. We may not officially be able to attend future consultations, or have any MEP's to comment on new directives, however the results of the process and every consultation is available on line. Technical alterations to Directives often encompass alterations to the International Standards, which the UK is well represented on. I am sure that the UK voice would also be heard through international federations and UK international companies with representation in the EU. Will the UK still be able to have input into the European and International standards. Generally as these standards become available or go through a maintenance update, they are harmonised into the European standards CEN or Cenelec for IEC electrical standards. These standards are then adopted by EU member states (in the UK they are adopted as a British Standard). Occasionally there will be notes at the beginning of a standard for local requirements, these can be numerous in some countries, but are becoming unusual in the UK. Generally we are very well represented on standards committees, and any problems we foresee in a standard are normally solved at the committee stage. Standards are not a legal requirement, but they normally help manufacturers and users meet their legal obligations. They also create a high standard of best practice for products and create a level playing field for products entering a market and a standardisation of products produced for that market. Will our notified bodies for Potentially Explosive Atmospheres retain EU notified body status after Brexit? This is an important issue.

The EU has 67 notified bodies in this segment. Eight of them are in the UK, compared to 12 in Germany, 10 in Italy, 6 in Poland, and 3 in Turkey, other EU members such as France have 2, 1, or no notified bodies. Turkey is perhaps the exception that proves the rule, which may help Brexit negotiations. Turkey is not even a member of EFTA, but this decision was issued by the Customs Union Joint Committee in document 2006/654/EC for "the elimination of technical barriers to trade in a particular product" and facilitate the progress of Turkey's application to join the EU". This does ring alarm bells if we have declared that we are leaving the Customs Union. The current UK notified Bodies will require a similar decision from the Customs Union Joint Committee to the one above. The notified bodies in the UK are well respected internationally and have a wealth of technical experience. They do a large amount of business with European and international companies requiring Certificates of Conformity for ATEX to sell their products in the EU. This includes products from America, China, and internationally, as well as those manufactured anywhere within the EU. Manufacturers not only require new prototypes testing, but continually modify and update their products. If this is to continue in the UK after Brexit, the sooner a Joint Customs Union Committee agreement is reached to clarify the situation, the better. The UK notified bodies need to be at the front of the negotiation agenda once Brexit is formalised. There are 188 bodies listed by the EU, who can test and issue Certificates of Conformity with directives covering everything from Shipping and Rail to manufactured products, medicines etc. These range from the UK accreditation company UKAS to specialist companies like SGS Baseefa, an AEMT member. These bodies use their specific expertise to test for conformity with every mandatory Directive including ATEX, Machinery Directive, Marine Equipment Directive, Pressure Equipment Directive, Lifts Directive, Low Voltage Directive, etc. The list is long and covers every area. To facilitate trade agreements with the EU, the UK Government will probably negotiate to abide by most of the directives, such as ATEX. The 188 bodies involved in testing and accreditation are world class companies employing staff with very specialist technical abilities.

Many of them stand on International Standards Committees and facilitate a huge amount of international trade in the oil, chemical and other industries. It is imperative that the UK Government ensures that Brexit and a split from the Customs Union does not jeopardise the incredibly valuable work that these companies carry out internationally, and ensure that this industry, maintains its leading place on the world class stage. There are many active groups looking after the interests of the industry, who will continue to communicate with the marketplace about developments and changes, as well as providing sensible advice to government committees. However, now is the time to address these issues. The mechanisms are in place to continue to ensure compliance doesn't become any more complex or onerous, and that our ability to do business successfully remains largely unaffected by this particular aspect of Brexit. For information see EU Website: www.ec.europa.eu/growth/singlemarket/european-standards/

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PECM Issue 27

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they would expect from any other piping system but with the Pass/Fail fusion long term weld statement. This increases the value of our offering and ensures it is fully Fit-forPurpose.” As one of the world’s most respected manufacturers of HDPE and other pipework systems, George Fischer strives to set the highest standards in quality control, both within the factory and throughout the installation process. The GF Piping Systems10 year guarantee backed NDT service can only enhance the overall offer to customers. For Further Information Telephone: 024 7653 5535 Fax: 024 7653 0450 Email: uk.ps@georgfischer.com Website: www.gfps.com/uk

Understanding SFP in Air Movement Geoff Edwards, Technical Sales Engineer at Axair Fans briefly discusses the challenge of specific fan powers for fan coil units. ans represent an enormous potential for energy savings and the reduction of CO2 emissions, equating to 9.3% of energy in the UK. This is a significant contribution when looking at lighting as a comparison which uses about 10% of the whole EU’s electricity consumption. Statistics show that in colder climates the energy consumption of fans in modern commercial buildings can be as high as 20% of the building’s total energy use and analysts predict that unless building regulations are enforced to limit fan power, this fan energy consumption could potentially double over the next 20 years.

Seasonality highly effects the energy consumption used by fans, for example the energy used by a supply fan ends up as internal heat gain in a building, whilst the exhaust fan energy is lost to the outside. This means a proportion of the fan energy is transferred to the inside of a as heat which is useful in the colder months when heating the desired effect of ventilation systems but causes a cooling requirement load on the ventilation system during the cooling system. The term used to measure the amount of energy used within a heating and ventilation system is known as Specific Fan Power (SFP). This energy is used to drive fans relative to the amount of air that is circulated. It is constant but changes with both air flow rate and fan pressure rise. The energy efficiency of fan coils is heavily influenced by the SFP, the lower the SFP the more efficient the fan coil. In the UK, where fan coil units (FCU’s) are popular,

regulations set separate limits on SFP for buildings and SFP for Fan coil systems. FCU’s with 4 pole motors AC motors can achieve SFP of 0.5~0.8 Watts per litre per second (W/(l/s) depending on capacity, while FCU’s with EC motors can achieve 0.15~0.4W/(l/s). The larger SFP of 0.5-0.8 from a single AC motor may not seem a problem, but when multiplied by 500 or 1000 fans in a large building, this mounts up to a large energy demand. Over the past ten years, small air handling units such as fan coil units have undergone many changes to improve efficiency with good reason and EC motors have brought the biggest efficiency gains to the fan coil market to bring energy consumption well below half that of their traditional AC counterparts. However power factor may be an issue with EC fans in a fan coil unit installation and active power factor correction would be necessary to raise the power factor of the installation to about 0.9. Fans to produce air flow rate through the unit are fitted in all fan coil units. They are forward curved centrifugal fans, usually double inlet although single inlet can also be used. Fan motors can be 2 pole or 4 pole AC or EC, single phase induction, capacitor start/run, up to approximately 200w capacity with sealed for life ball or sleeve bearings. All motors fitted in fan coil units have a limited torque characteristic and any external air static pressure across the unit, such as that created by ductwork or grilles should be kept to a minimum. In recent years fan coil unit installations have become one of the most popular

types of air conditioning system in both new build and refurbished commercial premises. The basic reason for installing fan coil systems is to provide comfort conditioning at the specified environmental conditions within the space. Whilst not an inherently complicated system a number of problems can arise with fan coil unit installations, such as those related to noise, thermal output and draughts, and care needs to be taken in the manufacture, design, selection and installation of the equipment to avoid common pitfalls. An inadequate or badly performing HVAC system can have adverse effects on the occupants and studies have been carried out that show a link between substandard working environments and productivity in the workplace. Therefore it is evident that the need to cool buildings will not go away and possibly with the continued effects of global warming, our demand for cooling will increase. The challenge will be to continue to deliver this cooling ability in an as efficient way as possible when combining the two considerations of installing energy efficient products within an energy efficient system with an intelligent control system to integrate the two. Axair Fans UK Limited offer an extensive range of industrial fans for use within original equipment manufacture such as Fan Coil Units. With low noise, constant pressure, constant volume and a range of speed control options there’s an efficient solution for current demands. www.axair-fans.co.uk Issue 27 PECM

editors choice

Sepura offers superior filtration

Corrotherm International

Junair

Shredded melt-blown polypropylene is widely used as a filter media in many oil/water separation products.

Corrotherm International stock and supply high-performance nickel and titanium alloys. Including MONEL, INCONEL and INCOLOY alloys, such as INCONEL 625, for use in a wide range of industrial applications where materials are subject to extreme environmental conditions. These materials offer outstanding corrosion resistance, good strength and the ability to withstand high temperatures. Stock includes seamless pipes, fittings, flanges and sheets.

Formaplex are a leading manufacturer of tooling and lightweight component solutions operating across many industries including automotive, industrial, aerospace and marine. With a reputation for excellence built on many years of engineering experience, and a dedication to dynamic working practices, Formaplex recognised the need for expansion. Having had previous positive experiences working with Junair on major OEM paint projects, the team at Formaplex naturally turned to Junair for the design and installation of their new semi-automated paint finishing facility. The Junair name is synonymous with innovation in spraybooth development, providing solutions that deliver energysavings, higher productivity, enhanced performance and ultimately, increased profitability for our customers.

But buyers should not be misled by claims that polypropylene shred, mixed with polypropylene pulp, will perform adequately or provide advantages as a condensate filter media says Richard Potts, managing director of filtration specialist Bowman Stor. Developed by Bowman’s research and development team, the SILEXA™ branded media is manufactured from recycled glass bottles and offers many environmental benefits, helping customers comply with legislation and meet their corporate and social responsibilities. For more information, please visit www.sepura-technologies.com

Corrotherm has recently introduced a pipeline valve service, offering a choice of valves that can be tailored to meet strict technical specifications, whether a single valve or a complex set. Unit 31, Stephenson Road, South Hampshire Industrial Park, Totton, Hampshire, SO40 3SA, UNITED KINGDOM Tel: +44 23 8074 8100 www.corrotherm.co.uk

The PFEIFER positioner INVERTO convinces with new features The PFEIFER positioner INVERTO ranks by all means among the allrounders when it comes to handling coils. If slewing or turning of steel coils, injection moulds or other tools – the INVERTO can be used everywhere, offers high safety standards, an outstanding priceperformance ratio as well as fast delivery times. Now the sturdy handyman was revised and complemented by numerous useful additional features.

Seminar: Optimising Industrial Processes with In-line NearInfrared Spectroscopy

For example the INVERTO is now also available in a smaller design for loads of up to two tons. Furthermore, the INVERTO was equipped with new technology. Control is effected by a sturdy and reliable radio remote control. „We have improved the INVERTO once again significantly“, emphasises Siegmund Erhard, head of the business unit Materials Handling at PFEIFER.

When operating processes in any industry, certain parameters within the product or process need to be monitored and maintained to ensure a quality end product comes off the production line. Rapid in-situ analysis and control of multiple physical and chemical parameters, can be realised with in-line NIR spectroscopy. Metrohm Process Analytics are pleased to present a free seminar on 7th September, which aims to provide a basic understanding of the principles and applications of NIR spectroscopy for pharmaceutical, polymer, fine, heavy, petro chemical and formulation manufacturing. Learn about the basics of vibrational and NIR Spectroscopy and how to integrate an NIR analyser into a process to improve safety and save money.

E-Mail verkauf-lt@pfeifer.de Web www.pfeifer.info/lift-and-turn

Find out more and register for free at www.metrohm.co.uk

PECM Issue 27

For more information on the Junair range of products visit www.junair.co.uk, contact the experienced team on 01706 363 555, or email sales@junair.co.uk.

Stocking up on specialist bearings Specialist supplier of miniature bearings, SMB Bearings, has introduced a new range of 316 grade stainless steel ball bearings to its catalogue. These have been specially selected for customers with applications in harsh environments, which the bearings can withstand due to their marine grade stainless steel construction. The bearings will find a home in food processing, chemical manufacture and pharmaceutical production as well as marine and other liquid process applications. The 316 bearings withstand temperatures to 500°C (if supplied without cages) and are highly resistant to seawater, salt spray and chemicals. For further information www.smbbearings.com sales@smbbearings.com

Editors Choice

editors choice

Getting it2017 right Subcon

from manufacture through T delivery to

hermaset - manufacturers of powder coatings were delighted to exhibit at SubCon 2017 for the first time. SubCon gave Thermaset the opportunity to showcase its products in an arena not previously visited more to powder by ourselves.here’s This had a positive effect on coatings than meets the eye our team during the three day exhibition and, according to one of in early June; from the first day to the last the UK’s leading players in we fully prepared and this in turn has thewere market, customers are increasingly led to lotsatofthe interest andofopportunities looking quality technical for us here atthe Thermaset. advice, range of available finishes

and a first class colour matching

service. During the time at SubCon the sale and marketing team were able to meet lots of Tamworth-based Thermaset Limited new contacts including some potential has, over more than 30 years, new clients which have already yielded established a reputation in the powder success. previous for years we have focued coatingsInindustry stability and

reliability. Commercial Manager Nigel Crane commented: “Manufacturers look to companies with a proven track record, but will always factor in quality, delivery and price.

“Our service covers the full spectrum of the industry. There is no colour that can’t be matched and no special requirement we cannot meet – whether

PECM Issue 27

on exhibitions aimed specifically towards the surfacing industry so this was a step out of the norm for us. We met some of our existing clients who were exhibiting and even showcasing products that have used Thermaset’s coatings. After the show there were lots of enquiries and orders as be BS, RAL, custom orthe match. aitdirect result from visiting team at Thermaset can meet our customer SubCon. needs from a few kilograms of powder coating - for a special order Thermaset able to bring along - through were to tonnes for a long-term samples from newadding: fluorescents range contract,” hethe said, “We have which generated huge interest and one ofhas the country’sa biggest ranges of stock powders for These next has gone live on ouravailable online shop. day stock delivery across the UK.” new colours, including pink, yellow,

orange, red and green give customers an Among the major markets for exciting new alternative not available from powder coatings are the furniture other powder coating manufacturers’. and industrial sheet metal products.

With more than 30 years of powder coating experience, Thermaset is one of the leading privately owned manufacturers and suppliers in the UK. We offer a wide range of stock coatings with the availability of next day delivery and a choice of the type of powder coatings including epoxy, nylon modified, polyester and architectural. Thermaset also offer a bespoke colour matching Made to Order powder with a 7 – 10 working day turnaround from the sample being received. This year we have released a fluorescent colours range; these are all manufactured onsite at our factory in Staffordshire. www.thermaset.co.uk

Nigel Crane says: “Powder coatings are used extensively on both commercial and domestic furniture primarily because of their toughness, hardness and corrosion resistance.

as well as automotive, shop fitting and enclosure components.

“In the appliance finishing industry the advantages of high corrosion resistance with single coat application has resulted in powder coatings being used on a wide variety of white goods,

For further information Contact Ben Jennens at Thermaset Tel: 01827 55777 or email: ben@thermaset.co.uk Web: www.thermaset.co.uk Issue 24 PECM

EDITORS CHOICE

Denso Stainless Band is a customer focussed leading supplier of stainless coil processed products serving many sectors including automotive, building and petrochemical industries worldwide.

Winn & Coales Denso Tank Base Protection System is being used at the Isle of Grain National Grid site on four of their LNG storage tanks. The installation work was carried out by contractors JPV Painters of Brentwood.

Stainless Band: plant overview • 10 slitting lines, 0.1mm to 4mm thickness range • 1 multi-spindle slitter/bobbin winder primarily for spiral wound gasket feedstock • 4 precision edge dressers capable of full round edge or deburred edges • 1 heavy oscillating spool winder, inished coil weights up to 1,000kg • 1 cut-to-length line 4 metres x 600mm x 3mm • 1 Jones 2-high rolling mill/flattening line • 1 polishing line • Stainless steel grades 304, 316L, 430, 409

To meet various operating conditions at the Isle of Grain National Grid site the Denso Tak Base system was chosen to give effective protection.

Stainless Band have a dedicated multi-lingual team, which is essential when working in the International marketplace.

The Denso Tank Base Protection System is flexible enough to move with the tank when it gets filled and emptied and provides a tough outer armoring.

For more information please visit: www.stainlessband.co.uk

Following surface preparation, Denso Hi-Tack Primer and Denso Primer D were applied. Densyl Mastic was then applied in the gap between the tank and the base. This not only provides a sealant between the concrete and tank base to prevent entrapment of water but also a smooth profile when applying the following Denso Hi-Tack Tape. A single layer of Denso Ultraseal RT Tape was applied and then finally a topcoat.

Rutronik presents IC for Batteryless RF Communication from Panasonic The MN63Y1221-E1 is compliant with JISX6319-4 (212kbps/ 424kbps), ISO/IEC14443 Type A (106kbps), and ISO/IEC14443 Type B (106kbps/212kbps/424kbps) 13.56MHz contactless IC card standard, thus guaranteeing global interoperability. The device comes in a small SON8 package and provides an I2C host interface. It benefits from 8Kbit FeRAM non-volatile built-in memory that enables 100 million write cycles and can be protected by a 128bit password from unauthorized access. www.rutronik.com

www.denso.net

Issue 27 PECM

Annual Photography Competition Celebrates British Manufacturing

hotographers of all experience levels are being asked to get snappy as the annual EEF manufacturing photography competition opens for entries.

defines modern British manufacturing. To give people the best shot at winning, companies are also being urged to open their doors to local photographers to demonstrate what makes manufacturing great.

The competition, now in its 8th year, is asking photographers to submit images that capture the essence of modern manufacturing. Photographs can portray any stage of manufacturing - from design, process and technology in action through to the finished product - and can cover traditional or high-tech sectors.

For information on how to do this, visit the EEF website.

The competition is designed to showcase the creativity, diversity and heritage that

PECM Issue 27

There are three categories to enter: professional, amateur and young photographer, with £5000 in prizes up for grabs between them. Entries will be shortlisted by a panel of photography and industry experts, with winners announced in December.

Terry Scuoler, CEO at EEF, says: “From investing in the future through apprenticeships to proudly standing at the forefront of world leading technology, British manufacturing is the beating heart of the economy. The manufacturing photography competition showcases the ingenuity and creativity that takes place every day in the sector.” The competition closes on Saturday 30th September. For more information and to enter the competition, visit www.eef.org.uk/photo 2017 Amateur category winner by Rob Watkins

The tube-flange connection before welding.

The TIG welding torch: controls for all functions are integrated into the grip, which means there are no cables to worry about. Thanks to the wire feed’s variable setting range, the torch is particularly adaptable to a huge range of applications.

Photo: EWM AG

Hering

with Chocolate ündersbach, Germany, 03/05/2017 – Separated by thick, black curtains, the welding booths line up one next to the other along the large production hall. Tubes of all lengths, thicknesses and diameters outnumber everything else on the workbenches.

All of them are one-offs – except occasionally when a customer orders two of the same heat exchanger. "There is probably not a single bar of chocolate in Germany whose raw material didn't pass through our heat exchangers," says Christian Rasch, CEO of Hering AG.

Production depends on welding

From thin-walled stainless steel tubes with diameters of just a few millimetres to large tubes that could easily swallow a man whole. In black steel and in stainless steel. Hering AG is a German company based in Gunzenhausen in Bavaria's Middle Franconia region.

At the heart of a heat exchanger is the tube bundle that carries the fluid. It is embedded into a large outer tube, or shell, that contains the coolant. The large surface area between the fluids facilitates the transfer of heat.

They turn these pipes into customised heat exchangers for an enormous range of applications, from large power stations, through equipment for the chemical industry, to equipment for the food industry.

Welding is by far the most widely used joining technique in production. Orbital weld seams are used to join the tube bundles to the tube plates. The shells have a wide selection of connection nozzles and flanges welded to them.

PECM Issue 27

The requirements on the weld seams are onerous, with fault-free weld seams being essential to ensure that the different fluids in the heat exchanger cannot mix with one another.

It is extremely important that distortion is kept to an absolute minimum to provide the accuracy of fit between the tube bundle and the shell. In use, these heat exchangers can experience temperature differences of several hundred Kelvin, which leads to extreme thermal loads on the components. Nonetheless, the weld seams must retain their integrity in the face of these extremes. Previously, the welding procedures of choice were MMA and MIG/MAG welding.

The high-quality seam is applied in a single step and requires absolutely no finishing work. Photo: EWM AG

Welding site in the Hering AG production hall. The pipe is mounted on a rotating bearing and turns automatically. This means that the tube-flange connections can always be welded in PA position. Photo: EWM AG

tigSpeed – save up to 50% with the TIG wire feeder from EWM

TIG welding had played a fairly insignificant role at Hering. tigSpeed: superb seam quality at top speed

Robert Bernhard works for Slatina Schweißtechnik, a sales partner for EWM, a welding machine manufacturer based in Mündersbach, Germany. He has been supporting manufacturing at Hering AG for many years and is always on hand to offer advice and assistance to the Head of Production, Manfred Lepp. On one of his visits, Bernhard suggested that Mr Lepp might wish to consider an alternative technique for welding the many tubeflange connections: TIG welding with tigSpeed. EWM tigSpeed is a TIG wire feed welding machine that is perfectly suited to welding tube-flange connections. tigSpeed mimics manual TIG welding by introducing forward and backward movement in

addition to a continuous wire feed. As a result, the welding consumable is repeatedly drawn out of the weld pool and passes over drop by drop. In the case of hot wire welding, the welding consumable is preheated. This further increases the deposition rate, which allows the consumable to flow better, thereby producing a very uniform weld seam. The advantages are obvious: thanks to the automatic wire feeding, the welder can concentrate totally on the welding process. Their second hand remains free and can support the guide hand. "It's a great help, particularly with long seams," explains Valmir Xhaferi, a welder at Hering AG. "A flange can be welded onto the tube in a single step – and there are no contact points caused because I don't need to change welding rods." A positioner makes the tube turn continuously. This means that the

operating point remains in the same place in the flat position. For the outer seam, this is on top of the tube, and for the inner seam, it is on the upwards-facing side of the inside of the tube. Combined with the high deposition rates of the hot wire technique, this constant working position means that high welding speeds can be achieved while at the same time ensuring outstanding seam quality.

Easy handling – quiet working It only took the welders at Hering AG half an hour to get fully up to speed with tigSpeed. Controlled using oneknob operation, handling is really straightforward, and a digital display guarantees reproducible parameter settings.

www.ewm-group.com

Thanks to its ergonomic construction, the welding torch is particularly easy in the hand and also allows welders to work for long periods without tiring. Because all functional controls are integrated into the torch neck, there are no cables to worry about. What's more, the wire feed has a variable setting range from 15° to 42°, making the torch particularly adaptable to a huge range of applications. During welding, the arc crackles quietly while the wire feeder emits a discreet hum. "The biggest benefit is how quiet the machine is," notes Valmir Xhaferi, "much quieter than the machines from other manufacturers that I know." When Robert Bernhard wanted to collect the tigSpeed again a week later, the welders were already arguing about who would get to work with the machine. It didn't take long before Hering AG decided to get a tigSpeed to call its own.

PECM Issue 27

And they have added another one every year. An increasing number of tube-flange connections that were previously welded using MMA are now being welded with the tigSpeed – delivering savings of up to 50% thanks to the reduction in non-productive time alone. "Imagine how high the savings must be at companies that don't have the set-up time that we do," speculates CEO Christian Rasch. Currently, each of the three welding procedures – MMA, MIG/MAG, and TIG – is used for about a third of the welding tasks. This means that many seams that were welded using MMA in the past are now TIG welded using tigSpeed. Christian Rasch is clear about the quality, "Our customers say there are many heat exchangers on the market. But none as fine as ours. And they are not talking about fine design or construction, but rather the weld seams. They are always the first thing that our customers look at."

Totally satisfied with the introduction of tigSpeed at Hering AG: Head of Production, Manfred Lepp, Hering AG; welder Valmir Xhaferi, Hering AG; Robert Bernhard, Slatina Schweißtechnik; Dieter Raab, Slatina Schweißtechnik. Photo: EWM AG

A controller with one-knob operation makes handling really straightforward, and the digital display guarantees reproducible parameter settings. Photo: EWM AG

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Hilsonic ultrasonic cleaning tanks are built to customer specifications

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Hilsonic is a specialist in the supply of ultrasonic cleaning equipment for the power7HO generation and ZZZ KLOVRQLF FR XN marine industries

PECM Issue 27

Issue 16 PECM

Editors Choice

THE BENCHMARK IN BEARINGS Ball, Needle and Roller Bearing solutions, ensuring precision engineering to give you maximum results! Our demanding applications lead to our innovative and class leading new Spherical Roller Bearing design.

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Issue 27 PECM

Air, Gas & Odour Control Air Gas & Odour Control

Helapet launch new Filter Device Catalogue 5IF art PG mMUSBUJPO UBJMPSFE UP ZPVS OFFET

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JASIC 500 pulse AC/DC TIG Gas A package nalyse r Filters

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Helapet are delighted to introduce our new Filter Devices Product Catalogue, showcasing our comprehensive range of off-the-shelf and custom made inline filters.

Our 8 page product guide showcases Helapetâ&#x20AC;&#x2122;s Putting air pollution on the map commitment to providing customers with an Introducing the MaxiFlow 30-C Nitrogen Gas of air pollution may have changed essential selectionTheofnature filtration products, covering Generator: the latest offering the in its latest high- solutions in recent decades, but a it still has a significant for supporting comprehensive spec equipment portfolio. MaxiFlow 30-C on health and wellbeing across the range of industriesimpact including medical, environmental, is a medium flow, medium purity Nitrogen world, especially for those with underlying laboratory and print. generating system, with an integrated air respiratory conditions.

MaxiFlow 30-C

Supported by a 5 year warranty, key features of this product include programme memory storage, pre-post flow time, up/down slope, AC function for aluminium and aluminium â&#x20AC;&#x2DC;plug &your way through our range of bespoke atalogue compressor, making it an all-in-one Navigate alloys, DC TIG function for carbon steel,ccopper To combat this global health menace, playâ&#x20AC;&#x2122; option. Perfect for areasfiwhere spaceoptions is ltration by countriesâ&#x20AC;&#x2122; selecting yourprocesses size, media, and non-ferrous materials, remote control many planning require limited, but reliability is crucial. Ink-Je t Filtersdisplay. interface, pulse adjustment and digital connections and printing or choose from calculationsoptions, for the dispersal of air pollution, Designed to deliver larger capacity flow our off -the-shelf standard fi lters perfect for your when developing new buildings and Industrial grade components ensure high rates of nitrogen, this generator is able to Available infrastructure. industry. in hard copy or to download, welding performance and reliability. transform compressed air from its surrounding contact information is also included help the access Mapping software is usedto to bridge gap environment into 99.99% Nitrogen, exceeding The TIG package includes TIG torch and free, dedicated consultancy support. between the science needed to understand it the specification of UHP cylinder gas. Nitrogen adaptor, gas regulator, work return lead and and engineering being planned to mitigate it. Helapetof filtration devices are manufactured to is produced by utilising a combination clamp. Understanding this can help people identify state-of-the-art purification technologies andand are ISO 13485 tested and validated in-house. An optional foot control unit is readily and control air pollution. high efficiency filtration. We work to the highest level of in-process quality available. www.soundplan.eu/english/soundplan-aircontrols and monitoring for all our filter components. In addition to our generator range, we also Online The Jasic 500 Pulse AC/DC TIG is available pollution/ supply world class air dryers and air treatment Request your copy by emailing through leading welding distributors. products for a range of systems and needs. Key Fea tures

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The Professional Choice for Portable Fume Extraction and Confined Space Ventilation he Miniveyor Air VAF series vane axial fans and ventilators form VAF Air Ltd are the professional choice for portable dust and welding fume extraction.

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. Compare this with conventional metal bodied fans that typically donâ&#x20AC;&#x2122;t last very long in the workplace, as the sheet metal bodied fans tend to dent easily when knocked, so they will need replacing. The plastic moulded fans from VAF Air are highly resistant so they can last a much longer time. Additionally, all the parts are replaceable so if anything does get damaged then they can be changed easily. The Miniveyor Air VAF fans work on both positive and negative air flow,

so are equally at home extracting as well as blowing and are great for ventilating confined work spaces. When working in confined spaces it is recommended that you change the air at least 20 times per hour, or once every 3 minutes, and that you not only extract the air but also utilize a blower to push clean air into the work space. To use this recommended method, you would need 2 or more openings to your confined work space and employ 2 fans. If you only have 1 opening, then you should use positive airflow and use the fan to blow air into the confined work space. New for 2017 is the VAF-EF400 which is designed to push large volumes of air into a hard to reach areas or through ducting. Driven by a precision balanced, cast aluminium 17 blade turbo impeller, the VAF-EF400 delivers a whopping 10,360 mÂł of air per hour. Visit us online at www.vaf-air.com or follows us @VAFAirLtd

Issue 27 PECM

Boilers & Maintenance

S Benefits from nomic Upturn

Boilers & Maintenance Imax Xtra EL top of the class on NOx emissions

Thermal Services, are beneﬁting from the vity increase in the manufacturing sector rly in the Aerospace, Automotive and Steel ‘Real Time’ Remote Major hospitalthe acts toeconomy ensure es. Although would seemMonitoring to have For The Boilerhouse continuity of heating in the corner and is now in‘HALO’ the right direction, it event of boiler systemheading failure uses cutting edge technology, creating a monitoring system uses analogue, for yet demonstrated suﬃancient growth orwhich stability A major UK hospital has implemented digital and mod bus for a critical overview into emergency contingency plan to ensure turers to invest in new capital assetplant. performance.Therefore the continuity of heating and hot water to wards, operating theatres and offices in the event of Benefits al production demands must beinclude: met by existing failure of its primary boiler system. The FM company responsible for building services on the large site has contracted Watkins Hire to provide a high efficiency standby boiler system to replace the main boiler in the event of failure, under the hire specialist’s Temperature Control Emergency Planning Services (TCEPS) scheme

WTS Benefits from Economic Upturn

Wellman Thermal Services, are benefiting from the productivity increase in the manufacturing sector particularly in the Aerospace, Automotive and Steel industries. Although the economy would seem to have turned a corner and is now heading in the right direction, it has not yet demonstrated sufficient growth • Cost savings through optimal or stability for manufacturers to invest in performance. new capitalIdeal plant. Therefore the additional Leading British manufacturer, Commercial Boilers is • Instant alerts on failures – ‘when it production mustboiler be metin byits existing committed to ensuring that every demands condensing range matters’. plant. outperforms current regulations in terms of output, efficiency and • The ability to determine both energy use. In keeping with thisand undertaking, the latest addition Running maintaining industrial heating maintenance and investment strategy. to its floor standing condensing boiler range, the Imax Xtra EL plant, in some cases as much as sixty years • Predictive maintenance to prolong launched in January 2016, is the aonly boiler to have been old, requires lot ofUK time and effort especially equipment life. awarded a Class 6 NOx given rating from the European Standard EN new demands for increased production, • Minimal downtime 483: resulting in increased 2000 relating to gas fired energy centralconsumption, heating boilers. Several reduced etc. revenue. have already been installed into the educational, religious and Tel: 0121 543 0000 manufacturing market sectors. T: 0113 220 3830 www.wellman-group.com E: info@jbcmail.co.uk Ideal Commercial Boilers W: www.jbcindserv.co.uk Tel: 01482 492 251 • Email: commercial@idealboilers.com www.idealcommercialboilers.com.

and maintaining industrial heating plant, in some cases as much as ars old, requires a lot of time and eﬀort especially given new demands eased production, reduced energy consumption, etc. With a pedigree For more details,years call 0800 999 6 365 orincorporating email ng back 110 and some of the UK’s best known furnace hire@watkinshire.co.uk , or visit www.watkinshire.co.uk/tceps together with an extensive archive and spares inventory, Wellman’s Team are perfectly placed to meet the needs of manufacturing industry ng its furnace equipment, regardless of manufacturer, operating at peak ance.

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PECM Issue 27

130x98mm CFB Boilers Advert.indd 1

Introducing Contour Plasma Profiling with Infinity Skew Head Technology THE ULTIMATE TECHNOLOGY IN WELD PREPARATION

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Brown McFarlane is one of the world’s leading specialist steel plate Distributors, Processors and Profilers. Dealing primarily with Western European mills we supply industry leading customers across the world. Our focus is on the supply of High Grade Carbon and Stainless Steel products with one of the most diverse stock ranges available anywhere in the world running from carbon Manganese through to Super Duplex Stainless Steels. Within our 100,000 sq.ft processing facility we possess a wide range of plate profiling equipment which has recently been complemented by the most sophisticated Messer machine yet, the Infinity Contour Plasma Beveller, capable of producing virtually all weld-prep configurations imaginable. Allied to our numerous accreditations including ISO 9901, 14001 and 18001 and Rolls Royce Nuclear approved, our ability to offer precision cut complex shapes in all thicknesses and grades is unrivalled.

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03/05/2017 15:18

PECM Issue 22

Tel: sales

Boilers & Maintenance

Boilers & Maintenance Your burner system is crucial, so we think it needs looking after. That’s why we created BurnerCare. We just think it adds up –

How do Gas you Process Burners Burner commissioning – on site start up service to ensure make sure that your maximum efficiency. burner operation Plus Annual service agreements – planned • maintenance, discounted service visits and cost is efficient effective spare parts pricing. • and reliable? Plus 24/7 breakdown response – single visit solution •

Lanemark gas burner systems offer users reliable, high efficiency, process heating solutions. FD Series Packaged Oven/Dryer Burners Specifically designed for process air heating applications in convection ovens and dryers High turndown/short flame lengths providing accurate process temperature control High efficiency gas + air modulation, gas only modulation and simple for most emergency call outs. high/low control options Heat Input Range: 9 kW – 1550 kW

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pes offered are Gas, Light Oil, LPG and Bio Fuel, with nation burners offered on all units from 500kg/hr upwards. vailable are a range of Electrical Steam Generators from 120kW. SS also offer a new “TC Model” with touch screen control l modulation from 50-100% firing. The TC offers output from 500-2000kg/hr and is compatible with many BMS ce provisions such as Profibus and Modbus etc.

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Issue 27 PECM

PECM Issue 10

How Are Aluminium Die Cast Products Produced? luminium die casting is used for a wide variety of applications, from door knobs to an entire engine block. Whilst many people have heard of the term few are aware of the processes involved.

Die casting was initially invented in 1838 for the printing industry and with the growth of consumer products some 20 years later it became part of the manufacturing process for many other goods. Starting off with lead and tin, the alloys used were then surpassed by aluminium and zinc. High-pressure die casting consists of four different stages, die preparation, filling, ejection and shakeout. Firstly the mould cavity of the die is cleaned and sprayed with lubricant, aiding in the removal of the casting whilst also

maintaining the temperature of the die. Once the two die halves are closed and clamped together, high pressure molten aluminium is transferred from the furnace into a chamber and injected into the die. This fills the mould cavity, which is pressure controlled (typically from 1,000 to 20,000 psi) cooling rapidly until the casting becomes solid. The injection time is usually less than 0.1 seconds to inhibit any one part of the alloy solidifying, although this injection time can vary dependent on the alloy used and the castings wall thickness - the larger the wall thickness, the longer the injection time. Once the molten aluminium fills the cavity and cools, the finished shape of the casting is formed. The die halves can now be opened and an ejection mechanism pushes the casting out of its mould. The force of the mechanism must be strong enough to eject the part as it shrinks whilst cooling and adheres to the die. Once

ejected any excess material is manually trimmed from the casting, and this unrequired material can then be reused. The advantages of using aluminium in die casting are that it has a very good stiffness, superior corrosion resistance when compared with other alloys, is strong yet lightweight and has a high electrical conductivity. It also possesses excellent finishing characteristics and is fully recyclable. UK based Mark Aluminium Die Casting (MADC) has been manufacturing cast aluminium products for over 30 years. As part of the Mark group it is established in the manufacturing of water pumps for a wide range of automotive manufactures, including such established names as Jaguar, Aston Martin and Land Rover. MADC also specialises in the production of heat sinks for LED lights and processors and impact resistant electrical enclosures.

"Having our own on-site foundry is a big advantage in being able to manufacture various types of high pressure die cast products. This enables us to be flexible in producing practically any type of small to large volume die cast product quickly and efficiently. We strongly believe in manufacturing a high standard of finished product but also understand that it needs to be cost effective for our customers. To this end we are able to offer a variety of dies and moulds to satisfy the largest range of price, precision and volume demands"

David Lewis Plant Manager of both Mark Aluminium Die Casting and sister company Mark Water Pumps

www.mwpl.eu

Award Winning Temperature Calibration and Measurement sothermal Technology Ltd (Isotech) was founded by John Tavener in 1980; the company has since developed a range of precision temperature measurement and calibration products becoming a world leader in the field.

In 2017 Isotech is celebrating winning the Queen’s Award for Enterprise, in the Innovation category, for the co-development of an innovative resistance bridge for use in the highest precision measurement applications and the establishing and dissemination of the International Temperature Scale (ITS-90).

Trust in Isotech Isotech have been pioneering the latest developments in Temperature Metrology for more than 35 years and continue to develop the best temperature standards used by top calibration facilities – our clients range from sole traders to the largest National Metrology Institutes.

The product, called the microK, is now in use in the world’s leading National Metrology Institutes (NMIs) alongside Primary Standards. Outside of NMIs the client base includes oceanography, aerospace, medicine and astrophysics. Complete Temperature Solutions Isotech also manufacture a full range of equipment for precision temperature measurement and calibration. The microK is used with Isotech Primary Temperature Standards, Fixed Point Cells and Standard Thermometers used internationally to establish the International Temperature Scale. Outside of Primary Laboratories Isotech manufacture and supply equipment for accredited temperature laboratories, research laboratories, pharmaceuticals, and oil and gas companies allowing clients to calibrate a wide range of devices from -200°C to 1300°C. For industrial calibration outside of laboratories there is a full range of calibration equipment that includes portable dry block calibrators, liquid baths, furnaces, infrared calibrators and thermocouple referencing systems. Calibration Laboratory Isotech operates an accredited laboratory (ISO/IEC 17025) with world leading uncertainties, better than many National Measurement Institutes. This not only ensures our customer’s receive the best possible calibration service but also helps maintain Isotech’s position as a global leader in its field as the laboratories form the focal point of Isotech product research and development.

www.isotech.co.uk

Isotech have Temperature Calibration Solutions for: • Industrial Temperature Sensors • Portable Temperature Calibrators from -100°C to 1300°C • ISO 17025 Accredited Laboratories • From -200°C to 1300°C • Cryostats, Stirred Liquid Baths, Calibration Furnaces • Primary Standards • ITS-90 Fixed Point Cells from the Argon Triple Point to the Freezing Point of Copper • Precision Temperature Measurement • From Thermometry Bridges to Precision Thermometers, accuracy better than 0.001°C • Infrared Thermometer Calibration • Blackbody and ITS-90 Fixed Point Systems • Thermocouple Referencing • For Laboratories and Multi-Channel Industrial Systems

Issue 27 PECM

In the future, we could see SCADA projections onto a pair of safety glasses or a virtual reality (VR) headset

What does the next generation of SCADA have to offer? Thirty years ago industry pundits were predicting the death of SCADA as a technology, saying it would have no place in the plants and factories of the future. But contrary to this the technology has constantly evolved in line with user requirements, and indeed continues to evolve. Paul Hurst, MD of Products4Automation (P4A) vendors of the Movicon SCADA Suite explains what the next generation of SCADA will bring to the party. Despite all the talk of 'lights out factories', there will always be a need for people to interact with machines and processes, to visualise operations and respond to performance indicators. Currently this usually happens locally, but there is a trend towards more and more remote access. Going forward, remote operation may become the norm. We are already seeing SCADA beginning to move from PC screens to remote devices. In the future, we could see projection

PECM Issue 27

onto a pair of safety glasses or the use of a virtual reality (VR) headset. Putting our imaginations into overdrive, maybe one day SCADA info will be delivered straight to the operator's cortex. But for now the need is to put information on a screen and allow operators to navigate through it and use the interface to make control adjustments. What will define the next generation of SCADA then, and how will it continue to drive the evolution of plant integration and process control? In short, the key innovations of this next generation SCADA are how it goes about collecting data and storing it so that it can be aggregated, processed and transmitted to the screen for display. The latest SCADA products are platforms with a suite of modules and options, rather than fixed hard-coded proprietary programs. This configuration makes them very flexible and scalable. Further we are seeing important innovations in communications and networking, cross-

platform compatibility, database flexibility and visualisation. A key driver for modern communications and networking is OPC UA (open platform control, unified architecture), and next generation SCADA products will increasingly be based on client/server architectures that use information models defined by OPC UA standards, exploiting the WCF (Windows Communication Foundation) technology in the communications infrastructure. Not only does this drive new levels of openness in the way SCADA is integrated with the plant automation and IT infrastructure, it also massively simplifies the way communications are established with control devices. OPC UA includes a large number of I/O drivers, so is capable of managing protocols of all the most widely used automation devices. This vendor neutral approach also extends to cross-platform compatibility, with next

We can expect further benefits too with technologies based on 64-bit.NET code to guarantee reliability, openness and performance.

generation SCADA offering web client solutions using HTML5 technology. This makes it simple to enable remote access to field applications with guaranteed performance and crossplatform integration. Furthermore we are increasingly seeing dedicated apps specifically designed for smartphones and tablets, making it even easier to securely control and monitor plants and processes over the web. Database flexibility is becoming increasingly important in SCADA applications, and next generation products will use their own virtual file system (VFS) to render applications independent from

persistent data models. This gives users the capability and flexibility to connect to relational databases, use cloud computing or use standard XML files on disk for historical logging and archiving process or project data. From an operator interaction perspective, perhaps some of the most important developments are in the visualisation capabilities of next generation SCADA. New user interface concepts use the latest generation of DirectX graphics acceleration to fully exploit the exceptional quality of WPF/XAML (Windows Presentation Foundation / eXtended Application Markup Language) vector graphics technology in 2D and 3D. This can make the visualisation of processes on the screen clearer and more intuitive. At the same time, todayâ&#x20AC;&#x2122;s tablet and smartphone generation of users now expect features such as multitouch and gesture control from the consumer environment to be standard within the plant control world. In next generation SCADA, a diverse selection of objects

and symbol libraries now provide native support to the very latest multi-touch and Kinect user interface technologies with Windows 10 styling and navigation. Plug-in models ensure full customisation of modular systems and integration of new customised modules. These frameworks can offer a full suite of functional modules capable of guaranteeing rich and complete supervision and user interface solutions with total openness and expandability. Some of this may sound futuristic, but all these functions and capabilities are available today in the Movicon.NExT SCADA platform. This was created using the best and most innovative technologies to ensure users reap the maximum benefits from supervision, HMI, control and plant intelligence systems. The result is that the Movicon.NExT satisfies all of todayâ&#x20AC;&#x2122;s emerging communications and interoperability requirements, while providing a platform on which users can build on the goals of Industry 4.0. www.products4automation.co.uk

In next generation SCADA, a diverse selection of objects and symbol libraries now provide native support to the very latest multitouch and Kinect user interface technologies with Windows 10 styling and navigation.

How to check if Cooling Output inside Enclosures is Sufficient By Jason Swann, Rittal Product Manager for Climate Manufacturing automation systems are delicate and very expensive pieces of kit, which perform vital functions for the businesses they serve. The enclosures that protect them must have strictly controlled internal environments with interior temperatures that are carefully maintained within a few degrees. If not, the impact can be harmful to the inverter drives, power supplies, contactors, PLCs and other electrical and electronic components operating within them. This requires careful control of the climate within the enclosure. Here, we offer some practical tips on how to evaluate an existing enclosure climate control through a series of simple checks. ike all electrical equipment, drives create heat and they therefore have a major influence on the temperatures inside enclosures. Drives are often quoted as having efficiency of 97 per cent, so one with a rated output of 150kW can produce as much as 4.5kW of heat.

an internal enclosure temperature of 35°C. This means that the performance of a cooling unit should be specified so that the average internal enclosure temperature of 35°C can be guaranteed under all load conditions and under all the ambient conditions that could be met at the machine’s location. Checking the enclosure temperature.

As well as the heat loss inside the enclosure, ambient temperatures within a production facility will also have an impact on the temperatures that a drive is operating within. A typical enclosure climate control system is designed for

The first check is to measure the temperature within the enclosure to assess its climate control capability. Temperature sensors should be placed in a position within the airflow of the enclosure,

sensors should not be placed on or near direct airflow from high temperature components. Otherwise temperature readings can be found to be inaccurate. The sensors should be left to monitor the temperature trend over a period of time. If the sensor records air temperatures of well over 35°C (set point) then the output of the cooling unit should either be considered insufficient or, alternatively, that there has been a malfunction of the cold air routing in the enclosure. This means that the cooling air cannot reach (or can only partially reach) the temperaturesensitive components.

Enclosures from the smallest to the largest. ENCLOSURES ENCLOSURES

POWER POWER DISTRIBUTION DISTRIBUTION

CLIMATE CLIMATE CONTROL CONTROL

Checking the control behaviour of cooling devices Another easy way of checking an enclosure climate control system is to observe the cooling unit’s control behaviour: Unlike speed-controlled cooling devices such as the new Rittal “Blue e+” cooling units, conventional enclosure cooling units begin with the two-point regulation of the cooling operation when a temperature inside the enclosure gets above of 35°C and finishes when the shutdown temperature of 30°C is achieved (at a typical hysteresis of 5K). If a cooling device does not reach the shutdown temperature,

IT IT INFRASTRUCTURE INFRASTRUCTURE

a conventional cooling unit will therefore continue to operate. If this happens, it’s a good indication that the cooling unit has an insufficient output and suggest that there is likely to be a deficiency in suitable cooling air to the components inside the enclosure. You can simply touch a device to determine a refrigerator’s operating status: the activity of the refrigeration compressor during cold production is accompanied by a slight vibration of the refrigerator housing that can easily be felt. Alternatively, the exhaust temperature of the cooling unit in the external air circuit may be measured. During active cooling operation, this will be significantly higher (potentially, anywhere between 10° and

40°C) than the ambient temperature. Locating hotspots You can also do a rough check of an enclosure’s climate control system with infrared thermography which measure the surface temperatures of the components inside the enclosure and these are recorded with an infrared camera. If any areas have significantly elevated temperatures (“hot spots”) it is an indication that they are not being supplied with enough cooling air. www.rittal.co.uk

SOFTWARE SOFTWARE & & SERVICES SERVICES www.rittal.co.uk www.rittal.co.uk

How secure is your PLC? any people fall into the trap of thinking that their business activities are of no value to hackers, and that therefore they’re unlikely to become a target for a cyberattack. However, all data and/or processes could be of value to somebody, whether it’s obtained via industrial espionage, state sponsored hacking, or organised crime and extortion. Protecting critical processes against cyberattack has never been so important.

transport layer security) is a handshake protocol that automatically generates a cipher to encrypt and decrypt communications for a session between authenticated devices. This prevents unauthorised devices from being able to communicate with the controller. SSL/TLS uses digital certificates for authentication while some other protocols do not.

A programmable logic controller (PLC) is a critical part of process industry automation infrastructure, and disabling one could take everything under its control with it. This can make them high value targets for hackers. When many of the fieldbus protocols used by PLCs, such as PROFINET and Modbus, were first developed, the focus was on maximising speed, functionality and reliability rather than security. Modbus, for instance, transmits data in plain text and has no protection against unauthorised access or interception of data. It therefore falls to the PLC to provide the required layers of security to protect systems against attack. PLC cybersecurity has come a long way in recent years, but the long lifespan of a typical PLC means that a company’s installed base may well predate these advances. Cybersecurity simply wasn’t the risk even 20 years ago that it is today. Retrofitting security features into existing controllers can be difficult, as older PLCs will often have very little memory and/ or CPU power to spare for adding in new features. So the challenge is how to upgrade PLC cybersecurity without causing too much disruption. Today‘s PLCs come packed with a variety of encryption protocols, VPNs (virtual private networks) and firewall capabilities to minimise the risk of unauthorised access. The appropriate combination of security measures for a particular controller will depend on how it is used. Much like a castle might have a moat, drawbridge, portcullis, high walls and turrets, no single one of these will deter all attacks on their own. They are instead elements of the overall security package, and are used in combination to protect systems. So it is with PLC cybersecurity. For example: •

SSL/TLS (secure sockets layer/

PECM Issue 27

•

SSH (secure shell) is a similar form of security that provides a secure channel over an unsecured network. This can be used for remote logins to devices, which is not possible using SSL/TLS alone. SSH can potentially enable secure access from anywhere in the world, assuming the user has the correct passwords. VPN (virtual private network) extends a private network across a public one, creating a secure virtual tunnel between devices, as if they were directly connected next to one another. Firewalls monitor and react to incoming and outgoing traffic, forming a barrier between the internal network and other, potentially nonsecure networks like the internet. It can help detect a DDoS attack, but is not always effective at defending against one in progress.

No system is completely infallible, but features like those described can help to reduce the likelihood of unauthorised access. However, it’s important to remember that these protections are largely meaningless if passwords are compromised, which is why many hackers increasingly use phishing attacks to prey on human error rather than any vulnerabilities in the system. It’s therefore crucial to keep passwords safe and secure, and to regularly change them, as the protections are only as strong as the humans who use it. WAGO’s PFC100 and PFC200 programmable logic controllers include a wide range of the latest security protocols, including SSL/TLS, SSH, VPN and firewall, as well as others such as IPsec, HTTPS and more. This affords users the flexibility to

use the appropriate protocols based on how the controller is used while ensuring a high level of security. The controllers are also compatible with all major fieldbus protocols, making installation quicker and allowing the WAGO PLC to work happily with devices from other vendors. Compatibility means users aren’t locked in to a proprietary protocol or language, as they can use what they’re already familiar with, and the installed base can be updated gradually rather than all at once. The Linux operating system is open-source, allowing users to access and develop patches for the source code. PLCs are just one of the many devices in a plant that must be considered in the context of cyber security protection. But considering its importance at the centre of a plant’s operations, it is vital to utilise the latest features and technologies in protecting against attacks. WAGO Limited Visit: www.global.wago.com/uk Telephone: 01788 568008 Email: ukmarketing@wago.com

Decentralised collection of sensor and actuator signals u-remote Modules in IP67: robust, versatile and flexible he rise in complexity of machines and systems is placing increasing demands on modern automation technology. Branched subsystems need to be precisely integrated into complex topologies. A rapid and reliable transmission of signals and data is critical for smooth operation. Small and adaptable components which can be integrated in an application-specific manner are needed. Flexibility in the design and cabling of your systems, reliability in the transmission of signals and data, and very compact solutions - Weidmüller's remote I/O systems for protection degrees IP 20 and IP 67 offer all this and more.

In both machine and plant construction, sensors and actuators from the entire machine have to be connected to the control unit. Depending on the machine, the size and also the count of the signals may be very large and therefore fieldbus and IO systems can be used to collect the signals locally. The progressive decentralisation requires more and more automation systems to be brought out from the control cabinet into the field, but decentralising machine automation can prove challenging for I/O systems’ mechanical properties. IP67 remote I/O modules are used wherever there are increased requirements in terms of particle and humidity protection. Indeed, they should offer high performance. But at the same time, they must remain robust, small and as light as possible, so they can be put to good use on moving machine parts. u-remote’s new IP67 family combines all the field benefits offered by u-remote IP20 in a device with an increased degree of protection and is perfectly equipped for signal connection outside of the panel. In the variants with a sub-bus system, this is

PECM Issue 27

done very flexibly and in a wide range of applications. Direct incorporation in the PLC programming environment, rapid definition of causes in the event of faults and a very narrow and lightweight design are the characteristics which make this system unique on the market. It is not only the manufacturing processes within machine construction that are complex. Companies that want to make worldwide deliveries to customers are frequently confronted with specific challenges. The Weidmüller u-remote IP67 product family makes sure that you are ideally equipped for international operations. When selecting the power supply, you have the simple choice between a 7/8” connection or an M12 connector with L-coding. The coded connections help ensure that no mistakes are made during cabling. What’s more, the power supply, fieldbus and I/O components are colour-coded, which facilitates intuitive working. The use of Weidmüller module markers helps to make work even easier, particularly for customers that do not have any specialist staff on site.

and solutions that can be used. This means that you are able to easily connect the corresponding IO link sensors and actuators. Alternatively, the channels can also be configured as standard digital inputs and outputs or you can use analogue IO link sensors and actuators. This allows for more functions to be mapped to an individual module, which often results in the capacity being able to be increased. The two compact and lightweight designs simplify the planning of installation surfaces und cable routing. The more complex a production process becomes, the greater the number of processing stages that need to be coordinated. A large number of sensors and actuators within the production facility are connected with the central control system. In many cases, these connections have to cover great distances and involve the processing of many different signals. When employed in such connections, u-remote IP67 ensures maximum power in the system. The M12 L-coded connectors provide a 16 A power supply – i.e. more power in the system – and need fewer power-supply units, which means that much less time and effort needs to be spent on cabling.

Smart inventory reductions are available as multi-protocol modules and mean you no longer need to use different modules for PROFINET and Ethernet/IP. You simply have to select the fieldbus using the rotary switch. Both fieldbus systems can be operated with an L-coded M12 connector or 7/8“ connections, with only a cable set being needed in both cases. This helps to reduce the number of items used and orders made, as well as simplifying your warehousing processes

A fully encapsulated zinc die-cast enclosure protects electronics from vibrations, welding sparks and moisture during operation making them perfect for industrial environments. With compact features in both 60mm and 30 mm wide designs, they are particularly suited to confined spaces. Even the short length of the modules and their low weight are to be highlighted as they offer advantages for many applications.

Featuring I/O link technology, flexibility is greatly increased. u-remote IP67 ensures the greatest degree of flexibility in the different types of connections

You can see more information on the Weidmuller website or www.weidmuller.co.uk; alternatively you can call on 0845 094 2006

u-remote : now with IP67

You need flexible I/O systems for your facilities u-remote offers more performance and reduces complexity Let’s connect. You need an I/O system that allows you to work fast and flexibly. A system that won’t leave you in the lurch as facilities become increasingly decentralised. The particularly compact u-remote system, which comprises IP20 and IP67 components, makes for maximum benefits and flexible use during automation. u-remote’s new IP67 family is perfectly equipped for signal connection outside of the control cabinet and combines all the field benefits offered by u-remote IP20 in a device with an increased degree of protection. With its M12 L coding and 7/8’’ connections, u-remote IP67 guarantees global flexible connectivity and maximum power transmission. And best of all, with Weidmüller as your partner, you have a complete solution in your hands. Sales: 0845 094 2006 Tech: 0845 094 2007 Email: marketing@weidmuller.co.uk

Multi-protocol function, extended diagnosis and parameterisation

High-performance with up to 16A of power supply

PROCESS INDUSTRY RMIG is the world’s largest manufacturer and supplier of perforated metal and related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service.

Solutions For The Process Industry

Boilers & Maintenance RMIG is the world’s largest manufacturer and supplier of perforated metal and related products. We know our customers’ requirements for price and quality and meet their demands with uncompromising service. Processing encompasses a vast number of potential applications for perforated products and is probably the sector where applications for perforation are most varied. RMIG has signi cant experience in the chemical, pharmaceutical, paper and o shore industries, to name but a few. Ranging from small, high-precision perforation in thin materials to large holes in thick sheets, we have the knowledge, expertise, tooling and the materials to deliver products according to your requirements. www.rmig.com

Processing encompasses a vast number of potential applications for perforated products and is probably the sector where applications for perforation are most varied. RMIG has significant experience in the chemical, pharmaceutical, paper and offshore industries, to name but a few. Ranging from small, high-precision perforation in thin materials to large holes in thick sheets, we have the knowledge, expertise, tooling and the materials to deliver products according to your requirements.

www.rmig.com

Choose the right tool

Get the results that only the right tool can give When you’re ready to automate your business, choose the automation tool that fits your needs exactly. Collaborative robot arms from Universal Robots work safely side-by-side with your employees. These innovative automation tools are lightweight and easy to move and program, so you can optimize production for processes from gluing, welding and assembly to machine tending and pick-and-place. And Universal Robots offers the fastest payback in the industry. Get the results that only the right tool can provide. Book a demo at your local distributor or read more at www.universal-robots.com

Issue 27 PECM

Optimas Solutions Supplies Global Expertise With A Local Touch he phrase 'global supplier' creates thoughts of shipping containers travelling the world and large multinational corporations employing highly complex logistical operations; all controlled from a centralized super-hub. However, this is not an entirely accurate reflection of what it takes to be a truly successful supply partner to a global customer base. Traditional global frameworks can be slow to respond to local concerns, while moving products around the world can also be costly and time consuming. Therefore, to effectively service demands with speed at a local level, a global approach must be blended with a local outlook - a scalability of service.

Optimas is a business that delivers its expertise globally â&#x20AC;&#x201C; aiding OEM manufacturers and tier 1 suppliers by streamlining logistics frameworks and providing high quality fasteners and c-class components for various stages of the production cycle. Of course, due to the range of industries and regions the business services, a uniform approach will fail to satisfy the differing demands of each customer. The requirements of building a heavy duty truck compared to manufacturing power generation equipment are entirely different, so the approach has to be different. Even the same customer may take a different approach in each of the regions it conducts operations, which complicates strategy further.

Choosing a global supplier should guarantee a certain quality in service and products. Simply put, companies that supply inferior products do not become global. Globalization ensures that only the most integrated and capable businesses fully benefit from the global marketplace; and to hold market position in what can be a volatile global economy denotes a business of clear objectives and exemplary practice. This breeds trust and confidence in a supplier. However, to successfully integrate with multiple regions as a global supplier, maintaining this confidence requires a consistently reliable and thoughtful service at a local level.

Optimas is a global distributor of fasteners and c-class products. Optimas at its core is a provider of integrated supply chain solutions and engineering support focused on delivering highly engineered fasteners to world-class customers around the world.

www.optimas.com

Ultimately, serving an OE customer globally across various geographical areas demands an innate understanding of that business, its products and the different regions where they are produced. It is therefore helpful to engage with local engineers and management on a branch by branch basis – which enables a supplier to view the landscape through their customers' eyes in terms of business structure and operations. This can be achieved by permanently stationing engineers on-site, or by supporting areas via local supply branches which are specifically tailored to service customers in certain locations. Either way, consistent local contact is the best method. Local support from a global supplier offers total flexibility in terms of service.

The pedigree of a proven product or service, delivered with the speed of a local supplier is undoubtedly the best of both worlds. It is a relationship that has been struck between Optimas and many of its customers around the world – relationships that have been ongoing for many decades. Operating a global supply chain should be seen as a collection of assets which are there to be utilized as necessary; rather than a one-size-fits-all supply solution. As a global business, offering customers the quality assurances and vast portfolio is highly beneficial. But to nurture and grow relationships, care must be taken on a local level.

Assessing a customer's facility locations, target sectors and overall size – then adapting the supplied services to suit individual operations accordingly – enables the global capacity to be utilized in the optimum manner. To compound this, engineers on the ground or at nearby facilities can become intimate with each project, helping customers to streamline processes for each individual facility. Via this method, OEMs can gain the benefits of a global supply chain, but with the local knowledge and responsiveness to tackle issues quickly. It's global expertise, but with local scalability.

Issue 27 PECM

Drives Gears & Motors

Highly flexible flange couplings in new sizes TR has extended the portfolio of highly torsionally flexible flange couplings of the BoWex-ELASTIC® HE line by two sizes. The new couplings are available in different Shore hardnesses and suitable for highperformance drives of up to 5,000 kW.

The BoWex-ELASTIC® HE is a flange coupling with high torsional flexibility consisting of a circular elastomer. The rubber element is made of vulcanized natural rubber and stressed for torque-to-bore ratio. It reduces the torsional vibrations occurring in the drive train as well as the cumulative forces and, due

to different elastomer hardnesses, the flange coupling can be adjusted to the respective application for a resonance-free operation. The plug-in coupling hub is designed according to the BoWex curved-tooth gear principle and compensates for axial, radial and angular shaft displacements. KTR has now expanded the BoWex-ELASTIC® HE line by the sizes 240 HE and 275 HE – making the coupling suitable for drives of up to 4,000 kW and 5,000 kW, transmitting torques of up to 32,000 Nm and 45,000 Nm. Possible application fields are gensets, pumps and compressors, as well as highperformance stationary and mobile drive systems.

Precision power transmission When accuracy and drive positioning is paramount think ROTEX® GS. This threepart coupling is backlash-free under pre-stress and offers varying hub designs and Shore hardnesses to produce the optimal coupling for each application in automation engineering. While still vibration-damping, the GS delivers optimal torsional stiffness without consession to accuracy, even in highly dynamic servo drives.

PECM Issue 27

ROTEX® GS

www.ktr.com

Drives Gears & Motors

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PPMA Show

Machining Chain Company Triples Capacity to Meet Demand Donghua Limited 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

The UK arm of one of the worldâ&#x20AC;&#x2122;s largest chain manufacturers has been established in the UK since 2009, doubling its turnover year on year to establish itself as one of the leading chain suppliers in the country. Located in Wolverhampton in the heart of the Midlandâ&#x20AC;&#x2122;s historic chain industry, Donghua has moved to a larger building on the same industrial park which has minimised disruption for their customers. Bob Wellsbury, managing director, of Donghua Limited explained: â&#x20AC;&#x153;This move heralds a new chapter for the UK team and is a direct response to the continued interest from UK 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;?

Anti Vibration Products

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

An additional, larger Kardex 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. The technical Workshop, 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 equipment 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 www.donghua.co.uk, email sales@ donghua.co.uk or call 01902 866 200

Balluff Vision Identification Sensor

Issue 27 PECM 47 Issue 23 PECM 69

KUSE X-life: a new performance class among linear recirculating ball bearing and guideway assemblies he infeed zones in linear recirculating ball bearing and guideway assemblies, i.e. the area in which the rolling elements are guided into the load-carrying element until the load is fully applied, are critical factors for life-limited components.

These zones ensure that the load is gradually rather than abruptly applied to the rolling element. By improving the design of the infeed zone on the carriage saddle plates, Schaeffler has now succeeded in increasing the load ratings for six-row KUSE linear recirculating ball bearing and guideway assemblies by up to 44%, depending on the size and design.

As a result, the rating life is three times higher than that of conventional designs. Due to the significant increase in performance, the redesigned KUSE series has been awarded the Schaeffler X-life quality mark. Up to 83% reduced pulse amplitude Six-row linear recirculating ball bearing and guideway assemblies in X-life quality have a high level of rigidity and extremely low pulse amplitude. They can now also be used in applications where vibration levels must be kept to a minimum and where very high accuracies are required, for example, in measuring machinery.

Pulse amplitudes of up to 1 µm (peak-to-peak) for a single ball are not uncommon. For the new KUSE X-life guidance systems, the contour of the infeed zone has been optimised in such a way that the stroke pulsation is considerably reduced, particularly at higher loads. For example, at a load of 1.35 tonnes, the pulsation amplitude is less than 0.1 µm – a reduction of 83%.

The highest rigidity

Six rows of balls with 45° and 60° contact angles ensure very high rigidity and load carrying capacity.

and load carrying capacity based on balls

KUSE X-life linear recirculating ball bearing and guideway assemblies offer one of the highest rigidity levels and load carrying capacities based on balls for any monorail guidance system currently available on the market. Instead of the usual four rows of balls, six rows of balls support the loads: four rows of balls support loads in a compressive direction with a contact angle of 45°, while two rows of balls support tensile loads. To increase their load carrying capacity, these two rows of balls have a higher contact angle of 60°.

designs perfect for combined load directions. Compared to four-row linear recirculating ball bearing and guideway assemblies, the combined rigidity can be increased by 15% on average. In combination with the very low stroke pulsation, KUSE X-life six-row linear recirculating ball bearing and guideway assemblies are particularly suitable for high precision applications in electronics production, mould production, microscopy, and optics, as well as for applications that require a high load carrying capacity and operating performance. www.schaeffler.co.uk

Lateral loads are transmitted by three rows of balls. This specific arrangement of ball rows, which is a combination of an ‘X’ and ‘O’ arrangement with 45° and 60° contact angles, makes KUSE X-life

In general, the recirculating rolling elements prevent a constant number of fully loaded rolling elements being present in the load zone of the carriages. Depending on the effective number of rolling elements in the load zone, the carriage balances deflections along the stroke to varying degrees. This causes a slight, pulsing equalising movement in the load direction of the carriage. This kind of movement is called ‘stroke pulsation’.

PECM Issue 27

Six-row linear recirculating ball bearing and guideway assemblies in X-life quality can now also be used in applications where vibration must be kept to a minimum and where very high accuracies are required, for example, in measuring machinery.

Early identification of faults on rail signalling power systems driven by new standards ony Edwards, Industrial Sales Manager at Bender UK has specific responsibility for the rail sector, looks at how increasing demands for more effective identification of faults is shaping more sensitive and responsive monitoring.

Every day rail maintenance crews face the challenge of ensuring that the power systems for operating signalling systems are free from faults to ensure that there is no interruption of service. Faults inevitably occur due to a natural degradation of the infrastructure or other common causes such as rodent damage or water ingress. The maintenance teams are set targets to rectify those faults – but they can only be achieved by deploying technology which helps them to identify earlier and more accurately where those faults are occurring. The ideal scenario is technology which gives them early warning of faults which are not yet critical – providing a breathing space to plan and deliver predictive and preventative maintenance solutions. The new standard for those products from June 2017 is detailed in the Network Rail Level 2 Product Specification: Insulation Monitoring and Fault Location Systems for use on Signalling Power Systems. It sets out Network Rail’s vision for Insulation Monitoring Devices (IMDs) and Insulation Fault Location Systems (IFLS) comprising their system requirements, network monitoring architectures, and IMD and IFLS capabilities along with requirements for portable models, and the integration of devices with Network Rail’s Intelligent Infrastructure systems. The document explains that the changes are designed to drive the development of new technology to provide additional parameters, for example capacitance to assess the safety of the Signalling Power System and further reduce the risk of electric shock. It also states that it wants to improve detection of signalling power cable failure before it interrupts a power supply leading to loss of signalling, and improve the ability to pinpoint the

PECM Issue 27

position of faults to drive reductions in time and the disruption caused by signalling power cable faults. Network Rail believes better monitoring will ultimately drive reductions in OPEX and CAPEX costs, enable the deployment of alternatives to more expensive auto reconfiguration systems, and extend the life of existing cables and networks. Bender UK is currently the only UK supplier with approved products to meet this requirement and the company has worked closely with its principal contacts at Network Rail to shape the development of the technology to meet the new standards. One of the key requirements is the need for enhanced sensitivity to narrow down the area where a fault is occurring. Bender has responded with the new upgraded RS4 integrated insulation monitoring and earth fault location system. It is more sensitive that the widely deployed RS3 and enables ‘first fault’ location (100 kilo ohms) before the fault becomes critical. It also measures capacitance, voltage and frequency delivering more information to help assess the health of the system. The insulation monitoring device within RS4 enables fault location at Tier 3 electrical system network level for the signalling system. It has proved very effective in meeting the ‘Red’ requirements within the standard, which must be complied with and achieved at all times. Earth Fault Location is the effective solution for sub-network Tier 2 monitoring to assist in locating the fault on a circuit, a key element in the Amber requirements within the new standard. The RS system continually monitors insulation values to show real time status of the power system. When the insulation value (IR) drops, the system records the fault and the Bender units put a test current signal or pulse into the system which is pulled to earth at the point where a fault exists. The new RS4 unit is much smaller and more compact to make it easier to incorporate in the panels serving systems operating at a lower power rating.

Later this year, a variant will be available tested and ready for easy ‘plug and play’ installation and commissioning alongside existing power infrastructure systems up to AC650V. Integration of RS4 devices with Network Rail’s Intelligent Infrastructure systems is achieved by incorporating GSM-enabled data loggers equipped for real time communication to deliver immediate notification of insulation faults which are identified by the system. Once the fault has been identified on a specific circuit, the portable EDS 3090 case is used in the field to pinpoint the location trackside by monitoring the pulse on the cable. In line with the new standard Bender has made significant improvements to the EDS 3090 unit which has more sensitive clamps and receiver technology. The unit is self-powered through connection to the trackside signal electrical network. It delivers live monitoring of the system status to immediately indicate if there is an earth fault and the status of the insulation. The portable unit can also be used to provide independent verification of the RS system performance. The new RS4 is just part of the huge Bender rail offering which includes power quality meters, insulation monitoring devices and monitoring software for rolling stock, signal power, points heating and trackside use. For more information, contact Tony Edwards: tony.edwards@bender-uk.com or call Bender UK on 01229 480123

KROY Kroy (Europe) Ltd Established in Reading, UK in 1981, Kroy Europe Ltd, are a major supplier of thermal transfer printing equipment, accessories and associated supplies throughout Europe, Middle East and Africa. We are the European importers of Kroy labelling cartridges and printers.

roy (Europe) Ltd, provides identification solutions to a diverse range of industries including, electrical, electronics, hydraulics, warehousing, distribution, rail & transportation, off-shore oil & gas exploration, marine, medical, military, civil & general aviation and health and safety.

We distribute a wide range of thermal transfer and direct thermal printers including portable hand held printers for â&#x20AC;&#x153;On Site - On Demandâ&#x20AC;? applications, low cost â&#x20AC;&#x201C; low volume entry level printers, medium to high volume rugged industrial models and high quality-high resolution printers for the production of labels, tags and panel labels requiring high density text, graphics and barcodes.

Kroy (Europe) Ltd also provide wire & cable marking solutions and offer a variety of printable commercial grade, UL approved, Military, NATO & LUL specification heat shrink tubing. Our range of self-laminating cable markers and tags provides easy identification of wires and cables after final termination has been completed. To complement our printer range, we offer an extensive and diverse range of labelling and identification products for many applications and environments. From thermal transfer printer ribbons, simple paper labels and economy grade synthetics and vinyl through to high temperature resistant and high

PECM Issue 27

performance labels, rating plates & overlaminating films. Kroy have installed a Roland LED UV Inkjet printer to produce full colour digitals labels, signs, posters and decals up to 1.3 metres in width. We welcome small volume enquiries with no minimum quantity restrictions. The printer is capable of printing on to a wide variety of substrates without the need for special ink receptive coatings, the inks are cured instantly and require no drying time. Ideal for interior or exterior use the inks are colourfast and weather resistant. www.Kroyeurope.com

KROY

Identify with Kroy

Kroy (Europe) Limited | www.Kroyeurope.com | Info@Kroyeurope.com | (0)118 986 5200

Why Waste Heat Recovery Is So Important ncreased energy efficiency is a constant challenge for industry, energy prices are rising globally so there is a short term necessity to reduce fuel bills in order to remain competitive. There is also a prescient environmental issue which cannot be ignored. These are two strong arguments why power generation operators and energy consumers operating hot water or steam boilers 'without' waste heat recovery systems in place need to act now.

boiler economisers, "Using an economiser provides a guaranteed method of reducing fuel usage while providing the same boiler output, typically achieving 4% to 6% fuel saving with a return in investment between 6 to 18 months. Even if you are only concerned about the immediate economics, it still makes a lot of sense. We also frequently see monitoring figures before and after installation, so we know it works."

Opinions vary on the environmental impact of carbon dioxide emissions, however the general consensus on global warming is that doing nothing is no longer an option - and if action is not taken now the situation may be irreversible as soon as 2020. A 2016 report produced by respected scientific journal Climate Dynamics* analysing current CO2 global emissions suggests that developed nations need to reverse carbon emissions at the latest by 2030 and other nations by 2050.

In an industrial boiler system heat is usually considered 'waste' when it is below 100Â°C as it can't be used in main processes for boiling, steam creation or sterilisation. This spent heat could be used for ambient heating of the factory or building, but its use is restricted to colder climates or during colder times of the year in temperate climates, plus, installations to provide this type of heating are often large and costly.

The process of reducing carbon emissions also frequently involves reducing other forms of pollution at the same time. Simply because the release of unburnt fuels into the environment and exhaust emissions from low efficiency burning cycles involving fossil fuel derivatives into the atmosphere can be very damaging to natural life-cycles, including our own. Why heat recovery? One of the key areas for potential energy saving in existing systems is waste heat recovery. It is important because by reducing the amount of fuel used to produce heat in a boiler installation, heating efficiency increases, resulting in lower fuel use. This serves both the requirement to increase efficiency and reduce carbon emissions. Best practice for business dictates that ways to improve operational efficiency should be constantly sought out. While the humble boiler became popular over 100 years ago, it remains a major energy consumer in many factories and other types of business, generating waste heat from the spent gases used to heat the water. Luke Hall, Project Manager at established heat recovery specialist ThermTech, supports the universal application of

PECM Issue 27

Applying boiler economisers

A more useful alternative technology is to apply a boiler economiser. Spent heated gases from the outlet or flue of the boiler burner are returned to the inlet of the boiler to pre-warm the in-feed water, thus providing a higher inlet temperature to the boiler. This results in less fuel demand to reach a usable water heat. This technique is often used in modern domestic boilers but is not common for industry. Many industrial boiler systems are often older installations and awareness of this energy efficient technique as a retrofit option is not always known, therefore energy savings are looked for elsewhere. How do economisers work? Installed between the boiler outlet and the flue or chimney, economisers operate on the principle of heat exchange, salvaging boiler gases to pre-heat the boiler in-feed water. This reduces the energy required to heat the boiler feed water to operating temperature. Usually constructed from carbon steel, the economiser design incorporates finned tubes containing the boiler feed water running perpendicular to the flow of hot outlet gases. By heat transfer the flue gas temperature reduces as it increases the feed water temperature. The extent to which the economiser pre-heats the feed water depends on the design of the economiser and existing boiler parameters. The key to efficient

heat transfer rate however is the design of the finned tube surface, which needs to maximise total thermal contact with the hot gas. Off-the-shelf or custom built economisers Since every application is different, each economiser should be purpose built to achieve the best transfer efficiency for the boiler design and the way it operates. This may include minor changes to an existing design, which is common for some more traditional designs based on boilers that operate continuously at maximum flow rates. More modern designs with variable flow-rates however, will usually require something more specifically suited to the application. ThermTech has been providing industry advice on heat recovery for over 25 years and is accredited by CHAS, ISO 9001, Achilles and ASME Boiler and Pressure Vessel Code Certification. The company's engineers' objective is to help assess the quantity and quality of available heat and matching it to the most effective re-use cycle, using the most cost effective and practically suitable forms of heat recovery equipment. *Climate Dynamics is a peer-reviewed scientific journal published by Springer Science & Business Media Photo Caption By reducing the amount of fuel used to produce heat in a boiler installation, the heating efficiency increases, resulting in lower fuel use. This serves both the requirement to increase efficiency and reduce carbon emissions. www.thermtech.co.uk

Electrical & Electronics

Power Upgrades On 11000v Distributions Engineered Systems Electrical Limited is a Yorkshire based Medium / High Voltage company but covering the whole of the UK, specialising in the design, supply, installation, maintenance and testing. A typical example upgrade would be to convert a simple single transformer radial circuit into a Dual Feed or a Ring Circuit. ESE Ltd can supply and install various types of

transformers to suit, oil / Midel cooled and cast resin and can offer a turnkey installation including organising the local authority upgrade / isolation if required. We can also offer to design, supply and install New supplies being a Lloyds Registered company. Please visit our website or contact our office to arrange a site visit. www.eselimited.co.uk

MachineryMate vibration meter kits Meggittâ&#x20AC;&#x2122;s handheld vibration meter helps find machine faults before they impact operation or cause catastrophic failures. The MAC800 kits increase productivity and lower maintenance costs by identifying vibration problems including bearing conditions in early and late stages of failure.

and comes with band filters for unbalance, misalignment, and looseness. The low Hertz range allows readings on machinery running as slow as 120 RPM. Combined with the DataMate software, the MAC800 becomes the foundation of a plantwide condition monitoring program.

This easy to use meter records, analyzes and displays vibration signals

01767 651058 www.kdpes.co.uk

PECM Issue 27

WHITE PAPER FISCHER FIBEROPTIC AT CRYOGENIC TEMPERATURES EDITION EDITION 1.0 1.0 || MARCH MARCH 2017 2017

The use of fiber optic sensors in cryogenic conditions is rare: our new white paper presents the performances of a Fischer FiberOptic Series connector when tested at low temperatures (1.9 Kelvin) at the European Organization for Nuclear Research's (CERN) SM18 test facility. The test results confirm the ruggedness of our connectivitiy solution, which is able to deliver precision optical performance in cryogenic and other extreme applications.

T H E R E L I A B L E E X P E RT

TR Fastenings Enters World Of 3D Modelling With Brand New Product Animations lobal fastener firm TR Fastenings is upgrading its online product catalogue with the introduction of exclusive new 3D models and animations to its website.

The models and animations, which allow users to move the product images around and see how they are installed and used with other materials or components, are hosted on Sketchfab.com, a VC-backed platform which acts as an online library for 3D models and virtual reality (VR) content. TR embarked on the project in 2016, and so far has 50 models and 10 animations online. TR will be adding new models to the site over the coming months and aim to have a 3D interactive model for each one of the 800 products categories on the website by the end of 2017. The videos not only show the products in a new and innovative light, but are also extremely useful for sales and customer service teams needing to demonstrate

PECM Issue 27

how the fasteners work to existing and prospective customers when they are not in the same location. The interactive models are more effective than static images, as customers can move around the model and see the product in detail from any angle. With regards to the animations, the files are much smaller than traditional videos and work on any device. No plug-ins are required and the animations have been designed with all browsers in mind. Keith Gibb, Head of Web Development at TR, comments â&#x20AC;&#x153;3D models are becoming more and more popular and we are very excited about offering this feature to our customers, partners and visitors to our website. The interactive element is invaluable when demonstrating products remotely, and the hosting technology provided by Sketchfab is a real find. This is a huge step for us and we are thrilled to be leading the charge in terms of engineering companies using this technology to showcase our products.â&#x20AC;?

The case for keeping cool and reducing costs, without traditional air conditioning Derbyshire electronics firm is no longer counting the costs of keeping cool, after installing an evaporative cooling system that allows them to keep servicing clients in the face of sweltering temperatures.

Kingfield required cooling to reduce internal temperatures from more than 30°C in the summer (even when the outside temperature was 15 degrees lower). The micro- electronics manufacturer decided to install five Breezair TBS580 Evaporative Coolers and the inside temperature dropped to more comfortable working conditions of 20°C. While the aim was to reduce the heat load within the factory, the management quickly realized that the product’s ability to reach the right level of relative humidity had other very significant impacts on their operations. In fact, higher humidity in the air minimized electrostatic discharge during manufacture, which lessened component failure during assembly. “We are glad we discovered an efficient cooling system such Breezair, which helped us improve the working conditions inside the plant, reducing running costs at the same time,” said Mr Darren Dooley, Production Manager at Kingfield. “We are keen to grow our business and install more electronic assembly machines: if this happens and we need to install additional coolers, we will be sure to opt for Breezair.” Evaporative cooling is fast becoming the most efficient option when cooling large areas. Air conditioning is not such a viable option, because in warehouses or industrial plants, the capital and running costs would be extremely prohibitive. Mr Sam Peli, General Manager Sales Europe, Africa and Middle East of Seeley

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International, the manufacturer of Breezair, explains: “Most industries with high heat loads, such as printing, ceramics, glass, rubber or electronics, have no cooling system installed, and this impacts on the workers’ morale, productivity, and health. “In cases where businesses have traditional cooling systems installed, they rely on recirculating the air in the indoor space, and that stale air can contain fumes and germs. Crucially, premises such as warehouses or big storage rooms, especially when dealing with food and pharmaceutical products, have specific temperature requirements.” In these environments, Direct Evaporative Cooling could be the right solution because it doesn’t use chemical refrigerants to cool the air, just a water pump to supply water to the wetted media where evaporation occurs and electrical power for the fan that then pushes the air inside the building. Breezair is the best example of evaporative cooling on the market. Available in different ranges to meet customers’ needs and 100% manufactured in Australia, it is famous worldwide for unbeatable quality and performance. Kingfield is just one example of numerous UK companies that have put their trust in Breezair for evaporative cooling, and joins printing facilities, manufacturing industries, automotive assembly lines and showrooms, ceramics, food industries, and warehouses. Seeley International is Australia’s largest air conditioning and ducted gas heating manufacturer and a global leader in developing ingenious, energy efficient cooling and heating products. Headquartered in Adelaide and with factories in Adelaide (South Australia) and

Albury (New South Wales), the company was founded by Frank Seeley, AM FAICD who remains Chairman. The Company is world leader in Evaporative Cooling solutions: with offices all over the globe (Italy, France, United Kingdom, USA, South Africa and of course Australia), the company ensures a strong level of commitment to the local markets and an everyday support to dealers and distributors. Renowned for ingenuity and innovation, Seeley International leads the market in the design and manufacture of air conditioning systems based on Evaporative Cooling technology, with award winning brand names including Breezair, Coolair, Climate Wizard and Coolerado. More information about Seeley International and its products can be found at www.seeleyinternational.com

Facilities Management

Cooltherm Since 1992 Cooltherm have been providers of professional chilled water services, including the repair service and maintenance of all types of industrial and commercial cooling plant, with over 40 in-house trained engineers covering the whole of the UK. We are so confident you will be impressed with our level of service we offer new customers a 2-hour free trial. We also have an awardwinning team who specialise in the design and installation

of new chilled water and process cooling solutions; be it straightforward or bespoke, large or small. We pride ourselves on our green credentials, with our TurbomiserTM chiller offering the best levels of energy efficiency available today, and pioneering the use of new environmentally friendly HFO refrigerants. www.cooltherm.co.uk 0117 961 0006 enquiries@cooltherm.co.uk

Mobile Coolers Available!!

Perfect for spot cooling during hot periods Instant availability, contact us today! Low Cost Industrial Cooling 90% less running cost than AC | Up to 90% less capital cost | Simple maintenance requirements - no need for refridgerant qualifications

Low Energy Single phase | Natural cooling using evaporative cooling | No refrigerants | Airflow rate 7000 mÂł for 400W |

Comfortable Conditions Supply temperatures of less than 25Â°C even on the hottest days | Comfortable conditions for staff | Fresh air system |

Safe and Simple Solutions Plug in and go - just add water | Can be wheeled to any location for cooling flexibility |

Proven Technology

Over 3,500 installations worldwide | Case studies online | Clients include: Cummins Diesel, Decathalon, Diageo, Premier Foods

www.ecocooling.co.uk

+44 (0)1284 810 586 | sales@ecocooling.co.uk

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Co-operation visible worldwide across a range of media, events and other promotions, including placement of the Konecranes logo on Bottas’s race overalls.

“

KONECRANES AND VALTTERI BOTTAS ANNOUNCE GLOBAL MARKETING PARTNERSHIP

“Around the globe Konecranes is recognized for being a technology leader, specifically in the areas that are core to any lifting operation: the gears, the motor and the controls,” continues Routila. “Together with new services like Konecranes TRUCONNECT® for remote monitoring, our business has strong parallels with the motorsports world, where top performance is also dependant on innovative technology, excellent teamwork and relentless focus.”

onecranes, a world-leading group of Lifting Businesses™, and Grand Prix winning driver Valtteri Bottas today announced a global marketing co-operation agreement for Konecranes to be an “Official Partner of Valtteri Bottas” until March 2018.

Speaking from Madrid, where Konecranes announced the partnership during its annual management conference, President and CEO Panu Routila spoke about the values and strategic intent that underpin the agreement: “Valtteri has all the makings of a true champion and we’re thrilled to work together with him on this mutuallybeneficial co-operation,” says Routila. “It’s still early in the 2017 motorsports season and Valtteri already has some great results with his new team, which makes the partnership even more exciting.”

In the coming months, existing and potential customers of Konecranes will see the partnership come to life across the web, social media, outdoor advertising, videos, events and more. Bottas will also place the Konecranes logo on his personal website and social media domains, as well as on his race overalls. Bottas, fresh from a weekend of racing in Barcelona, was also in Madrid for the launch event. He spoke about his motivation for choosing to work with Konecranes.

together some of the best engineering and teamwork on the planet. And about focusing on being the best at what you do – yet never losing sight of where you come from.” Bottas’s agent Ville Ahtiainen, who represents the driver for all his personal marketing deals, says the agreement with Konecranes is all about mutual benefit and respect. “The best and most fruitful marketing partnerships are those where the parties truly believe in each other and see the world in the same way,” says Ahtiainen.

“I’m very happy to make an agreement of this kind with Konecranes, a company that aligns so well with my background and what I personally believe in,” says Bottas. “This is about having proud roots in Finland, yet working around the world.

“This is exactly how it is for Konecranes and Valtteri Bottas. It really is an ideal match.”

About using cutting-edge technology and purposebuilt equipment that brings

www.konecranes.com

You can follow the Konecranes and Valtteri Bottas partnership at powermeetscontrol.com, and in social media with the #powermeetscontrol hashtag.

www.powermeetscontrol.com

Issue 27 PECM

“

LOBO Systems launches construction plant work platform

20 minute assembly time

onstruction plant is used in landscaping, agriculture, construction, waste management, forestry and mining applications. Deploying a wheel loader, back hoe, loading shovel or excavator makes your material handling and loading jobs safer, faster, more precise and more profitable.

The Problem A safe working at height platform is necessary for work shop and field based maintenance repairs. Maintenance tasks are a high priority, for example servicing, which includes regular inspections of engines, gearboxes and hydraulics, identifying faults and repairing or replacing faulty parts and carrying out routine servicing of plant and equipment.

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The Solution The LOBO Advanced Platform System is a perfect working at height product that offers the solution and provides a safe, sturdy and quick to assemble system around, under and over any construction plant machinery. The LOBO System is a versatile work platform product that combines the flexibility and strength of traditional scaffolding with the simplicity and mobility of tower systems. This combination provides the ultimate access system that can be utilised across all maintenance industries and no assembly tools are required. The system is particularly useful if you have awkward and restricted areas to reach.

LOBO can be easily configured to fit all the major manufacturers including JCB, Caterpillar, Case, Hitachi, John Deere, Hyundai, Kawasaki, Manitou, Volvo and many more. The LOBO System comprises of trestle legs that vary in size, with adjustable top and fixed side bracing clamps. Steel or aluminium tubes are then passed through the clamps; the clamps are hand tightened to form a trestle. Sway braces, wheels, handrails, out riggers, adjustable extensions and even a lifting beam can be added to enhance the construction. The LOBO System can be transported from site and assembled with ease from a flat pack into any required configuration, by your own vehicle mechanics.

Conformities EU: BS EN1004:2004 BS 1139 parts 3 & 4, USA: OSHA Compliant, ANSI A10.8, 29 CFR Part 1920 (General Industry) Canada: CAN/CSA Z797-09 & S269.2 Australia: AS/NZS 1576.1:2010 and AS/NZS 1576.3:2015 Tower

Product Benefits

Cost Benefits

Experience shows that deploying the LOBO System reduces the costs associated with hiring scaffolding and constructing bespoke access systems. By reducing your reliance on out-sourced scaffolding and engineering companies cost savings will be achieved – easily in a 12-month period.

Towerstore

LOBO is scalable, adaptable and adjustable to meet your on-going and changing requirements. Simply add more components or alter your existing configuration to satisfy the demands of the next task. Protect your initial investment with a product that will meet all your access needs safely! LOBO is a rigid and stable product, which meets or exceeds current safety regulations. Handrails can be fitted in seconds, at any point in the erection process. LOBO’s steel structure ensures many years of product life cycle and a system that will not shake or rattle. The system also includes a slider lifting beam kit and a Towerstore storage unit. LOBO’s modular approach means components fully integrate and can be hand carried. Fully constructed systems can also be made mobile by the addition of wheels.

With this quantifiable reduction in costs comes the added savings associated with reduced down-time and greater productivity from your maintenance department. Available 24/7, quick to erect – and above all safe – it is immediately adjustable for your next job with no staff waiting time while scaffolders are engaged or new fixed-frame structures are manufactured. Re-configurable, again and again, this product comes with no disposal costs and minimal replacement and on-going training costs. For more information and to arrange a product demonstation please contact us by either email : sales@lobosystems.com Telephone + 44 (0) 1332 365666. www.lobosystems.com Issue 27 PECM

Holmøy Maritime of Norway selects energy efficient LED lighting from Glamox for new 3,300-tonne freezer trawler Glamox has supplied a variety of energy efficient LED lighting solutions to Holmoy Maritime for its latest fishing trawler.

The Holmøy freezer trawler (Photo: Glamox)

Freezer trawler Holmøy is a 3,317-tonne fishing vessel, the newest in the fleet of Holmøy Maritime of Norway. The vessel, which was built in Spain by Construcciones Navales Paulino Freire, SA, is classified as DNV 1A1 ICE-1B Stern Trawler EO. The trawler is equipped with modern facilities for catching, onboard processing and cold storage of fish. The trawler is equipped with a complete state-of-the-art, high quality LED lighting scheme from Glamox. Installed lighting products include TL60 watertight LED luminaires, FL60 LED floodlights, MIR LED outdoor lighting fixtures, 1076 series floodlights, Norselight XS1000 R60 searchlights, and series 65 LED Arctic navigation lights. The watertight TL60 LED luminaries are

PECM Issue 27

installed in the main deck area and other parts of the vessel that are exposed to the elements.

expectancy of up to 50,000 hours, low energy consumption and are virtually maintenance-free.

Due to its extremely long operating life (up to 50,000 hours), the TL60 LED is designed to meet maritime requirements and to minimise energy and maintenance costs.

The trawler is also equipped with Series 65 Arctic LED navigation lights from Glamox. These lights are specially designed for Arctic conditions and can withstand very low (and high) ambient temperatures.

The combination of an innovative lighting design and use of high quality components and materials ensures excellent heat management and a reliable, long operating life. The FL60 LED series of high performance LED safe area floodlights provide instantaneous, high intensity light and are immune to voltage drops. As well as offering excellent heat management, the floodlights have a life

Compared to conventional signal lights, Series 65 Arctic LED navigation lights set new standards in terms of lifetime, efficiency and reliability. The main and back-up systems are integrated in one housing. The MIR LED outdoor lighting fixtures with LED luminaires are suitable for many different applications on a vessel, including workshops, engine rooms, stores and passageways.

www.glamox.com/gmo

These energy efficient, long life lighting fixtures are also designed to enable easy conversion from a T8 fluorescent tube to LED technology. The Norselight XS R60 searchlights are specially designed for vessels that operate in harsh winter and

ice conditions such as tugs, icebreakers, offshore supply vessels or ice-classed vessels. The Xenon R60 Searchlights provide reliable lighting in a wide range of watt sizes and different voltages. They are also designed for Arctic environments with temperatures down to -50°C.

The fish processing/storage area of the Holmøy F/T (Photo: Glamox).

The main deck of the Holmøy F/T (Photo: Glamox). Issue 27 PECM

Pulsar® Model R86 brings a new, smarter NonContact Radar transmitter to process industries

he latest innovation from the Magnetrol® Think Tank provides safe, efficient and cost-effective liquid level measurement

Magnetrol International has launched the PULSAR Model R86 Non-Contact Radar transmitter, an advanced level control solution that offers radar technology with improved performance for a wide range of level measurement applications. The PULSAR Model R86 is designed to provide outstanding accuracy, reliability and safety for virtually all process industries. Latest-generation features include: Improved Performance The 26GHz radar signal has a smaller wavelength, resulting in smaller antennas and improved 1mm resolution.

PECM Issue 27

This is an important distinction for demanding process conditions because the smaller beam angle allows for installation into process connections as small as 1½”. As a result, The PULSAR Model R86 assures precise, dependable control for a complete spectrum of level applications. Advanced Diagnostics The user interface experience of the PULSAR Model R86 is driven by advanced diagnostics that transforms the way that radar level measurement is used. Automated echo capture conveys realtime waveform and trend data so users can assess the situation at a glance. In addition, the event history shows up to 20 events including diagnostic and configuration data to pinpoint any issues. Troubleshooting tips are also given to provide practical solutions that can help companies reduce downtime.

True Versatility The PULSAR Model R86 uses circular polarization, which means there’s no need to rotate the antenna to ensure proper orientation. This simplifies installation and delivers proper alignment in virtually every application. High Temperature antennas are designed for use in extremely demanding applications and punishing conditions up to 750oF (400oC). There are also nozzle extensions ranging from 4” to 72” (10 cm to 1.8 meters). That means nonstandard nozzle lengths and buried vessel standpipes are not an issue for this advanced solution. The PULSAR R86 introduction represents the latest radar innovation from MAGNETROL, the company that introduced the very first 2-wire, looppowered guided wave radar transmitter for industrial liquid level applications. www.magnetrol.com

Fluid Handling Waste Management ... always an intelligent solution &OHDQVLQJ 6HUYLFH *URXS RSHUDWHV IURP VLWHV VWUHWFKLQJ IURP &RUQZDOO WR .HQW DQG XS WR 0DQFKHVWHU 0LGGOHVEURXJK LQ WKH QRUWK ZLWK GULYHUV DQG RSHUDWLYHV ZRUNLQJ WKURXJKRXW WKH 8. COMPRESSION FITTINGS 2XU VHUYLFHV LQFOXGH

ORIGINAL RANGE Sizes 15 -100mm

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LEAK SEALING CLAMP Sizes 10 -100mm

TAPPING CLAMP

Malleable

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For detailed information contact our sales department: C. A. Baldwin & Co. Ltd., Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY Telephone: 020 7703 2138 Fax: 020 7701 8436 info@cabaldwin.com www.cabaldwin.com

PECM Quarter page, CABCO.indd 1

70 130

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PECM issue 13

10/03/2016 10:38

AODD pumps: Correct configuration is key Air-Operated Double Diaphragm (AODD) pumps are reliable and cost-effective, but only if they are configured correctly. n a variety of applications across a number of industries, Air-Operated Double Diaphragm (AODD) pumps provide reliable, high performance pumping. They have come to be known as the “work horse” of industry, when it comes to handling and transferring fluids at relatively low flows and pressures. Above ground or below ground, on land or on sea, in normal or extreme conditions, the versatility of AODD pumps ensures that processes keep moving. Key to safe and reliable operation of an AODD pump is correct configuration. This involves taking fluid characteristics into consideration, such as pH levels, abrasiveness, temperature and fluid density. Also important is to check chemical compatibility: manufacturers often provide guides on their websites to ensure pump materials are suitable for the fluid being transferred. These same websites often feature online pump selector tools to assist in configuring a pump in a matter of minutes and with a few clicks of the mouse. However, some of these configuration tools can appear overwhelming at first, especially considering the vast number of alternative materials that can be specified for pump components. Making the right choice can significantly reduce the overall cost of the pump – while making the wrong choice can give you a pump that is too expensive for your requirements. This article identifies and recommends popular ball, seat and diaphragm materials (internal pump components) and pump fluid sections (pump bodies) to perform in applications with varying fluid characteristics. These are general guidelines and points to consider when specifying the correct configuration. In parallel with these recommendations, it’s always advisable to check the manufacturer’s specifications and chemical compatibility guides.

highest heat resistance, rated to 160°C and 135°C respectively. Next in line are PVDF and PTFE, rated to 107°C and 100°C respectively. At the other end of the thermometer, glycol transfer pumps are required to withstand cold environments down to -20°C, thus requiring aluminum, stainless steel, EPDM, FKM and Santoprene. Key takeaways: • For high temperature applications: Stainless steel or aluminium pumps with FKM, EPDM, PTFE or PVDF wetted materials. • For low temperature applications: Stainless steel or aluminium pumps with EPDM, FKM or Santoprene wetted materials. Corrosive environment? If you want your AODD pump to handle corrosive chemicals or fluids with fluctuating concentrations and/or pH levels, then it’s vital to make the proper selection of pump bodies and internal pump components to avoid pump corrosion, ensure compatibility, and reduce maintenance requirements. For such applications, plastic pump bodies such as polypropylene, PVDF, Kynar® and PTFE are often chosen on account of their chemical inertness. The highest chemical compatibility is offered by PTFE, which can generally be safely used with the most basic chemicals to the most acidic acids. It could be, however, that PTFE is an over-specification. Other materials such as polypropylene or PVDF may suffice. It therefore makes sense to refer to the manufacturer’s chemical compatibility guides for guidance as to which are the optimal pump materials to use for the chemical or fluid you are working with. Key takeaway: • Check manufacturer’s chemical compatibility guide.

What temperature? The first guideline is to remember to identify the temperature limits of all components in the pump. The internal pump components may be rated to an extremely low or high temperature, but that does not imply that the pump body material is rated to the same level, and vice versa. When configuring an AODD pump, it’s important to identify temperature ratings of all components, by referring closely to the manufacturer’s product specifications.

What’s the fluid density? Surprisingly, when configuring a diaphragm pump the most frequently overlooked specification is fluid density. It’s an important factor to consider because diaphragm pumps utilize ball checks that rise and fall as pressure changes occur within the fluid chambers of the pump. Ball checks come in a whole range of metal and elastomer configurations. Each of these materials has a different weight, or specific gravity. Understanding how this weight relates to the fluid has an influence on the material specified.

Increasing the working temperature has a significant consequence on material selection. For example, plastic pump bodies are not recommended because cold flow and creep can lead to leaking. As temperatures rise above 80°C, the choice of compatible internal components further decreases. At these elevated temperatures, materials such as ethylene propylene diene monomer rubber (EPDM), polytetrafluoroethylene (PTFE), polyvinylidene fluoride (PVDF) and fluoroelastomer (FKM or Viton®) are preferred. FKM and EPDM have the

If a low-viscosity fluid is being transferred, the weight of the ball is not of critical importance because the fluid is not restrictive during the ball seating process. A 30% slurry, on the other hand, has a higher viscosity and therefore requires a heavier ball to move through the slurry so the ball seats properly. If the ball is too light, it will hang up in the slurry and will not seat, leading to poor pump performance that includes priming issues and cavitation. A rule of thumb is the denser the fluid, the heavier the ball check.

PECM Issue 27

Key takeaway: • Neoprene, stainless steel and PTFE ball checks have the highest specific gravity, or weight, allowing ball checks to seat reliably through high-viscosity fluids. Want to minimize wear? For abrasive fluids, metal pump bodies are generally recommended. The most commonly used materials are aluminium, stainless steel, and Hastelloy®. Santoprene® and Geolast® are good for internal pump components as they provide longevity and resistance to destructive abrasives. Applications with petroleum-based fluids, such as waste oil, are best paired with Geolast ball, seat and diaphragm materials. Santoprene, one of the most versatile elastomers, offers good chemical compatibility and excellent abrasive resistance. PTFE offers a high level of chemical inertness and compatibility in high-temperature applications, but it is often incorrectly specified in abrasive applications, such as chemical slurries. Again, it’s important to check chemical compatibility of all these materials. Key takeaway: • Stainless steel pumps with Santoprene or Geolast wetted materials . Looking to reduce costs? When configuring a cost-effective pump, aluminium, polypropylene, Geolast, TPE and EPDM need to be high on your shopping list. As variables such as temperature or abrasives become more challenging, using an ultra-high molecular weight polyethylene (UHMWPE), neoprene or nitrile may be required, but this is going to increase the pump’s cost. Other materials that will add to the cost of the configured pump are specialty materials intended to handle the most extreme fluids. These materials include PTFE, PVDF, FKM, Hastelloy and stainless steel. A useful tip is to be open to using a different material when your pump has to be repaired. It might not be necessary to re-order exactly the same material. Consulting a chemical compatibility guide might help identify other materials that are perfectly suited for the same fluid but at a lower cost. Key takeaways: • The most cost-effective materials: Polypropylene, Geolast, EPDM, TPE and aluminium. • Midrange materials: UHMWPE, neoprene and nitrile. • Higher price range: PTFE, PVDF, FKM and stainless steel. More information Graco offers a broad range of air operated diaphragm pumps, which can be configured with an online selector tool at graco.com/huskyselector-tool. If you have further questions relating to the configuration of an AODD pump, email Walter Leeten at walter.leeten@graco.com.

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Swivel joint design and manufacture from Rotaflow Rotaflow design and leading Labtex supplies manufacture a range of including laboratory products swivels joints. Swivel Joints HUBER liquid temperature allow fluids to be transferred systems, DIEHM glass across control rotating interfaces, systems to 100 litres, withoutreaction leakage. Simple single flow PREMEX units are used and in AMAR high pressure autoclaves, POPE many applications including loadingwiped arms,film articulated or short path pipework and hoseand reelers. evaporators distillation Some applications require systems, Nutsche filter dryers, articulated pipe work or hoses to allow fluids; such BOLA labware in PTFE and as Hydraulic Power, Air other technical plastics, (pneumatic) control lines, or mixed Vacuubrand process fluids to be pumps, vacuum used on moving machinery. ASECOS storage solutions

for hazardous materials to ball bearings and needle The strong bearing area, of both rollers,BS is EN complimented with a choice of sealing materials 14470-1 and SICCO for maximum application compatibility. Over the passed desiccators. 30 years Rotaflow have provided design solutions within many processing sectors. We also work with LLG

Swivel joints will allow the movement on a slowly rotating Germany, the 3rd largest lab drum or remove the damaging effect of twisting on hoses. supplies distributor in Europe We manufacture in both carbon steel and 316 stainless and â&#x20AC;&#x153;specialsâ&#x20AC;? have a catalogue steel with in any of grade of metal to suit customer 20,000 -items from over 200 respected brands. specification range of sizes from Âźâ&#x20AC;? to 36â&#x20AC;? nominal bore.

Tel: +44(0)1663 735003 Email: sales@rotaflow.com www.rotaflow.com

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Fluid Handling

PTFE Fluid Handling from Bohlender Bohlender offers a vast range of finished and semi finished products in technical and fluoroplastics. A variety of different materials like PTFE, FEP, PFA, PEEK and others enable innovative products to be produced with excellent chemical resistance and high thermal resistance.

Screw joints and ground joint components, tubing and connectors allow an infinite number of combinations to create sophisticated systems of fluid transfer using standard laboratory bottles and containers. For distillation of strong acids or alkaline products BOLA manufactures reaction vessels up to 6 litre capacity in PTFE or PFA. All parts exposed to the medium are either made completely of PTFE/PFA or jacketed like the thermometers. The BOLA catalogue also includes a wealth of technical information on the materials used including physical properties and chemical resistance and the safe use and care of fluoroplastic labware. Further advice on the pressure resistance of tubing and the correct choice for pressure or vacuum applications make the catalogue a useful reference. www.labtex.co.uk

Fluid Carrying

PECM Issue 24

PECM117.indd 64

04/01/2017

Flexibility Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel Joints Swivel joints allow pipework to rotate whilst carrying fluid under pressure 1/4â&#x20AC;? to 20â&#x20AC;? and beyond. Vacuum to over 6000psi. Stock and bespoke production. Unique bearing/seal design for longer life. ISO 9001 CE marked where applicable.

Rotaflow FV Limited | Rotec House Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY

Tel:

01663 735003

E-mail:

sales@rotaflow.com

www.rotaflow.com Issue 27 PECM

19 MW Generator Fully Refurbished In Just 30 Days asteâ&#x20AC;&#x201C;to-energy plants perform a key role in reducing the amount of waste that goes to landfill and are critical in the generation of power for the local grid.

This enabled its removal from the building and loading onto transport for immediate delivery to the local Sulzer Service Center in Birmingham.

However, when a generator fails it is essential that repairs are completed quickly to get the plant back online. Sulzer was contracted to rewind a damaged generator and managed to return it to operation within just 30 days, minimizing the costs associated with lost production.

With time such a critical factor in this project, the generator was dismantled overnight to allow the rotor, stator and coils to be tested. Apart from the need to rewind the stator, the tests also showed that the rotor required further investigation as the insulation resistance tests did not meet the acceptance criteria of 100 MÎŠ.

For a mid-sized plant, processing over 200,000 tonnes of waste per year, keeping downtime to a minimum is essential to maintain efficiency. Operating a comprehensive, preventative maintenance program is crucial to operating a costeffective plant. However, unforeseen maintenance issues will occur; in these situations, it is the speed of response and the quality of the repair that will determine the success of the repair project.

Designing and manufacturing new stator coils is a complex task, one that the engineers at Sulzer have perfected over many years. Using the latest class F insulation materials allows for thinner layers that can withstand greater dielectric stress, higher temperatures and also creating more space for copper within the same slot area. This reduces the resistance of the stator winding, which runs cooler, allowing a small increase in output.

A waste-to-energy plant owner in the UK experienced an unexpected failure of the site's sole generator, which meant that the heat generated by the incinerator could no longer produce energy. Keen to resolve the issue quickly, the maintenance manager called in Sulzer engineers, who arrived within two hours, to carry out an initial inspection to determine the cause of the failure.

Meeting the tightest deadline

The results showed that the stator had suffered from a coil shorting to earth on the turbine side of the winding, as well as suspected damage to the stator core. The plant operator had to move fast. The order was given to remove the generator from the site for further investigation of the core and rotor which were not accessible without a full dismantle.

By using the latest CAD software, the new coils were precisely formed to ensure an exact fit in the stator slot, making the installation process more efficient. The new coils were manufactured in Sulzer's coil winding shop in Birmingham, UK, which uses its in-house copper rolling mill to enable round-the-clock coil production to meet even the tightest deadline.

Comprehensive investigations

Once the stator had been stripped of the old coils, the stator core inspection revealed a damaged tooth that would need to be repaired before the new coils could be installed. The damaged slot section was machined out to allow the installation of an epoxy glass block G11, which was machined to restore the stator slot profile to the correct dimensions.

The generator is central to the entire business, both financially and physically. The first task was to disconnect all of the ancillary equipment and remove a section of the building's roof to allow a 400-tonne crane to lift the generator from its operating plinth onto a set of skates.

Keith Barbier, Head of International Contracts and Projects at Sulzer UK, comments: "The re-build process is a very skilled and time consuming task because precision

PECM Issue 27

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

www.sulzer.com

is essential to achieving a high quality finish. The engineers worked round the clock to manufacture the new coils and install them into the stator."

After just 30 days the generator was back on site, being craned into position and reinstalled with all the ancillary equipment, before being put back into service.

Prior to the rebuild, the coils were stress tested to earth in accordance with EN60034-1, tan delta tested and interturn tested using EA Technical Specification 44-5 as the pass mark.

Projects such as this have highlighted Sulzer as a leading provider of engineering solutions to the power generation sector, from on-going condition monitoring to complete turnkey projects. With a global network of repair centers capable of completing generator and turbine repairs, Sulzer ensures it employs experienced engineers, equipped to complete projects on site if necessary.

At the same time, the rotor was refurbished and then reassembled with the completed stator before the final tests were completed.

Issue 27 PECM

Preventing diffusion of ammonia in the Kalina process

ntil now, the secondary circuit in geothermal power plants, which is used in the Kalina process for the ammonia-water-steam generation at low temperatures, has always been protected by safety valves. Due to the limited leak-tightness of re-sealable relief devices (safety valves) especially over longer periods of time, some operators have now begun installing rupture discs downstream from the safety valves.

Manufacturers such as REMBE GmbH are now offering rupture discs specifically for this type of application. Dr. Stefan Rüsenberg, the man responsible for

PECM Issue 27

this development, said "The KUB® GT is specially tailored to the needs of geothermal power plants. We use highquality, corrosion-resistant materials to ensure the rupture discs are permanently leak-tight and can be in service for a long period of time. The key word in this application is zero emissions. This is also important for the acceptance of these power plants amongst the population." The GT in the product name stands for geothermal”, Rüsenberg added. These rupture discs are used to secure a vast range of steam and condensate lines as well as condensers, evaporators and heat exchangers. By installing the rupture disc in a special holder on the

process side of the safety valve, the valve will be protected from the process medium during normal operation. The KUB® GT rupture disc has a completely smooth surface on the process side. In combination with the corresponding holder, a metal-on-metal gasket is created which guarantees a much higher leaktightness than the use of a safety valve as a stand-alone solution would provide. Even if the Kalina process was primarily used by geothermal power plants, it is fundamentally also suitable for all processes that use corrosive, hazardous or polluting media and require a high degree of leak-tightness. www.rembe.de

Issue 27 PECM

Health & Safety

State Of The Art Spd Surge Protection Devices Ltd has launched a class leading Combined Lightning/surge arrester with Full mode protection. Both common and differential protection with a maximum let –through voltage of 600volts is essential to protect todays sophisticated electronic systems and machinery. Downtime can cost £thousands contact us now for a free in house survey of your factory/offices on Tel 01484 851747. Full details at www.surgedevices.co.uk

Compatibility is key when selecting combined Head and Hearing Protection Often users of Personal Protective Equipment need a combination of items of Personal Protective Equipment (PPE) to make sure they are adequately protected in work environments. A very common combination is head and hearing protection. To work properly, however, the different types of PPE must be compatible. Manufactured in Oxfordshire, the Sonis® helmet mounted cups can be coloured to meet a corporate identity and can also be printed with a company logo for improved brand recognition and to prevent theft. This exceptional range of Sonis® Helmet Mounted Ear Defenders is Kitemarked, and meets EN352-3. JSP has been producing quality safety equipment and selling it across the world for 50 years. www.jsp.co.uk

PECM Issue 27

Smart & Small Power Distribution for First Time Rittal, the leading global provider of solutions for industrial enclosures, power distribution, climate control, is offering manufacturers of small control panels and switchgear an innovative and tested power distribution system. The new RiLine Compact allows the user to mount different types of protective and switching devices onto a system, and then supply it with electrical power. Its standardised and standards-compliant technology means it is suitable for use in control panels in both the IEC and UL markets. Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd

Health & Safety

Leuze Electronic Demonstrates Power In Safety At Work Leuze electronic expands its product range in the area of safety at work. With the new generation of programmable safety controls and the expanded line of safety relays, Leuze electronic offers safe solutions for all applications in machine and system construction. Together with the wide range of safety sensors, the perfectly matched safety components offer complete safety-related automation solutions for a wide range of machine types.

Expanded by more than 20 components, Leuze electronic presents its product range in the area of safe relays and safe controls and shows itself to be a competent partner for efficient safety at work: With the new safety relays, many smaller safety tasks can be solved.

The safety controls are suitable both for the safe monitoring of simple safety functions as well as for performing more complex safety tasks. In addition, the controls can be flexibly expanded to up to 116 safe inputs and 56 safe outputs. With the MSI.designer programming software, the project planner can easily configure each application of the safety circuit. For logic programming, an extensive library of up to 40 certified function modules is available. Up to 300 of these can be freely integrated per project by means of drag & drop. www.leuze.co.uk/en/united_kingdom/

From the monitoring of simple components, such as E-STOP or safety switches, to the integration of optoelectronic sensors or standstill monitoring of motors: with the 22.5 mm housings, the relays have a compact design and can be installed in the switch cabinet in a space-saving manner. Modules with adjustable time delay and contact extensions round out the offering. With the new safe controls of the MSI 400 product family, Leuze electronic offers both 24 inputs/outputs as well as an Ethernet interface and integrated industrial Ethernet protocol such as Profibus and Ethernet IP in a likewise compact design of just 45 mm.

SMARTER PRODUCT USABILITY

SMART IS, WHEN A PROFINET GATEWAY IS ALREADY INTEGRATED INTO OUR SAFETY CONTROL Thanks to the integrated interfaces and additional gateway modules you can integrate our safety controls into all common fieldbuses.

integrated connec

tivity.

Alexander Mielchen, Product Management Safety

Phone 01480 408 500 â&#x20AC;&#x201C; www.leuze.co.uk

Issue 27 PECM

Preventing Nut & Bolt Self-Loosening – What Are The Options? Many applications require a dismountable, yet durable, screw joint but often this freedom to dismantle comes at a price because the chosen securing method has limitations. Many of the traditional thread locking devices are unable to maintain bolt tension and clamping forces resulting in premature failure and potentially, costly downtime.

Why assemblies fail Threaded assemblies generally fail because of a loss of bolt tension, the main causes of which are relaxation and self-loosening. Relaxation results in a change in bolt tension which leads to reduced clamping forces. This effect is mostly triggered by settling – pressure-induced smoothing of the surface roughness – or creeping, the time-dependent yielding of substrates when loads exceed the compressive strength of the material; clamping gaskets are a typical example. If the elastic capacity of the assembly is inadequate, for example, if bolts are too

PECM Issue 27

stiff or the wrong length to diameter ratio is selected, there can be no compensation for loss of bolt tension.

but due to gaps between the threads, their ability to withstand vibrational loosening is compromised.

Self-loosening is caused by any type of dynamic load, such as vibration or changes in temperature, insufficient clamp load and poorly fitting parts, allowing relative movements to increase the risk of selfloosening. These load changes lead to short-term frictionless situations where the bolt unwinds from the nut. The sum of these very small movements ultimately results in the loosening of the threaded assembly.

Thread locking adhesives resist vibrational loosening as they fill all the voids between the nut and bolt. This can be demonstrated by comparing a range of joints, secured in different ways, in accelerated vibration tests on a transverse shock machine. Initially the time taken to loosen a nominal ‘naked’ nut and bolt, tightened to a typical 80% proof load, was determined. From a bolt tension of 30kN, it came loose after just 15 seconds.

While relaxation can only be reduced by changes in parts design - such as the length to diameter ratio - or the use of elements, self-loosening can only be avoided by using appropriate thread locking devices.

As you can see from the graph, a spring washer fared no better, while a nylon ring nut lasted around 25 seconds. A distorted locknut achieved a little longer, although most of the bolt tension quickly disappeared. However, the joint secured with thread locking adhesive did not fail at all and exhibited no loss of bolt tension. Quite simply, this is because the joint is completely filled with adhesive, presenting no opportunity for loosening.

Thread locking options Essentially these fall into two camps, mechanical methods and adhesives. There are benefits from using mechanical devices

labelling but that would not be the case today. Continuous development, however, has seen their formulation change in line with these new regulations and users can therefore be assured they are adopting the best practice in terms of workplace safety.

Real life applications

Better and better All thread locking adhesives under the LOCTITE® brand are anaerobic, which means they only cure in the absence of air. Indeed, it was the very problem of vibration that led Dr. Vernon Krieble – the pioneer of LOCTITE® adhesives – to develop anaerobic adhesives. This technology enables the adhesive, when applied to a bolt, to stay liquid almost indefinitely until the nut is applied.

With no air in the contact areas, the adhesive soon solidifies to a tough thermoset plastic. Although this is a relatively mature technology, advancements continue to be made. There is now a huge range available offering differences in viscosity, strength, temperature resistance, chemical resistance, oil tolerance, cure speed and hardness/flexibility. Products are now also rated for higher temperature use and are more tolerant of surface contaminants.

So how is adhesive thread locking being applied in the engineering world? An example that demonstrates this method’s ability to withstand an extreme, high vibration environment is on a snow drive jam nut within the clutch assembly of a snowmobile. In a similarly safety-critical application, a manufacturer of tow hitches and couplings is using a thread locking adhesive to secure the grub screw in the pin that retains the trailer on the vehicles. Again, there is no margin for failure. Another example is an application on the tunnel boring machines that are excavating the extension of the Crossrail Line through London. In common with other giant TBMs manufactured by Herrenknecht AG, these machines were constructed using a thread locking adhesive to lock bolts which have to resist massive pressure as the machines eat into the sub-soil. Elsewhere, another user is applying adhesive to threads of plastic air diffuser mushrooms for securing to stainless steel pipe manifolds in sewage treatment plants. The joint needs to offer sufficient strength to last for the lifetime of the system. Rework or repair, for obvious reasons, are not particularly desirable.

Continuous development of product chemistry is especially important in the light of changes relating to CLP Regulations. This is a European Regulation on classifications, labelling and packaging of chemicals that has been implemented in stages since 2009.

In summary, thread locking adhesives not only resist vibration but also protect against shock and thermal cycling, seal against corrosion and prevent galling. In addition, the joints provide better clamp retention than mechanical clamping devices and offer straightforward disassembly using correctly specified tools.

The LOCTITE® Health and Safety range is a good case in point in this regard. When these products were introduced, their chemical components required no hazard

For more information on this subject visit www.loctite.co.uk

Issue 27 PECM

Everything in its place and a place for everything PM Group, the Leeds-based printing company is a shining example of a lean operation where each piece of equipment has its place and each person is an effective team player working with coordinated effort to provide total customer satisfaction, Consistent and Reliable Product Quality, with Short LeadTimes to enhance brands speed-to-market.

Privately-owned OPM (Labels & Packaging) Group Ltd was established over 40 years ago, originally as an engineering company manufacturing mechanical overprinting machines. The company was bought by the current shareholders in 1988 and rapidly began producing plain and printed self-adhesive labels under the new name of OPM. The addition, in 1999, of a further site allowed for production of flexible packaging. Having relocated all sites into larger premises on the outskirts of Leeds in 2013, owners Chris and Sue Ellison had a clear vision that has been carried through every aspect of the business. ‘The move into what was essentially an empty box, gave us the opportunity to build an optimised workflow according to lean principles and completely customise our facility to our needs,’ said and everyone can visually connect. This promotes

PECM Issue 27

a team environment and enhances communication.’

ideas, talk about investment needed, potential for future innovation, and other day to day issues.

There is a natural flow through site with client-facing operations at the front of the building and production central to operations – all based around improved use of time and just-in-time production. There is even a fully equipped gym and shower facilities to promote staff wellbeing..

Chris Ellison stated, ‘You can’t grow your business if you don’t grow your people, and I get a huge amount of satisfaction out of watching staff grow in confidence and professionalism. You have to make the jump and share control to let the business grow.’

The focus is firmly on customer satisfaction and OPM believes that this can only be achieved by having a fully trained and happy who are satisfied in their roles. ‘We passionately believe in happy people who are on top of their game. It is paramount that they have the most advanced tools to do their job to a high standard and that we show the team that we believe in them. This gives our customers a positive experience and confidence in us as a company.’

On the factory floor stand six Nilpeter UV flexo presses; these are complemented by finishing equipment from Bar Graphic Machinery. In 2013, OPM invested in a Nilpeter FA-5 584 mm 10 colour press with inline solvent lamination (the only of it kind in Europe), and in 2014, it added an advanced crossover units for the production of multi-layer labels. The latter enables production of intricate coupons in a number of ways with different features and embellishments.

As well as establishing an in-house training academy, backed up by detailed training guides for each job, OPM has also brought in external training experts to coach the Heads of Departments (HoD) team. The team has received continual professional development (CPD) in communications, understanding the dynamics of the production chain, staff management, time management and other management skills. It meets once a month to exchange

In 2016 inline inkjet was also added to provide sequential numbering. Consistent and repeatable colour reproduction is achieved across multiple presses on multiple substrates and all presses are calibrated and can record print data. AVT 100% inline print inspection units monitor printed images economically and to reduce human error.

All products are produced to Certification to PS9000:2011 , ISO 9001:2008, BRC/IoP Global Standard Food Packaging standards Grade AA packaging in a dedicated low migration ink site. A complete colour management system is in place to drive efficiencies and avoid downtime on press. Using a combination of X-rite spectrophotometer, a FlexiProof 100 print proofer and a gravimetric GSE inks dispensing system, OPM has automated colour matching in the ink lab. In addition to the colour quality software, the company also has Ink Manager 6.0, which allows spectral data to be converted into a specific ink formulation. The output of self-adhesive labels, flow wrap, sachet laminate and lidding film from the factory floor is around 5.2 million metres per month, mainly for the cosmetic, health and beauty, nutrition, automotive, horticultural, household, and pharmaceutical sectors. OPM offers a fully equipped Esko Studio for artwork and repro file preparation. It enhanced its automation by sharing the Tharstern MIS data to drive Esko’s Automation Engine to achieve a leaner workflow. The system now streamlines and automates artwork/repro and business workﬂows from estimate to delivery. Sue and Chris Ellison said, ‘We have continuously looked to improve

profitability and output through lean manufacturing and automation. This provides strong, reliable data to improve communication between our team and our customers. With such an adaptable system, linking to all assests driving , storing and recording data it ensures complete traceability for every job. ‘This empowers us to take control of our production capabilities, manage delivery deadlines, optimise capacity and react to ever-changing demands and priorities. Every step of the process is managed and customers are kept informed at all points throughout the critical path.

The company lives and breathes ‘lean’ and these principles are carried through to every level, be it dealing with waste or sending out confirmation emails. Chris Ellison said, ‘We have taken the most effective attributes of lean, gathered from world class manufacturing industries, adding our print-based expertise and developed a series of hands-on programs, then coached our teams in the application of lean and best practice techniques.’ Firmly based on the continual development in the printing market, OPM has a strong focus on innovation.

‘We’re committed to growing through continued investment in people and world class technologies,’ said Chris Ellison. ‘We always think about the long-term strategy. We don’t want to be average and we’re passionate about helping our clients to achieve excellence in all areas of their work. That’s why we stay up to speed with the latest technology.’ We partner customers and suppliers looking beyond traditional markets, to actively promote new ideas and add diversification to our ever-evolving product offering. OPM’s key to successful innovation is finding inspired Customers, proactive suppliers, passionate and talented staff who are committed to working together and who embrace the philosophy of collaborate-to-innovate. We look at innovation to develop customer value through solutions that meet new needs, needs that may not have even been expressed yet, or existing market needs in unique ways. Our innovative employees increase productivity by creating and executing new processes which in turn may increase competitive advantage and provide meaningful differentiation.

Over the last three years OPM has delivered a number of innovative new products to market including the thicker closure seal with moisture lock properties & the peel and seal label with integrated hanger. We are currently progressing a number of innovative “peel and read” labels and tamper evident solutions for a variety of market sectors – which we will release throughout 2017 – 2018.

The other cornerstone is continuous investment in both technology and people. Since 2009, the company has invested over £6 million in various assets, which include the improved MIS system, printing presses, and ink technology, amongst others, to ensure that it is always at the forefront of label and packaging technology. www.opmgroup.co.uk

The Key to Retail Success ... M P O t a k o o r l e s l c o T ake a hel p you i ncr eas e we c an t n i . p f r o r e w p e o sale s wi th th ! n ti e p o m ti e th o st c a g a t u in o Stand

At OPM (Labels & Packaging) Group weĘťre experts in delivering innovative, agile printed packaging solutions to forward-thinking organisations. An intelligent brand owner uses print and packaging to inform and inspire the user, with a balance of decoration and functionality creating an identity that is as emotional, colourful and multi-layered as the consumer.

OPM work in partnership to deliver quality print that protects your brand equity ensuring our clients are positioned in the market to achieve positive consumer experience for their brand and its products. Get in touch to discuss your print needs today

sales@opmgroup.co.uk

0113 2311000

OPM offer services for customers of all sizes, across all sectors. From long runs to convenience quantities with short lead times. At OPM we take great pride in the superior quality of our printed products across our portfolio. Our technical team are always looking for ways to improve pack decoration without impairing product function by providing innovative packaging solutions.

OPM manufacture Performance products for a variety of applications to exacting GMP standards providing : High barrier to moisture, light and gasses, high mechanical resistance, address physical challenges , whilst maximising packing efficiency and maintaining excellent image and text definition. Certification to PS9000 : 2011, ISO 9001 : 2008, BRC/ IoP Global Standard Food Packaging Standards Grade AA Full low migration ink site

Label Solutions include

Flexible Packaging Solutions Include

Security, Authenticity & Tamper Evident Labels, Peel and Reseal, I.V. Hanger Labels, Braille & Tactile Warning Labels, Multi-ply Peel and Reveal Labels (AKA Peel & Read), Industrial, Blank Labels, Sequentially Numbered, Thermal Print, ID Labels, Thermochromic Labels.

Lidding Films and High Grade Papers, Laminated Films, Stick Pack, Flow Wraps (foil & non foil), Blister Foils, Wet Wipe Wraps and Re-Seals, Liquid Pouches, Peelable Pouches.

OPM (Labels & Packaging) Group Limited, The Colour Box, Gelderd Road, Leeds, LS12 6TG

Lifting & Handling Equipment

New VLBG PLUS Now Offers 45% Higher Working Load Limit (M8-M30) UD Chains is a leading manufacturer of lifting and lashing equipment that helps guarantee ultimate safety when lifting and moving heavy loads. Their diverse product range offers over 600 tested and certified lifting and lashing points for bolting and welding covering a working load capacity range from 0.6-250 tonnes. The ever popular RUD VLBG load ring has been developed to offer the new VLBG Plus. The innovative VLBG Plus now includes RUD’s robust ICE- Bolt. The ICE-Bolt is made from their revolutionary patented fine grain steel which is operational to temperatures as low of -60°C.

Lifting points are often used for turning, rotating and tilting which adds a considerable risk to the lift. When lifts are turned under full load it results in high friction between the bolt head and the rotating connecting element, which subsequently can lead to the opening of the bolt mid lift which can occur with DIN 580 / standard eye bolts. However this does not happen with the new RUD VLBG plus.

and holds the suspension ring in the requested position. A clear marking of the minimum working load limit for all loading directions is also highlighted on the load ring.

The VLBG Plus bolt offers a considerable safety feature to the operator and equipment being lifted; it will stay firmly fastened under full loads, vertically or horizontally. The ICE-Bolt is quick and easy to install and assembly is possible with a flat/ ring wrench or Allen key.

Complex lifts where the load has to be manoeuvred and tilted in all directions can be safely and effectively done with the use of the VLBGPlus load ring. The VLBG Plus can be used across a variety of working environments from engineering, construction, rail, offshore, handling and MOD projects to name a few.

The VLBG plus offers an impressive 45% higher working load limit (M8M30) compared to the VLBG. It rotates 360º and the suspension ring pivots 180º. The clamping spring works as a noise reduction function

For more information please call 01227 276 611 Email Katie.crane@rud.co.uk or visit us at www.rud.co.uk

RUD Chains Ltd

Tradition in Dynamic Innovation

Ultimate Safety working at Heights with RUD Fall Protection Anchorage Points

• Safety imperative & legal requirement when working at heights • RUD fall protection permanently attach to structures • Fall protection range: PSA STAR-POINT & PSA INOX-STAR • PSA STARPOINT: safety factor 4:1 & can be ﬁxed permanently to structures • Used across Offshore, wind tower installation, construction & engineering

PECM Issue 27

Barnshaws Polska used 40 tons of precision rolled steel cylinders and cones to construct a tapered column to support the huge triangular sign structure.

Barnshaws Polska first sourced the steel plates in a range of gauges incorporating 12, 14, 16 and 18 thickness to fabricate these plates into the cylinders and cones required for the tower sign.

Rolled Steel From Barnshaws Polska Used For Giant Retail Sign new giant retail sign in Hungary has been erected using steel fabrication expertise from Barnshaws Polska. The expert metal bending and fabrication company used 40 tons of precision rolled steel cylinders and cones to construct a tapered column to support the huge triangular sign structure. A company from Budapest was the main contractor and chose Barnshaws due to a track record of supplying curved structural steel sections, pipes and tubes to many of Europe's largest construction projects.

Barnshaws Polska first sourced the steel plates in a range of gauges incorporating 12, 14, 16 and 18 thickness. To fabricate these plates into the cylinders and cones required for the tower sign, Barnshaws Polska utilised its in-house rolling capacity to deliver the finished shapes.

Diameters of the finished cones and cylinders ranged from 1000 mm to 1500 mm, with the height of each cylinder measuring in at 3000 mm. The next step of the fabrications process was to bevel the edges of all the cylinders and cones, then weld them together for final delivery to the customer. The bevelling process ensured a strong durable weld, a key aspect for a structure that will spend the entirely of its service life outdoors. All work was carried out in-house by Barnshaws Polska engineers, offering the client a turnkey fabrication solution to fit their application requirements. Maciej Walkowicz, Director at Barnshaws Polska commented: "The wide range of services we offer means that we can take on all aspects of precision curving and fabricating metal. This turnkey approach, supported by our in-house capability, translates into reduced costs and lead times for our customers. Our breadth

of expertise includes projects that vary from bridges, to vehicles and stadia, for example; we have provided structural steel and aluminium for the Sopot Forest Opera venue, a new tram design and bridge structures for the Wielun ring road." Barnshaws Polska Branch is located in Siemianowice Slaskie, a perfect position from which to service engineering and construction projects across Europe. The facility offers bending services for IPE European section beams and profile section sizes up to 533mm, steel tube bending up to 508mm, plate rolling to 3m wide at 20mm thick and 1.5m wide at 40mm thick. In addition, aluminium bending is available from an exclusively non-ferrous workshop. Capacity from Barnshaws in the UK is also available to help supplement larger diameters. www.barnshaws.com

Issue 27 PECM

Modulift Launches Off-the-Shelf Adjustable Lifting / Spreader Beam with Next Day Delivery Modulift has launched a combined lifting and spreader beam utilising a clamp system that provides a safe, fast and adjustable beam, enabling users to lift from multiple points top and bottom.

he Adjustable Lifting / Spreader Beam (or MOD CLS) is stocked as a boxed product for immediate shipping and eliminates delays incurred waiting for alternative solutions, which often have to be manufactured to order.

The specialist manufacturer conceptualised the MOD CLS in response to demand from sectors where light industrial lifting scenarios inside or outside factory environments are commonplace. The fully adaptable system particularly lends itself to applications where flexibility and speed is key to productivity. Sarah Spivey, managing director at Modulift, said: “The MOD CLS is gamechanging from a lead-time perspective as

PECM Issue 27

users no longer have to wait for beams to be built. The launch is yet another example of Modulift responding to industry demand and providing distributors with a revolutionary, off-the-shelf, below-thehook solution.” The beam is being introduced in one size of up to 8.5t capacity, depending on configuration, but offered with four clamps as standard to adjust the lifting points to enable flexibility between a single top lifting point (lifting beam) or double top lifting points (spreader beam). The clamps are pre-assembled on the beam together with markers to show alignment and the centre of lift. Clamps on the upper / top side of the beam are of a larger rating and size than the two clamps fitted to the bottom / underside of the

beam. The MOD CLS can also be adapted to suit with up to an additional four clamps on the bottom side of the beam allowing users the flexibility of additional lifting points. If more points are needed, the flexible system can also be designed as a H-Frame, providing infinite lifting points.

Lifting system Ian Locke, senior design engineer at Modulift, said: “Despite a host of individual component features, the product stands out as an entire lifting system, not just a spreader, lifting beam or clamp. This is where we differentiate ourselves from existing products in the marketplace. Rather than releasing the clamp design on its own, we set out to create a complete below-the-hook solution.”

Users can amend the lifting points between a single or a double point lift at the top.

However, Locke singled out the product’s reversible lug plate that grips onto the spreader when a load is applied. For additional safety, he said, there are two tightening screws / bolts at both ends of each clamp, allowing the user to apply a small pre-load to the clamp in order to keep it locked in position before the main load to be lifted is applied. The product represents further diversification of a portfolio that recently welcomed an innovative new end unit system with an integrated load cell (Active Link). Locke said: “Although the design fully reflects Modulift’s core design principles of providing customers with both flexible and adaptable solutions, there is nothing similar in our existing product range and it therefore represents another dimension to the range that our distributors have found hugely exciting.” The product’s launch marks completion of extensive research and development that started over two year ago. The MOD CLS will be manufactured to a minimum stock level to facilitate next day availability as an off-the-shelf product for Modulift’s global distribution network, while plans are already afoot to offer another model with a higher working load limit (WLL).

The clamps are pre-assembled on the beam together with markers to show alignment and the centre of lift.

A reversible lug plate grips onto the spreader when a load is applied.

Modulift www.modulift.com

Colpa precision wins new customer that Re-Engineers vintage or redundant components General manager Martin Branch says that they were approached by a company that wanted to replace the distributer in 1952 255 GT Ferrari as parts were no longer available and the drawings couldnâ&#x20AC;&#x2122;t be sourced the only option was to Scan the existing part and redraw and reverse engineer this. We were asked for 20 units although their requirement was for 2 completed units they were confident that they would be able to sell the extra 18 units as this engine requires of two these units. One of the main problems was that the customer wanted the main shaft and outside flange to be made from one solid billet of material whereas the original was made of 5 parts both turned and pressed components With some careful programming on one of our twin spindle Doosan machines and the experience of our engineers, we proved that it was more than able to cope with producing the complex part. The diameters on both ends of the shaft were ground between centers and bearings were fitted.

The main body was also to be made from a single billet of material so yet again it was scanned and redrawn before any machining could be done. The Points Cam again had to be scanned and redrawn this had to be perfectly machined as if it was quarter of a degree out of position the engine would not start and this could result in serious damage to the engine. Again some complex programming was involved, yet again our twin spindle machine and experienced engineers coped with this. The parts were then checked by Colpa Precisionâ&#x20AC;&#x2122;s inspection department and were passed off ready for dispatch. Within a couple of hours after the parts had been collected by the customer he came back to let us know that when he assembled the twin distributers to the 1952 255 GT Ferrari and fitted it, the car roared into life first time .

For a quote or additional information call us today on 01923 237596 or e-mail sales@colpa.co.uk

www.colpa.co.uk

Colpa Precision Engineering Ltd, Unit 7 Paramount Industrial Estate, Sandown Road, Watford, WD24 7XG

PECM Issue 27

Precision Machined Components

Colpa Precision Engineering Ltd Unit 7 Paramount Industrial Estate Sandown Road Watford WD24 7XG

• • • • • • • • •

Established in 1946 Colpa Precision Engineering has been supplying quality manufacturing solutions for over 70 years. ISO 9001 Approved. We have an array of Turn/Mill machines from Fixed head twin spindle machines to sliding heads. Prototype components Large and small batches Kanban & Faxban Mill/Turn Bar Capacity 3mm to 65mm Chucking Capacity up to 250mm All Materials – Plastics, Stainless Steel, Brass, Aluminum, Titanium

For a quote or additional information call us today on 01923 237596 or e-mail sales@colpa.co.uk l www.colpa.co.uk

interesting and expensive injection moulding machines will not operate properly.

that reputation.

Plastic vs Metal â&#x20AC;&#x201C; 5 reasons to switch to Plastic

Machining

More OEMâ&#x20AC;&#x2122;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 metalâ&#x20AC;Ś 5 REASONS TO SWITCH TO PLASTIC 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

Anti Vibration Products

ThermHex, based in Halle/Saale, central Germany, offers a brand new type of polypropylene (PP) honeycomb cores, which has proven to be an excellent choice for producers of sandwich composite panels. But in contrast to the traditional discontinuous cutting from a block production of thermoplastic honeycomb cores, the continuous production process by ThermHex enables a significant saving of costs, material use and energy. As a result there is a considerable price advantage because of the significantly reduced manufacturing costs. In addition, the continuous production process with direct recycling of production waste also leads to an economical use of resources and improves the CO2 balance. A further advantage of the ThermHex production process is the high level of automation and automated quality control. Find out more at: www.ThermHex.com

Renmar Plastics Machinery is the UK distributor for the AEC range of mould heaters and the reason why Tech Group has chosen to base their mould heater replacement policy around AEC, is reliability.

Key features include MCU chip for high accuracy, consistency and performance, HF or lift TIG ignition, 2T/4T, spot time and on demand fan and water cooling. The digital panel with interface for easy software upgrades and the up/down slope, pre/post flow, crater/initial/weld current adds to the abundance of features this Pulse TIG offers.

Riello introduces low NOx versions to popular RS series

The modular design includes trolley and water cooler and the

PECM Issue 24 PECM

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Riello has introduced low NOx (<80mg/kWh) â&#x20AC;&#x2DC;blue flameâ&#x20AC;&#x2122; versions to all sizes of its RS range of burners. This is achieved through the use of a low NOx combustion head to ensure emissions conforming to EN 676 Class 3 in capacities from 3,600 kW to 6,250 kW. The RS series of high-power monoblock burners is characterised by the advanced technological developments that have contributed to its design and energy-efficient performance, delivering high power levels whilst minimising size and weight. Dual fuel RLS low NOx models will soon also be available, featuring a dedicated pump motor to ensure a long life for the oil pump, combined with energy-savings. For further information visit www.rielloburners.co.uk

Practically every other competitive range of mould heaters will have a heat exchanger and water reservoir. With this arrangement, the build-up of sediment is inevitable which means a reduction in efficiency and frequent maintenance. The AEC mould heaters from Renmar have a pressurised system which means that flow rates are much higher, mould heating is more consistent thanks to turbulent flow and there is no sediment build-up to worry about.

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

JASIC PRO TIG 400 Pulse - Setting the Benchmark for Pulse TIG welding inverters ew from Global Welding Manufacturer Jasic, the Pro TIG 400 Pulse offers industrial grade IGBT inverter technology featuring DC Pulse TIG/MMA with VRD function.

Over the past seven years, as part of their own replacement policy, Tech Group has purchased a total of 119 specially modified mould heaters. The modifications include an advanced control panel which allows communication between the mould heater and injection moulding machine through a chosen protocol, different control valves for dealing with the process water and a customer specified paint treatment.

ThermHex uses a continuous production process in which the PP material is unfolded to honeycomb cores (Source: ThermHex)

Emco has over 40 years of experience within the Education sector and has built up a loyal customer base to be proud of. We are now pleased to announce the opening of Emco Industrial Ltd, giving us sole coverage of the Emco brand within the UK.

For more information please contact Renmar Plastics Machinery on 0844 6933225.

Emco Industrial focuses on top quality CNC Lathes and Mills that provide high performance and reliability across a wide range of applications, all backed up by our UK after sales service and technical support.

package also includes TIG torch & adaptor, gas regulator, work return lead and clamp. There is an optional foot control unit also available. Free product demonstrations on site or at the Jasic Welding Academy are available through authorised Jasic Distributors.

In addition to this Emco also offer complete solutions for Manual Mills & Lathes, Routers, Laser cutting/ marking and the Stratasys range of 3D Printers.

This machine is supported by a 5 year warranty when registered at jasic.co.uk and meets all industry quality standards. Wilkinson Star Limited is the Sole UK Importer of Jasic Welding and Industrial equipment.

For full details on the product range available, please visit our website at www.emco.co.uk

Wilkinson Star Limited Tel: 0161 793 8127

JASIC PRO TIG 400 Pulse Setting the Benchmark for Pulse TIG welding inverters 06/01/2017 14:51 04/01/2017 23:40:29

PECM117.indd 75

New from Global Welding Manufacturer Jasic, the Pro TIG 400 Pulse offers industrial grade IGBT inverter technology featuring DC Pulse TIG/MMA with VRD function. Key features include MCU chip for high accuracy, consistency and performance, HF or lift TIG ignition, 2T/4T, spot time and on demand fan and water cooling. The digital panel with interface for easy software upgrades and the up/down slope, pre/post ow, crater/initial/weld current adds to the abundance of features this Pulse TIG offers. The modular design includes trolley and water cooler and the package also includes TIG torch & adaptor, gas regulator, work return lead and clamp. There is an optional foot control unit also available.

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Southern Springs and Pressings posts record sales and profits Issue 24 PECM

04/01/2017 23:40:30

South of England based spring manufacturer, Southern Springs and Pressings Ltd, has achieved record turnover and profit for their last financial year. The company has generated an increase in turnover of 12% in 2016/17. Pre-tax profits also increased by 20%. Tim Page, Managing Director said â&#x20AC;&#x153;Weâ&#x20AC;&#x2122;ve had a fantastic 12 months which has been the result of some hard work and team effort. On the back of this, we have invested in the business and look forward to another successful yearâ&#x20AC;?. Visit www.southernsprings.co.uk to find out more.

Wilkinson Star Limited Tel: 0161 793 8127

COMPLEX COMPONENTS MACHINED IN ONE OPERATION CMZ TX Range

multi-turret conďŹ gurations for â&#x20AC;˘ Twin-spindle complex turning & milling applications or three Y-axis turrets for minimum cycle â&#x20AC;˘ Two times and maximum productivity robust design for consistent accuracy â&#x20AC;˘ Rigid, in demanding production environments CMZ CNC lathes are built for accuracy and durability. Box-section guideways on the X, Y and Z axes offer exceptional rigidity. This gives excellent metal removal rates and better than average tool life. email: info@cmz.co.uk â&#x20AC;˘ tel: 01788 562111 â&#x20AC;˘ web: www.cmz.com CMZ-HP-MACHINERY.indd 1

PECM Issue 27

1/15/2016 4:13:37 PM

Watkins Hire rolls out new WASPS service to cover mandatory steam boiler inspections and emergencies

leading UK packaging manufacturer is among the first companies to sign up for the pioneering Watkins Annual Steam Protection Service (WASPS), which guarantees business continuity during mandatory steam boiler inspections.

which had to go ahead without a replacement hire boiler unit due to lack of availability, because of seasonal demand over the winter.

new plant by the manufacturer, replacing this with a monthly payment that for tax purposes can be treated as a standard business expense.

The forced shut-down resulted in an unplanned loss of production, resulting in additional costs and delays to orders.

All steam boilers are subject to an annual insurance inspection, resulting in downtime for the boiler and potential interruption of manufacturing. The standard solution is to hire a temporary boiler; however, equipment availability cannot always be guaranteed, leaving manufacturing facilities potentially exposed and open to rapidly escalating downtime costs.

The WASPS contract now in place ensures availability of a replacement boiler package for all annual steam boiler inspections at all of the company’s sites, to ensure continuity of manufacturing. The agreement covers a six year period, (3 + 3 year extension).

The WASPS agreement includes full servicing and maintenance costs for the boiler rental plant for the duration of the contract, ensuring equipment is always in tip-top condition with no unbudgeted expenditure.

To address the problem, Watkins Hire introduced its WASPS scheme to guarantee customers access to a dedicated boiler package to cover downtime of steam plant for all locations, with an agreed number of transport movements and commissioning charges for a fixed monthly fee.

One of the first companies to sign up for WASPS is a leading UK packaging specialist with five manufacturing sites across the country, all using steam as a critical element in the production process. Its interest in the scheme was sparked following an annual steam boiler inspection at one of its sites in December,

The first stage is a comprehensive site survey carried out by Watkins’ specialist team, to identify the plant support requirements across the customer’s estate. This resulted in a 7000kg/hr 250psi trailerised steam boiler package being specified to cover all planned steam downtime. Once the ring-fenced boiler support package is in place, Watkins’ team liaises closely with key staff at all sites to programme anticipated annual inspections and co-ordinate boiler supply logistics to ensure it is always available when and where needed. When the temporary boiler plant is not on a customer’s site, it is held by Watkins on permanent standby to cover emergencies resulting from breakdowns or unplanned maintenance. The arrangement overcomes the need for substantial capital outlay on

Terry Stevens-Smith, Watkins’ director – National Accounts, says: “Mandatory inspections of steam boilers are a vital part of the safety and insurance regime for this critical piece of equipment. For manufacturers who depend on such plant, however, it often presents a significant logistical challenge, due to the importance of such plant for industrial processes and manufacturing. “The WASPS package provides complete peace of mind for end users in this position, ensuring continuity of manufacturing, budgetary certainty, and providing a valuable additional safety net in the event of plant breakdown. We are in discussions with a number of companies who are similarly reliant on steam plant, and believe this contract will be the first of many similar agreements in the near future.” For more details, call 0800 999 6365 or email hire@watkinshire.co.uk , or visit www.watkinshire.co.uk/wasps

Blueacre Technology leaning is a large part of many industrial processes. Whether it is to remove rust from steel components or carbonised polymer material from molds, cleaning is a consumable and manpower intensive operation that has not evolved much over the previous decades.

A new method for cleaning has been developed that utilises laser light to vaporize surface contaniments, providing a cost efficient, non-consumable alternative to chemicals or abrasive material. Laser cleaning is the process by which coatings, debris or impurities (e.g. rust, carbon, silicon and rubber) are removed from the surface of a material by using laser irradiation. At the core of laser cleaning is a non-contact process, which is fast becoming the go to solution is industries ranging from automotive to aerospace and pharmaceutical to agrifood. Blueacre Technologyâ&#x20AC;&#x2122;s laser cleaning process is based on very powerful, short laser pulses that interact with the surface of the material to selectively remove the contamination layer, be it rust, carbon, organic material or paint. As the laser interacts with the surface in two ways. Firstly, it is absorbed by the contaminant material, causing it to

PECM Issue 27

vaporise and sublimate from the surface. Secondly, it sets up a localised shock wave on the surface, which shakes contaminate material free. This dual action process, allows laser cleaning to be used on a range of materials with high efficiency. Conventional cleaning techniques are either chemical based or utilise abrasive media to blast the contamination away. Both these methods require a high degree of preparation, such as masking, and require continuous replenishment of the cleaning material. In the case of chemical based cleaning, post processing steps are required to ensure no chemicals remain and with bead blasting, significant workload is required to clean away the abrasive media. On the other hand, laser cleaning has no consumable cost with the laser itself requiring single phase operation. It is highly accurate and easy to use and will clean only where the laser is pointed. The contamination is vaporised and can be collected with simple extraction systems. The laser cleaning system developed by Blueacre Technology is an environmentally friendly means to remove contaminations and coatings. No solvents, detergents or abrasives are used and so there is no added waste.

Laser cleaning is an economically proven technology, where investment costs can be recouped in 1-2 years. Laser cleaning can be integrated into 24/7 fully automated production environments requiring on operator interaction. This reduces stopped lines, improves cleaning consistency and leads to increased profitability. www.blueacretechnology.com

Blueacre laser Technology: Providing the most effective, environmentally friendly cleaning solution

Low Power Laser Cleaner

High Power Laser Cleaner

20W – 200W

200W – 1000W

Rust Removal

Automotive

Architectural

Metal Polishing

Laser Cleaning Definition Laser cleaning is the process by which contaminants, debris or impurities (e.g. rust, carbon, silicon and rubber) are removed from the surface of a material by using laser irradiation. Blueacre Technology laser cleaning technology is the perfect tool for cleaning your products to their original condition, other advantages include;

As the laser is tuned to remove surface containments it is nondestructive to the base material

•

Removes coatings, oxides, oils & more in all in one step.

•

Base material is not damaged

•

Higher levels of 'clean' can be reached

•

Versatile system suitable for Automated and handheld applications

•

Lower sensitivity to corrosion after cleaning

Laser cleaning removes the need for expensive consumables and due to high efficiency electrical running costs are kept to a minimum •

No chemical waste

•

Low noise, no dust

•

Stable process

Laser cleaning has the lowest operating costs of all industrial cleaning methods •

Minimum training required

•

Can be operated remotely

•

Can be used for micro-scale or large-scale cleaning of a number of materials.

www.blueacretechnology.com | info@blueacretechnology.com | + 353 (0) 42 9386922

PT100 SENSORS FOR INDUSTRIAL USE The use of a platinum resistance thermometer probe in industrial and scientific applications will normally result in good, accurate temperature sensing without the need for special cables (unlike thermocouples). To achieve the best possible accuracy and reliability, care is needed with installation of the probe, connections, and choice of the host instrumentation.

CHOICE OF WIRE-WOUND OR FLAT FILM SENSING RESISTOR The resistance element is produced in one of two forms, either wire-wound or flat film. Metal film resistors consist of a platinum layer on a ceramic substrate; the coil of a wire wound version is fused into ceramic or glass.

applications. Such sensors have fast thermal response and their small thermal mass minimises intrusion in the media being tested. Such sensors are known variously as flat film, thin film or chip sensors.

WIRE-WOUND RESISTORS

Fundamentally, every sensing resistor is a two wire device. When terminating the resistor with extension wires during probe construction, a decision must be made as to whether a 2,3 or 4 wire arrangement is required for measurement purposes.

Various methods of detector construction are employed to meet the requirements of differing applications. The unsupported "bird cage" construction is used for temperature standards, and the partially supported construction is used where a compromise is acceptable between primary standards and use in industrial applications. Other constructional methods include the totally supported construction which can normally withstand vibration levels to 100g, and the coated wire construction where the wire is covered with an insulating medium such as varnish. The maximum operating range of the latter method is limited by the wire coating to usually around 250oC.

FLAT FILM RESISTORS Flat film Pt resistors take the form of a thin (1 micron) film of platinum on a ceramic substrate. The film is laser trimmed to have a precise Ro value and then encapsulated in glass for protection. A wide range of styles and dimensions are produced to allow for different

In the sensing resistor, the electrical resistance varies with temperature. Temperature is measured indirectly by reading the voltage drop across the sensing resistor in the presence of a constant current flowing through it using Ohm's Law: V = R.I The connection between the thermometer assembly and the instrumentation is made with standard electrical cable with copper conductors in 2,3 or 4 core construction. The cabling introduces electrical resistance which is placed in series with the resistance thermometer. The two resistances are therefore cumulative and could be interpreted as an increased temperature if the lead resistance is not allowed for. The longer and/or the smaller the diameter of the cable, the greater the lead resistance will be and the measurement errors could be appreciable.

In the case of a 2 wire connection, little can be done about this problem and some measurement error will result according to the cabling and input circuit arrangement. For this reason, a 2 wire arrangement is not recommended. If it is essential to use only 2 wires, ensure that the largest possible diameter of conductors is specified and that the length of cable is minimised to keep cable resistance to as low a value as possible. The use of 3 wires, when dictated either by probe construction or by the input termination of the measuring instrument, will allow for a good level of lead resistance compensation. However the compensation technique is based on the assumption that the resistance of all three leads is identical and that they all reside at the same ambient temperature; this is not always the case. Note: The wiring configuration (2,3, or 4 wire) of the thermometer must be compatible with the input to the associated instrument.

HIGH ACCURACY OPTIONS (TOLERANCE CLASSES) Assuming a 3 or 4 wire connection, and the use of a class B sensing resistor, a standard thermometer assembly will provide an accuracy of around 0.5oC between 0oC and 100oC. Considerable improvement on this figure can be achieved by various means including the use of closer tolerance sensors.. The overall accuracy of any measuring system (e.g. sensor, instrument, interconnection, application etc) is compromised by the sum of the uncertainties in that system.

PECM Issue 27

Labfacility Ltd Bognor Regis Telephone: 01243 871280 info@labfacility.com www.labfacility.com

Hinged lid up shows inside the vessel with the ‘sparge’ pipe for aerating/mixing the product

80GHz level radar solution for agricultural bio-science sector Contactless radar level sensors success in small turbulent feedstock vessel he BASF Agricultural Specialities Limited production site in Littlehampton, West Sussex produces industry leading biological pest control products formulated from beneficial nematodes. These products are used by farmers and growers across the globe in agricultural, protected ornamental and home and garden markets. Liquid rhizobium inoculants produced at Littlehampton are also used as seed treatments.

Nematodes are naturally occurring microscopic worms, already present in the soil, beneficial nematodes attack and kill targeted garden pests. After application, using a garden hose or watering can, they attack the larval stages of pests and slugs. Once inside, they quickly kill the pest by releasing bacteria that stops it from feeding. The nematodes reproduce inside the dead pest and release a new generation of nematodes, which disperse to hunt down more pests. The research scientists have isolated individual species of beneficial nematodes that target only specific garden pests including slugs, vine weevils, chafer grubs, leatherjackets, caterpillars, and codling moth. The state of the art production facility in Littlehampton produces trillions of nematodes in a form that is easily applied by growers and gardeners. The production process involves several stages of organism development and growth in special vats, nutritional feedstocks are added to provide perfect

PECM Issue 27

conditions to produce the nematode product. As part of this, the feedstock is mixed heated and aerated in a small just over 1m high batching vessel before adding into the process, ready for further growth and development stages. The container has ‘sparge’ pipes which blow air up through the product to mix and aerate, creating a turbulent foaming surface. The lid is hinged and removable for cleaning and inspection, so any long probe guided wave radar would be impractical and prone to damage, as well as causing a cleaning issue. Of course, any pressure based systems would have their level reading affected by the changing density during the process. A few years ago, it was identified that a contactless device, insensitive to these conditions was needed. A 26GHz radar was previously used, however, there were some limitations on the performance due to the small measuring range when the liquid level was high and surface conditions. Recently, BASF turned to the new VEGAPULS 64 80GHz radar, which has world leading sensitivity to handle both the turbulence and foam on the surface as well as condensation on the antenna of the sensor. It now provides a true level and contents measurement over the whole vessel height, the site Process Development Manager commented, “The radar works perfectly, even at very close proximity to liquid when the vessel is full”. The unit was supplied with the optional Bluetooth communications, which allows set up via

Smartphone, Tablet or PC. It was just as well, as during the set up, the Manager also reported, “My computer got destroyed by accident during the setting up of the radars. So I loaded up the VEGA Bluetooth App on an old iOS phone. I have to say I was impressed.” 80 GHz contactless radar is offering new solutions to level measurements that were previously thought impossible with a contactless device. As well as handling these challenging conditions, they are also capable of measuring very low reflectivity hydrocarbons, long ranges, even liquid gases, pure solvents, seeing past complicated vessel internals, long nozzles, even operating through process isolation valves. The customer concluded, “There is always excellent technical support by VEGA, from legacy devices we have had for many years, through to latest innovations like this radar”. www.vega.com/uk

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

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

Wireless adjustment via Bluetooth with smartphone, tablet or PC. Compatible retrofit to all plicsÂŽ sensors manufactured since 2002.

e are the recognised global authority in the manufacture of Intrinsically Safe Tools & Instrumentation. We are known for bringing straightforward solutions to complex safety challenges which others haven’t dared to tackle. We are copied, envied and respected across the industry.

We understand and embrace the challenges associated with hazardous environments. We look to design and manufacture products which are new and different in the marketplace and which tackle those challenges. Our focus is on unmet needs and simplified process. We will not be deterred. We invest time, money and energy in getting things right. Our products are strong and functional – they can be relied upon. At CorDEX we are leaders in the innovation and manufacture of instruments used every day in the world’s most challenging work environments. All of our instruments are specifically created for safe use in hazardous environments, which make

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us the authority in Intrinsically Safe Instrumentation. We invest in product development and certification to make sure our customers have the confidence that you need to stay safe. So our tools offer more than just safety, performance and accuracy – they give our customers the confidence to do the job. Our products may be Intrinsically Safe but you won’t see a trade-off in terms of usability or features. Our products, such as our range of IR Windows, have all of the usual advanced functionality you would expect from an industrial instrument. And like any other high quality instrument it comes with a full warranty and ongoing support from our in-house technical team. Find the contact information below for our regional offices and speak to our CorDEX customer solutions team to help you find the most relevant distributor from our global network. Email: sales@cord-ex.com Phone: +44 (0)1642 454373 Fax: +44 (0)1642 424737

Introducing the MONITIR panel mounted and industrial automation thermal imagers.

Eliminate risk with real time infrared monitoring of your switch gear and systems. PLC compatible with fully configurable alerts and alarms.

PRODUCT DETAILS

MONITIR MN4000 PANEL MOUNTED THERMAL IMAGER

MONITIR MN4100 CONTINUOUS MONITORING THERMAL IMAGER

• Measurement accuracy of ±2º/2% from -10 to +120C • Easy to install and removable while live • Communicates with MODBUS/TCP and is supplied with

• Measurement accuracy of ±2º/2% from -10 to +120C • Compact and lightweight, measuring 120x70x70mm • Communicates with MODBUS/TCP and is supplied with

pre-written PLC Function blocks for communications, alarms, measurement and analysis • Provided as standard with CorDEX MONITIR Software for large scale deployments and analysis • On-board web server for point-to-point communication

contact our sales team on sales@cord-ex.com 0r +44 (0) 1642 454373 FOR MORE INFORMATION

RUGGED AUTHORITY

www.cord-ex.com

Measurement & Monitoring

From Modbus to the Cloud Every day seems to bring a new request to connect a Modbus device to our SmartHub™ in order to give clients that rich functionality, to monitor, manage and inform. All done remotely, real time and on-line. So how do we get Modbus Controllers talking to the CDL SmartHub™ so quickly, securely and seamlessly? Once the NanoULTRA is connected to your target device (RS232 or RS485) and powered up, all of the configuration work is then done via the SmartHub, there is no need to connect to the device directly with a PC to configure Modbus communications. This can all be achieved, securely via any browser/Smart Device.

CeramTec goes with the flow with fully-integrated flow body and ultrasonic sensor solution CeramTec has streamlined the design process for manufacturers of domestic and industrial water metering systems with the release of a new flow body component which features an in-built 2MHz ultrasonic sensor. Available in a range of materials, including lead-free brass to ensure compliance with the applicable water-safety legislation, CeramTec has the design capability to develop bespoke products to meet specific customer requirements. www.ceramtec.co.uk

For more information, please visit www.captiondata.com

Mounted any way you need it: compact flow sensor with rotatable display from EGE Gettorf – For flow measurement of water and water-based media in large pipes, sensor specialists EGE launch the new SNS 552 flow sensor that features an I/O-Link interface and a digital display. The compact device facilitates fast readout of flow volumes by showing liter or cubic meter measurements on a display that can be rotated for better visibility. In addition, the responsive sensor is highly resistant to temperature variations and provides integrated temperature measurements in a range from 0 to +80 °C. www.ege-elektronik.com

New PT900 Portable Flow Meter from GE Panametrics

More than redundant: Special encoder with three separate measuring systems Berlin – Sensor specialist FSG presents the new special magnetic encoder series MH680-IIIMU-G which provides maximum reliability through multiple redundancy. The device enclosures are manufactured from Hart-Coat aluminium and provide corrosion, shock and vibration resistance. Thanks to their wide temperature range of -30 °C to +80 °C and IP67 ingress protection they are suitable for even the most demanding environments. The new encoder features a resolution of 14 bit and covers a measuring range of 0-360°. Signal output is provided per channel via a 4-20 mA current interface. FSG provides each channel with its own membrane keypad for signal setting, therefore allowing for independent calibration of every signal output. www.fernsteuergeraete.de

Dual laser infrared thermometer The high-performance, handheld OS758-LS dual infrared thermometer from Omega is a non-contact temperature measurement instrument. The OS758-LS offers a wide array of features including adjustable emissivity, color backlit LCD, 60:1 distance to spot, hi/ low temp alarm, max/min/avg/ diff temperature monitoring and data storage. This meter is also designed with a microSD card slot (SD card included). The OS758-LS offers a rugged design that is shatterproof at 1 m (3.3’) with an ergonomic rubber boot handle. A Type K thermocouple input is included for contact measurements, often used to verify emissivity. www.omega.co.uk

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The PT900 is the latest generation of portable clamp on flow meters from GE Panametrics. It has been designed based on its successful predecessor, the PT878, and still features the same high performance. The user interface, clamping fixtures and transmitter have all undergone a complete redesign to make them even more user friendly allowing an accuracy of ±1% of reading to be achieved. The PT900 uses wireless Bluetooth® technology to communicate with the transmitter and tablet. The free app is available from Google Play and features a setup guide wizard to achieve quick setup and measurements within minutes. Please contact us for more information. RS Hydro Ltd | +44 (0) 1527 882060 | info@rshydro.co.uk | www.rshydro.co.uk

Measurement & Monitoring

Stereoscopic Depth Sensor Gets Even More Accurate About one year ago, Nerian Vision Technologies introduced the SP1 stereo vision system, which is an innovative sensor solution for 3D depth perception. The SP1 is an embedded system that con- nects to two industrial cameras, which are placed at different viewing positions. Similar to human vision, the SP1 is able to infer the depth of the 3D scene, by comparing the images from both cameras. This system is based on a programmable logic device, a so-called FPGA, which provides the necessary processing power to perform all image processing in real time. This hardware-based design lends itself to massively parallel computations, which lead to a vast performance gain when compared to software-based solutions. www.nerian.com

Martindale Electric Sets The Tone With New Sound Level Meter Now available from Martindale Electric – one of the most trusted brands in electrical safety – is the new SP79 Class 2 Sound Level Meter, which is suitable for health and safety personnel who want to carry out workplace noise assessments and comply with Noise at Work legislation. Designed for both industrial and office on-site measurement, the SP79 is a user friendly sound level meter which features A and C frequency weighting and fast and slow time weighing. Compact and lightweight in design, the SP79 offers ease of use and can be conveniently handheld for spot checking noise levels, or mounted on a tripod for longer term monitoring of Min/Max values.

New Fs02 Braggmeter HighSpeed Optical Tunable Filter For Demanding Applications

Pw15ia Hbm Load Cell Offers AllIn-One Solution To Automated Applications

Now available from HBM – a market leader in the field of test and measurement – is the new high speed optical tuneable FS02 BraggMETER filter, which is suitable for both static and dynamic optical filtering applications.

HBM – a market leader in the field of test and measurement – is pleased to announce the arrival of its new PW15iA Digital load cell, which offers a flexible and cost-effective solution to a wide range automated applications.

Featuring an integrated proprietary cavity design without guiding optics, the FS02 is a compact, robust and vibration-resistant device with an encapsulated filter to ensure excellent stability. Featuring low voltage excitation and wide and fine tuning with top resolution and noise to signal ratio, the new FS02 is suitable for most optical filtering applications in test and measurement, telecom and fibre optic sensing. Best suited for integration of high-end products and also for research and education purposes in universities and R&D laboratories, typical applications include fibre swept laser sources, optical sensing equipment, optical coherence tomography (OCT) systems, and spectral characterisation tools.

The innovative PW15iA load cell from HBM is fully adaptable and features a range of integrated functions - which include a wide range of algorithms for check weighing, filling and batching – which eliminates the need to undertake these functions separately. This means that development times can be significantly reduced. Compatible with industry standard dimensions (SP4M footprint), the new PW15iA load cell can also be quickly and easily integrated into existing systems, without any additional construction effort, minimising costly downtime.

www.hbm.com

TSC Inspection Systems proud to launch a new portable ACFM® crack detection solution and probe range - PACE™ & SENSU™.

New Wtx120 Makes The Most Out Of Your Measurement Chain.

Over the last 30 years ACFM® technology has played a major role in ensuring safety and integrity of critical infrastructure worldwide. With a proven track record in the energy, transportation and defence sectors, ACFM® continues to gain positive recognition in the field of advanced NDT as the most accurate solution for surface crack detection. As new industrial sectors have discovered the time and cost saving benefits of using ACFM, the demand for a more flexible and lightweight instrument has increased. Responding to this through user consultation and field testing, TSC are proud to release a revolutionary new portable ACFM® instrument - PACE™. www.tscis.com

Highly versatile in form and function, the new WTX120 weighing terminal from HBM – market leader in the field of test and measurement – is designed for uncomplicated integration into industrial and rail mounted weighing applications. Suitable for use in filling, dosing and sorting plants and machines, for example in the food production, pharmaceutical and process industries, the new high performance terminal is based on the very latest HBM strain gauge technology and is approved for legal-for-trade applications. Offering real-time communications via industrial Ethernet and Fieldbus interfaces, the WTX120 from HBM can be easily integrated into standard industrial control systems and is compatible with PanelX software. www.hbm.com

www.martindale-electric.co.uk.

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Ethos Performance Optimisation and Energy Management saves refrigeration users thousands of pounds A new performance optimisation and energy management service developed by consultants Star Technical Solutions for refrigeration equipment is helping big energy users to reduce their energy bill and stay compliant. A scheme by consultants Star Technical Solutions, part of the Star Refrigeration group of companies has delivered proven savings of thousands of pounds to customers by making their cooling systems more efficient. The performance optimisation and energy management system called Ethos uses a data-led approach to monitor

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performance and identify solutions to keep energy consumption at a minimum. Cooling and heating costs are often hidden within an electricity bill, but remote monitoring techniques from Star’s Technical team can help owners of industrial plants understand consumption. The energy management service has already saved one of the UK’s largest retailers £100,000 annually at one site, and a Brewery in Glasgow has also managed to slash its electricity bill by £50,000 a year. www.star-ts.co.uk

Since 1911

EU Manufacturer of Process Instrumentation Available in the UK from KOBOLD Instruments Ltd

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www.van-beek.nl

Efficient Reduction With Cryogenic Screw Heat Exchanger Van Beek has developed the cryogenic screw to prepare bulk goods for grinding in a process. On leaving the screw the bulk goods are ready for grinding for example in a pin mill. This screw heat exchanger is also suitable for processes where it is important that the products must cool in a short time (quickly), for example in the food industry or in chemical processes to give certain product properties.

Perfect mixing of nitrogen by nozzles and paddles

Due to the extremely low temperature tough products or products that are sensitive to heat input can be reduced more effectively and efficiently.

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The cryogenic screw freezes the product in a short time by using several nozzles that add liquid nitrogen to the product. The screw heat exchanger is fitted with paddles that ensure good mixing of the product and the nitrogen.

Easy to clean The conveyor has a twin-walled casing and there is a vacuum for insulation. The screw is easy to remove from the body using a demountable flange on the outlet side. This makes the screw quick and easy to clean.

Curious? Interested in whether this type of screw heat exchanger can help your process further? Ask Van Beek-sales engineer Joram van der Heijden about the options. Contact him via info@van-beek.nl or call Van Beek on +31 (0)41 63 75 225

HBM Strain Gauges Fast Ordering. Quick Delivery.

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

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

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News & Events

High performance sealing solutions

Seals, bearings and engineering consultancy

Far East partner network expanded

Elastomer O-rings, seals, gaskets and custom moulded components that perform in difficult applications, last longer, require less maintenance and deliver the lowest cost of ownership.

Problem solving and optimising operation processes with custom engineered solutions is what we are all about. From extending cleaning and maintenance intervals through to improving equipment performance and lifespan, we thrive when given a challenge.

Engineering services provider Blue Diamond has extended its network of production partners in the Far East, enabling the company to offer customers even greater scope to take advantage of Far Eastern product pricing, but without the risk of trying to find manufacturing companies and dealing direct.

Whatever your sealing challenges, PPE can satisfy the most demanding requirements including extreme temperatures, high pressures and chemically aggressive environments. Our sealing experts can help you select the best materials and optimise seal designs to meet your needs. We can manufacture seals and gaskets in any size, quantity and material to suit any application. FDA, USP, 3-A, WRAS, NORSOK, NACE, TOTAL, ISO10423, ISO23936-2 compliant materials available plus many other industry approvals. Contact us for a FREE initial consultation. Tel: 01254 295 400 Web: www.prepol.com

Our extensive product offering includes static, rotary and reciprocating seals comprising mechanical seals, hydraulic seals, PTFE seals, gaskets, compression packings and various types of bearings. When there is no off-theshelf solution available, our team of skilled engineers work with the latest materials and technologies to design custom solutions that are fully optimised to your needs. Contact us for a FREE initial consultation. Tel: 0845 120 7415 Web: www.ftl.technology

Working with its long-established suppliers, Blue Diamond can provide all the benefits of global procurement for engineered machine component parts with the convenience of a single UK source. This enables companies that don’t have their own in-house resources to access volume production in the Far East for standard components and materials manufactured in metal, rubber or plastic. www.blue-diamond.co.uk sales@blue-diamond.co.uk

REMA TIP TOP UK MATERIAL PROCESSING

Lorien Supports Expansion For E&S Industry Lorien Engineering Solutions has completed a factory upgrade to support the growth of laundry and cosmetics manufacturer E&S Industry in Poland. The project included an extension of manufacturing lines at the company’s Wroclaw site and the creation of extra storage facilities for raw materials. E&S Industry commissioned new laundry and washing-up liquid production lines and mixers after it was awarded a manufacturing contract with a major Polish retailer. The design of the new facility incorporates the retailer’s specific manufacturing and hygiene requirements. E&S Industry wants to expand its portfolio of personal washing and cosmetics products, so Lorien designed and commissioned a new, hygienic plant to handle additional capacity. www.lorienengineering.com

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REMA TIP TOP UK awarded contract for chute & bunker linings at Drax Power Limited REMA TIP TOP Industry UK has been awarded the chute and bunker lining contract at Drax power station, Europe’s largest co-firing power plant. REMA TIP TOP will be supporting the operations at Drax by supplying on site lining services to the Maintenance and Engineering Dept for the materials handling plant on the coal and ash & dust conveyor systems, with UHMWPE and stainless steel liners to protect the plant against wear as well as enhance throughput of fuel & ash through the materials handling system. For more information and enquiries on this article please contact Paul Edson at REMA TIP TOP INDUSTRY UK LIMITED on 01302 711233

REMA TIP TOP specialises in the consistent optimisation of production plant operational readiness. In over 50 years of research and development work, we continuously improve production and application capabilities in cooperation with our customers. The use of specific REMA TIP TOP products lengthens the service life of conveying and processing plant and reduces downtime. Special products optimise operational readiness, increase production capacities and thus maximise profit for the plant operator. SURFACE PROTECTION In the industrial world, corrosion causes millions of pounds of damage every year. REMA TIP TOP corrosion protection systems prevent such damage and maintain the value of your plant while contributing to environmental protection. Wherever chemicals and abrasive materials cause damage to containers, pipes, valves etc., we offer world class corrosion and wear protection solutions. www.rema-tiptop.co.uk

FLEXIBLE SOLUTIONS FOR ANY ATMOSPHERE A

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

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

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

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

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Process Technologies

National Technical & Distribution Centre for Dual Containment FT Pipeline Systems’ water treatment division is the perfect partner for all your dual containment needs. We offer solutions for chemical dosing and chemical transportation in both rigid and flexible pipework, with leak detection as standard. Flexible hose up to 2” / 50mm internal diameter is available in PVC, LDPE and PTFE and is suitable for most chemicals. PF-Detect (pictured with the alarm box) is a new innovation and is the first leak detectable chemical dosing hose. Expensive catch-pots are no longer required and an alarm will sound the moment the system has a problem. Rigid dual containment hose is available up to 225mm and is available in PVC, CPVC, PP, PE and PVDF. A choice of systems is available and both offer easy-to-install solutions. www.ftpipelinesystems.co.uk Tel: 01543 416024 Email : rattisha@ftpipelinesystems.co.uk

Infra-Red Ensures Duerr’s Suffer No Shocks As They Convert to Air Rinsing From Water Rinsing of Jam Pots A purpose-built carbon infra-red oven has been instrumental in allowing Duerr’s of Manchester to change from a hot water rinse system to a cold air rinse system at their Wythenshawe jam-making site. As a result, water-usage and water-heating bills have been significantly reduced and more effective control has been established over the total jar heating and rinsing process. Duerr’s is the oldest, family-owned jam-maker in England and has been making quality preserves for over 135 years. It is especially proud of its range of jam jars, which can be recycled after use to create items ranging from light fittings to cocktail glasses. However, the prime purpose of jam jars is to carry the jam and they are filled in a continuous process with hot jam on a bottling line. www.heraeus-infraredsolutions.co.uk

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Aerospace engineering firm cuts costs with high efficiency compressors BOGE is saving a leading aerospace engineering and treatment company at least £18,000 a year by installing two of its high efficiency compressors. The business operates from two locations – a precision engineering site (manufacturing high integrity, complex, aerospace components and assemblies), and a treatment site (providing non-destructive testing, surface treatments, and painting to major aerospace companies and their suppliers). Both sites previously ran off unreliable, fixed-speed compressors (powering CNC machines at the engineering site and coatings technology at the treatment site). Keeping these operational was proving increasingly expensive and disruptive uk.boge.com/en

Foam Control Controlling foaming in your industrial and other processes will improve efficiency, quality, hygiene, reliability – and reduce overall costs. For over 45 years Basildon has manufactured high quality silicone based and non-silicone antifoams for use in areas as diverse as industrial, pharmaceutical, food, personal care, fermentation and biotechnology. We advise customers how to solve their foaming issues in many applications and recommend antifoams from our Foam-Clear range. These are suitable for use in high surfactant, extreme pH and high temperature environments and are available in 100 % active forms as well as emulsions, which readily disperse in the foaming medium. Emulsions can be added manually or added automatically using foam detection and dosage equipment – which we also recommend and supply. Tel. 01235 526677 www.baschem.co.uk sales@baschem.co.uk

Captec Introduces Powerful New Industrial Computer Range Captec, designers and manufacturers of specialist computing platforms, has introduced its new 2U and 4U rackmount industrial computer range. The portfolio offers customers optimised flexibility in configuration, while creating competitive lead times of two to three weeks. The development of a unique three-tiered selection model for chassis and motherboard enables customers to define the specifications that meet exact performance and budgetary requirements. This creates 18 configuration variants, supported by a full scope of options for CPU, memory, storage, operating system and expansion cards. It is available with Intel’s latest 7th generation processing technology, delivering unprecedented power and performance. For more information please contact us: T: +44 (0)1489 866 066 E: enquiries@uk.captec-group.com www.captec-group.com

amixon® amixon® specializes in the development and manufacturing of mixers and dryers for the processing industry. One focus of the amixon® product range is on sterile equipment which fulfils even the highest hygiene requirements. Continual innovations such as mixing devices and processes for complete discharge have enabled amixon® to make further improvements in productivity and hygiene standards of the process equipment. Many solutions patented. The individual fabricated machines find application in many branches. For the testing of mixing processes, amixon® has 6 test centers worldwide. www.amixon.com

Process Technologies

Sepura’s winning formula K-manufactured SEPURA™ has an excellent reputation for superior oil/water separation with the popularity of its low, medium and high capacity units continuing to grow on a global basis. But what is it that sets SEPURA apart from the competition in the filtration market?

requirements - with outlet quality better than 10ppm. Pure and simple approach

As a Bowman Stor brand, the name has become synonymous with enviable standards of product quality and customer service - a status earned through many years of testing, development and continuous evolution.

Sometimes, keeping it simple keeps it working! With SEPURA there are no moving parts and no stagnant reservoir of condensate to breed unhealthy bacteria. Also, there is no oil container to deal with, because all the oil is retained in the filters. With 100% performance on most synthetics it’s easy to see why tens of thousands of installations worldwide experience SEPURA satisfaction.

Clear condensate - clear conscience

Trust the experts

Value for money Fast, easy installation and low maintenance combine with up to 4000 hours of filter life provide customers with a reliable cost-effective solution for all of their air compressor condensate oily water filtration needs. For further information on SEPURA technologies or to place an order call +44 (0)1543 379212 or email sales@sepura-technologies.com. Comprehensive product data is available on the website: www.sepura-technologies.com

SEPURA technology is designed and built in Just 250ml of oil can cover acres of water Britain, developed and honed in Bowman’s surface, reducing the effectiveness of in-house laboratory. treatment plants, preventing oxygenation, and killing wildlife. Apart from a duty of care, There are inferior imitations on the market companies now have a legal responsibility but only SEPURA branded products contain to ensure that industrial discharges are Bowman’s unique SILEXA™ filtration media. restricted to specific levels (usually a In trials this patented media has been proved maximum of 20ppm). SEPURA offers an to be much lighter, 20% more absorbent and economical, reliable and environmentally cleaner compared to other traditional OEM sound method of complying with the legal Sepura WINNER Ad 132x180L (QN02963)_Layout 1 07/06/2017 12:11 Page 1 products.

Every one’s a winner! Whichever Sepura™ product you choose you can be sure that you have backed a winner.

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Only Sepura separators contain the superior Silexa™ filtration media. Sepura is part of the Bowman Group

www.sepura-technologies.com

+44 (0)1543 379212

e: sales@sepura-technologies.com

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Process Technologies

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

Accuracy and reliability

•

Easy verification of equipment

•

Multiple high speed control points

It also discusses successful applications of weight based quality control and how to remove defective parts, modules or kits from the manufacturing process. METTELR TOLEDO's compact and rugged weigh modules optimise in-production quality control and ensure zero error weighing. The weigh modules are easily integrated into machines and instruments and provide fast, accurate and precise results. For more information download the zero error white papers: www.mt.com/ind-wp-zero-error

www.cwst.co.uk T: 01635 279621 Shot peening is a cost effective method to help prevent: l Metal fatigue l Pitting/Fretting Engineered coatings help with: l High lubricity/low friction l Anti-corrosion l High release/anti-stick l Low noise/anti-squeak C.A.S.E.TM super finishing is used to: l Increase gearbox efficiency l Reduce surface/contact fatigue l Decrease lubricant temperature l Reduce transmission noise

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Schaeffler continues the success story of UniAir technology that has proven itself many million times n 2009, Schaeffler set new standards with the start of volume production of UniAir – the world’s first fullyvariable electrohydraulic valve control system. In doing so, it set standards in environmentally friendly and dynamic engine technology, which also marked the beginning of a new era in valve control systems. Schaeffler’s latest generation of UniAir also now allows vehicles in the upper-class automotive market to operate more economically and with lower emissions.

HERZOGENAURACH, May 31, 2017. UniAir controls the engine valves based on cycles and offers an extended range of strategic options for matching engine operation to specific situations and requirements. This technology makes it possible to achieve significant reductions in fuel consumption and emissions, as well as a significant improvement in torque curves. By using UniAir, customised operating strategies for modern combustion processes, such as the Miller and Atkinson cycles, can also be realised in accordance with customer requirements.

significant retardation of the ignition timing. “We are continuously developing UniAir technology in order to meet the increasing demands of our customers to produce drives that reduce fuel consumption and emissions,” explains Prof. Peter Pleus, CEO Automotive Schaeffler AG. “Since its development, market interest in the system has steadily increased. The fact that other automotive manufacturers are now using this innovative technology provides us with a source of recognition and of motivation to continue along this path.” Ron Lee, Powertrain Director in the Development department at Jaguar, explains that “with the Jaguar Land Rover Ingenium gasoline engine, we have successfully completed the first stage on the way back to producing our engines in-house. The close collaboration with Schaeffler has made a significant contribution here.

The engine scores points with its outstanding driving behaviour, excellent performance, and reduced fuel consumption.” From the finger follower through to the fully-variable UniAir valve control system, Schaeffler offers a modular system for variability in the valve train. Complemented by decades of experience in vibration damping, a high level of driving comfort is also guaranteed in demanding operating modes. Optimum interaction between the technologies is a decisive factor for ensuring further reductions in fuel consumption and emissions. In this respect, Schaeffler offers the automotive industry benefits like no other supplier thanks to its unique expertise and the comprehensive cooperation between specialist departments such as Engine Systems, Transmission Systems, Chassis Systems and Electric Mobility. www.schaeffler.co.uk

The latest generation of UniAir technology is also demonstrating its potential. In this specific case – a newly developed four-cylinder gasoline engine series – the UniAir system is combined for the first time with two hydraulic camshaft phasing units in accordance with customer-specific requirements. The additional degree of freedom offered by the system with its optimised mass design means that the engine can operate in an even broader spectrum of the data map with optimum efficiency. This means, for example, that the engine can be switched off in start-stop operation and can be started again at lightening speed, keeping vibrations in both instances to a minimum. Another advantage of the technology is the fast and precise control of the valves to match the relevant cycle. This allows an instant increase in torque without impairing the efficiency of the engine due to the Issue 27 PECM

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Competence and safety in lifting and lashing Competence and safety in lifting and lashing

Stamping of the serial number

Testing in pewag laboratory

he premium Austrian chain manufacturer Pewag – standing for innovation, quality and safety – produce high quality products that set new standards within the chain industry for the lifting and moving of loads.

confidence with innovative product design.

Pewag Winner Profilift lifting points are perfectly suited as an addition to the world wide successful Pewag Winner lifting chains.

The range of lifting points are produced in Pewag’s ISO 9001 and 14001 certified plants and guarantee a 4 or 5 fold safety factor respective of product type and a maximum dynamic load of min. 20.000 load cycles, tested at 1.5 fold working load limit.

The company places great emphasis on continuous improvements and innovations in the field of lifting points, thus keeping one step ahead of the market at all times. Simultaneously Pewag constantly strives to extend their range of lifting points whilst keeping safety, user friendliness and compatibility their primary focus. Each Pewag Winner lifting point is marked with an individual serial number and offers

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Pewag Winner Profilift lifting points correspond to the Machinery Directive (MRL) 2006/42/EC and Machine Safety Prescriptions (MSV) 2010 as well as EN 16771 technical specifications.

The user manual supplied with each lifting point contains a table showing the respective working load limit depending on the type of application, number of legs and angle of inclination. Additional technical information can be found at www.brindleychains.co.uk.

www.brindleychains.co.uk

+44 (0)1925 825555

Size matters: selecting the right heat exchanger for your thermal processing needs By Matt Hale, International Sales and Marketing Director, HRS Heat Exchangers

hermal processing is an essential part of many production processes and many manufacturers will be using a heat exchanger to carry out their thermal processing requirements. Yet, with such a variety of applications possible, it’s important that you select the right heat exchanger for your individual requirement.

Know your process There are a number of types of heat exchanger on the market: plate, tubular, corrugated tube, scraped surface, etc. Each is suited to a particular application, so think carefully about your process, including the nature of the material/s to be heated or cooled, the objective of the process and any restrictions of the environment where the heat exchanger is to be used. The driving force for heat transfer is the difference in temperature between the two substances (in most cases fluids) and this heat transfer will be influenced by the type of heat exchanger. One size does not fit all Once the correct type of exchanger has been chosen, processors must then make sure that the model supplied is correctly sized for the job. In other words, that it offers the right amount of heat transfer for the fluid/s being treated at the throughput required. The heat exchanger must have a large enough heat transfer area for the specified fluids and their specified inlet and outlet temperatures. Most calculations should also factor in variables such as whether the heat exchanger operates using counter-flow or parallel flow.

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Breaking down barriers Another important factor controlling heat transfer is the resistance to heat flow through the various ‘layers’ that form a barrier between the two fluids. One way to prevent the build-up of these layers is to increase the speed at which the fluid passes through the heat exchanger so that turbulence is formed and the boundary layer breaks away from the surface of the tube. Another option is to scrape barrier layers away in a scraped-surface heat exchanger.

State of the art calculations As with any kind of science, the mathematics and understanding of thermal dynamics is continuing to evolve and improve, although much of the science used for heat exchanger design is up to 80 years old. It is therefore important to choose a supplier which utilises the latest understanding of thermodynamics in order to design heat exchangers which provide the very best levels of performance.

www.hrs-heatexchangers.com

MANAGING ENERGY EFFICIENTLY HRS provide a range of Tubular and Scraped Surface heat exchangers, components, modules and complete processing systems that help you to optimise production, make the most of raw materials, while reducing energy consumption, waste and emissions: Food

Heating

Environmental

Cooling

Chemical (Processing)

Evaporation

Pharmaceutical

Crystallisation

info@uk.hrs-he.com +44 (001923 232 335 www.hrs-heatexchangers.com

Fat and Flour, mixed finer and faster by Boone Delta Blade Mixer John R Boone’s cost-effective Delta Blade technology brings process improvements to manufacturers of fat and flour catering mixes, allowing a higher fat addition, significantly reducing both batch processing time and capital cost. he preparation of fat and flour Catering Mixes was traditionally achieved in conventional ribbon mixers fitted with thin piano wires. Although a reliable method of producing a light, free flowing mix, the process was time consuming, limited to about 18% fat addition and the piano wires were prone to frequent breakage.

As the demand for Catering Mixes increased a more efficient and versatile method of mixing was introduced by using the Plough Type mixer with side cutters. This mixer had many advantages, processing an increased fat content, free flowing, mixture in a much shorter mix time. John R Boone has now gone a stage further and have introduced their Delta Blade Mixer to produce high content ‘Fat & Flour’ mixes.

The re-design of the plough to a delta form with wings mounted on patented blade arms, has given this mixer a clear advantage over the current range of plough type mixers. Dependent on fat formulation, side cutters may not be necessary or their number reduced, for the arms carry out the chopping of the fat whilst the delta blades disperse it throughout the mix. (In recent tests 30% was dispersed in less than 2 minutes without cutters). The blades, arms and their attachment to the shaft give a smooth crevice free agitator construction. This design also reduces the cost of the mixer and its’ cost of operation / cleaning making it very competitive with the standard plough type mixers.

Test mixers available for each type of mixer supplied

A wide variety of recipes can be produced including ingredients such as milled sugar, starch, milk powder, powdered egg, emulsifiers and flavours. The type of fat used can also vary from block lard to liquid shortening to produce such products as:•

Shortcrust Pastry

•

Scones

•

Doughnuts

•

Choux Pastry

•

Sponge Cakes

•

Madeira Cake

J R Boone also produce Interrupted Spiral Mixers up to 10,000L ( HHBM ) and Rotary Drum Mixers up to 25,000L ( RDB ) in working volume. Continuous alternatives are available for all our mixer types www.jrboone.com

System for 4 x pallet mounted drums

System for IBC’s

Kecol Pumping Systems Ltd ecol Pumping Systems Ltd is the leading UK manufacturer of air driven piston pumps and priming devices in polished stainless steel or painted construction, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general Industries.

With over 30 years’ experience in solving difficult pumping applications, Kecol has supplied systems to most major food, pharma and cosmetic companies throughout the World to transfer viscous materials quickly and efficiently. Kecol air powered drum pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open

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top containers with an internal diameter up to 1500mm. All contact parts are manufactured from 316L stainless steel and clamp construction pumps are also available for the hygienic markets. Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity, can be transferred cold. Products with a viscosity up to 10,000 poise can be transferred at ambient temperature, and the Kecol follower plate system will wipe the inside of the drum or vessel to minimise product waste. Typical applications in the Food Industry include transferring: Tomato Puree, Concentrated Fruit Juice, Honey, Fruit Pastes, Biscuit Creams, Jams, Butter, Margarine, Sweet Mince Meat, Sausage Meat and Meat Pie fillings with cooked vegetables.

Applications in the Pharmaceutical and Cosmetic industries include transferring: Mascara, Petroleum Jelly, Face Creams, Base creams, Magnesium Hydroxide, Aluminium Hydroxide, Toothpaste, LipGloss Waxes and Suntan Lotions. Applications in the Chemical & General industries include: The transfer of, Paints, Resins, Adhesives, Polymers, Latex, High Viscosity Grease, Mastics and Inks – all pumped cold without pre-heating the products. As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to solve your particular production problems. www.kecol.co.uk

KECOL

STILL NO.1 FOR VISCOUS PUMPING SOLUTIONS With over 25 years experience in pumping viscous materials, Kecol is the number one choice of many of the Worldâ&#x20AC;&#x2122;s leading pharmaceutical, cosmetic and food manufacturers. Kecol equipment is used to transfer flowable & non-flowable materials from drums, IBCâ&#x20AC;&#x2122;s, mixing vessels and process vessels of various shapes, sizes and designs, without heating the material. Kecolâ&#x20AC;&#x2122;s extensive range of equipment is designed to transfer products from triple concentrate Tomato Paste through to Petroleum Jelly and Mascara, quickly, cleanly and efficiently from standard 200 litre drums, tapered or conical drums fitted with an aseptic bag, tote bins and IBCâ&#x20AC;&#x2122;s. Our vast experience has shown there are never two applications the same and thatâ&#x20AC;&#x2122;s why we also offer bespoke systems designed and manufactured to suit your specific vessels and production requirements.

System for IBCâ&#x20AC;&#x2122;s

Trolley Mounted Vertical or Horizontal pumps

System for 4 x pallet mounted drums

NOW ATEX APPROVED

Tel: 01746 764311

STANDâ&#x20AC;&#x2C6;H30 VISIT US ON STAND E41

Fax: 01746 763375 Email: sales@kecol.co.uk

& & )'( + $ ( %&$ ) (' + %)"% . (&$! )" !!- . # ' )" - &$, . ' & . #$! # . % !$'' . Ve( & # &- & "' . - #(" #(' . & # , . &) . ( # !' . ! ' * ' . $$( % '( . , . )# $( $#' . !)" # )" - &$, . # & "' . * # & " . !- & # . $# - . (( & . )(( & . -$## ' . #)( )((er . &) ( $# #(& ( . & & # . " . $" ($ )& . $%% $" ($ . !! # ' . -&)%' . ' ) ( & "' . & " ! &$ ) ts . &) ( '( ' . $$ # (' . $# #(' . + ( # ( . ' $' (- & ' . '( . $$ !! & . ! $# . #( . I# . $!-" &' . %$,- '( ' . ! #(' . !) . ' #

www.kecol.co.uk

Customize for Optimal Efficiency

electing a standard product from a catalog can often mean compromising on fit and performance for system and product manufacturers looking to find a solution that meets the unique needs of their application. Understanding this challenge, TLX Technologies works directly with manufacturers to develop custom electromagnetic solutions matched to their requirements, supplying the optimum fit and efficiency.

The use of core technologies and optimization in solenoid and solenoid valve design offer a myriad of solutions for manufacturers seeking an efficient component for their system. For applications requiring precise control, proportional solenoids supply exact positioning with high accuracy. Proportional solenoid valves offer repeatable and precise flow control as well. TLX has successfully achieved an integrated flow control solution that provides zero leak and adjusts component performance based on real-time data feedback. A fail-safe position can be designed into the solenoid valve providing assurance that a power failure will not cause unwanted damage from a valve stuck in one position. For applications where minimal power is available or where power consumption needs to be reduced, latching solenoids and valves are an ideal solution. Latching technology allows a solenoid to actuate and stay in the latched position for the time required while consuming no power. A short pulse of power in the opposite polarity de-latches the solenoid

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returning it to its original state via spring return. Latching solenoids and valves are particularly useful for battery operated applications and reduce overall power consumption where utilized. Extreme environments offer another challenge that may require high and low temperature solutions to achieve optimal performance. TLX Technologies specializes in designing for these environments with attention given to material selection and design optimization to produce solenoids and solenoid valves that provide control in extremely hot or cold temperatures. Utilizing magnetic modeling and fluid dynamic analysis, our design team creates the most efficient, best-fit solution for an applicationâ&#x20AC;&#x2122;s requirements even for the most challenging specifications. Our engineers work closely with a customerâ&#x20AC;&#x2122;s design team to help define specifications and quantify ideas. This customer-focused

approach throughout development fosters a team environment as ideas move to production. Next time you are faced with a challenge and solenoids or solenoids valves may be a solution, we can help! Whether you require a fully-custom solenoid or solenoid valve, an integrated assembly or perhaps a semicustom solenoid from one of our base models, we are here to help develop what you need to get the job done. Give us a call to discuss your project.

Email: sales@tlxtech.com Website: www.tlxtech.com

CUSTOM SOLENOIDS AND VALVES FOR INDUSTRIAL APPLICATIONS

Answering unique system demands with superior electromagnetic solutions. Call us with your challenge. When you canâ&#x20AC;&#x2122;t find the right solenoid to fit your needs, TLX Technologies works with you to design and manufacture the best solution for your application. Whether you require a fully-custom solenoid or solenoid valve, an integrated assembly or perhaps a semi-custom solenoid from one of our base models, we are here to help develop what you need to get the job done.

PHONE:

+1 262-372-2165

EMAIL:

sales@tlxtech.com

PRECISE CONTROL HIGH-SPEED EXTREME TEMPERATURE MINIMAL POWER CONSUMPTION INTEGRATED CONTROLS FAILSAFE MODES REAL-TIME DATA FEEDBACK

ON THE WEB:

www.tlxtech.com

Product News

Extraction Services Royal Holloway During a two-day shutdown period, Western Air Ducts fully decommissioned and removed the old extraction system from the carpentry workshop, and installed the new fan and filter units along with the Inteliair™ system. Inteliair™ was installed with mechanically operated dampers controlled by Inteliair™ damper control units and our own design current sensing switch, these switches detect the change in current when an item of machinery is turned on for use, a signal is then sent to the damper control unit, which opens the damper and informs the Inteliair™ main control unit that extraction is required. In turn the main control unit signals a variable speed drive which controls fan speed and ramps the fan up to the required levels. For more information, please visit www.westernairducts.co.uk

RUBIS-PRECIS / MICROPIERRE / HIGH TECH CERAM Starting from January 2017 the french RUBISPRECIS Group is able to offer new products in Advanced Ceramic + Metal Assemblies on the basis of customers’s drawings , materials offered in such High Tech Materials are : For Metals : Titanium , Tungsten , Molybden , Nickel , Platinum , Gold , , Tantalum ,Hafnium , Niobium , Rhenium , Aluminium , Magnesium , ,Zirconium , Carbon , Peek , Chromium Cobalt , Carbide , Inconel , Iridium and Graphite .

Dr. Shrink’s New European Flame Retardant Shrink Wrap Passes Fire Test Requirements All products used in construction in Europe will need to meet Flame Retardant specifications under the Single Burning Item classification (SBI Method). Dr. Shrink’s new European Flame Retardant Shrink Wrap has passed the Fire Test according to EN 13823 SBI and meets the criteria for: ISO 11925-2:2010, BS EN 13823:2010, and Fire Classification B-s1, d0.

Fine Ceramics like Alumina Oxide , Zirconia , Silicon Nitride or Carbide , Sapphire , Ruby , Quartz , Glass , Zerodur , Tungsten Carbide, Macor and Silicium.

Dr. Shrink, Inc. is an international, one-stop supplier of premium shrink wrap and all installation supplies and accessories. With shrink wrap immediately available in widths up to 60’, it also offers heat tools, adhesives, and venting. Always meeting the needs of current and future customers, they are noted for their world class customer service, industry first products and experienced application advice.

www.rubis-precis.com

www.dr-shrink.com

Twinplast

Verderflex® Vantage 5000 Easy to Program Easy to Use!

For Advanced Ceramics :

Pharmaceutical Serialization Mediline Track and Trace, with inline coding module for all serialization requirements - from Atlantic Zeiser. A new, highly productive, flexible and compact module for the inline serialization of erected cartons. Due to its compact design, functionality can be extended to the application of tamper-evident labels and/or checkweighing. With an integrated interface to MEDTRACKER software, serialization can be rendered fully audit-proof with maximum process safety.A precise transport system means coding results become reproducible even at higher production speeds of up to 350 units per minute. Format changes can be actioned in under 5 minutes, including the possibility to mechanically swap the position of the printer and inspection camera, without the need to install additional devices. For more, visit www.atlanticzeiser.com or call +44 1264 324222

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Twinplast Ltd is the leading UK based manufacturer and supplier of polypropylene Twinfluted corrugated plastic sheeting. Established in 1986 Twinplast has earned its reputation for manufacture and supply of: •

Specialist building and protection materials

•

Converter to packaging requirements corresponding to customer requirements, Bespoke or Fefco styles available.

•

Commercial Internal and External POS, signage and display solutions

www.twinplast.co.uk

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

Issue 27 PECM

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tion

loss of quality to the dosing process.

Application Story Application Story Water purification Water purification using using Verderflex Verderflex Dura peristaltic Dura peristaltic pump and Verderhus pumppump and Verderhus centrifugal centrifugal pump

and

A water purification plant in Malaysia was experiencing significant problems when handling lime chemical as part of their treatmentwhen process. A water purification plant in Malaysia was experiencing significant problems handling lime chemical as part of their treatment process.

reviously, the plant had solenoid metering pumps pumps installed for the dosing of the installed for the dosing of the chemical. Solenoid metering pumps are chemical. Solenoid metering known for their highly accurate delivery of pumps are known for their chemicals, however in the case of handling highly accurate delivery of chemicals, lime this pump typeof often experiences however in the case handling lime this difficulties due toexperiences the nature of the lime pump type often difficulties chemical. Lime of chemical is achemical. suspension due to the nature the lime

Previously, the plant had solenoid metering

of the milled lime in water, which has a

Limedistinct chemical is a suspension of theofmilled tendency to ‘coat’ all areas the lime pump in water, hasparticles a distinct tendency due which to the lime falling out of to 'coat' all areas of the pump due to the suspension and culminating in a stubborn lime particles falling out of suspension and build-up. As the fluid passes through the culminating in a stubborn build-up. As the metering pump, the ball valves, small tubes fluid passes through the metering pump, and chambers begin to block, similar to a the ball valves, small tubes and chambers artery furring with fatty deposits. beginhuman to block, similar to a human artery furring with fatty deposits. This eventually causes a significant

This eventually causes blockage blockage and a rise ainsignificant back pressure, and which a risecauses in back anypressure, sealing to which fail and causes any catastrophically sealing to fail and catastrophically leak, coating the leak, surrounding coating theenvironment surrounding withenvironment the chemical, with which the chemical, which is very difficult is very difficult to remove. For everyto remove. For every failure, inspection and failure, inspection and service, the plant was service, the plant was losing many hours losing many hours in downtime, expense in downtime, expense of the labour and of the labour and spares charges and the spares charges and the inconvenience of inconvenience of clean-up costs. clean-up costs. A local contractor was calledininto tosolve solve this A local contractor was called this problem. The contractor recommended problem. The contractor recommended the move from metering pumps the move fromsolenoid solenoid metering pumps to Verderflex hosepumps. pumps. to Verderflexperistaltic peristaltic hose As As part part of of this this recommendation, recommendation, bothboth the the contractor and local Verder team contractor and the the local Verder team worked worked together to deliver a presentation together to deliver a presentation of data, of data, reference sites and operational practices to demonstrate the quality and success of the pumps in other installations.

Presented were the key benefits of using a Verderflex peristaltic pump • Excellent at handling abrasive, viscous fluids such as liquid lime • The constant compression and relaxation of the flexible hose which prevents the lime coating the flow path • Faster and easier to service than other pumps as there is just a simple hose and lubricant change to perform • The constant

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revolution of the rotor assembly delivers The pump is insensitive to clogging and a flow rate proportionate to the rpm. This changes in viscosity. The customer gains reference sites and operational practices to The installation of 4 Dura 35 pumps (35mm results in an accurate delivery of chemical the benefits of a positive displacement demonstrate the quality and success of the hose ID) has seen a great improvement in which can be easily controlled through pump in terms of the viscosity handling pumps in other installations. the dosing process: The pumps are now an inverter and if necessary an analytical and the benefits of a centrifugal pump for operating for aflows. consistent and unbroken probe such as a pH meter. larger Presented were the key benefits of using

period with only a planned inspection and

installation of 4 Dura With procedure the proven performance aThe Verderflex peristaltic pump35 pumps (35mm maintenance necessary. The

of the

ID) has seen a abrasive, great improvement in Verderflex pumps, the plant has specified 4 •hose Excellent at handling viscous expenditure on service contractors visiting

the dosing process: The pumps are now pumps eachgreatly at further 3 dosing fluids such as liquid lime the plants has been reduced with no processes operating for a consistent and unbroken with additional Verderhus • The constant compression and relaxation loss of quality to the dosing process.pumps to ensure period with only planned inspection and the smooth circulation of the lime. of the flexible hoseawhich prevents the maintenance procedure necessary. The lime coating the flow path expenditure on service contractors visiting www.verder.co.uk • Faster and easier to service than other the plants has been greatly reduced with pumps as there is just a simple hose and no loss of quality to the dosing process. lubricant change to perform

•The The constant revolution of the rotor water purification facility

were so assembly delivers a flow rate to their facility, impressed with the upgrade proportionate to the rpm. have This results in the engineering team specified the Verderhus screw-channel centrifugal an accurate delivery of chemical which pump circulating the lime can befor easily controlled through an chemical within the tanks, which maintains inverter andholding if necessary an analytical the homogeneity the suspension. This probe such as a pH of meter. has an exponentially beneficial effect of reducing the cleaning of the tank due to sedimentation and prevents the pump from having to work as hard drawing in extra-viscous lime slurry. By choosing the Verderhus screw-channel, the purification plant has the perfect pump for handling a high flow rate of a viscous, yet flowable slurry. Thanks to its open impeller and helical, corkscrew-like impeller, the Verderhus excels at the efficient passage of lime slurry with a BEP in excess of 70%.

Appli Wate Verd pump centr

A water pur when handli

Previously, the plant had solenoid metering pumps installed for the dosing of the

ication Story er purification using derflex Dura peristaltic p and Verderhus rifugal pump

rification plant in Malaysia was experiencing significant problems ing lime chemical as part of their treatment process.

Switches & Sensors

WE BELIEVE IN ACCURACY

Red Lion Unveils Next Wave of Compact NT24k Gigabit Ethernet Industrial Switches Red Lion Controls, the global experts in communication, Introducing our new G5 Seriesmonitoring and control for industrial automation and networking, announced the addition ÂŽ process weighing instrumentation with Gigabit of 18 new compact models to its N-Tron series NT24kâ&#x201E;˘ managed Ethernet industrial switch platform. The new NT24k 10-to-14 port DINextensive communication options rail mountable switches feature Fast Ethernet, Gigabit or dual-mode fiber ports alongside eight Gigabit copper ports with optional IEEE 802.3af/at Power over Ethernet Plus (PoE+) support. With over 100 mixed-media configuration options, the rugged NT24k platform combines the benefits of noise-immune fiber with the versatility of 10, 100, 1000Base copper connectivity to provide a robust migration path across varying industrial applications. For more information and specifications, visit www.redlion.net/NT24k.

LED UV curing system: Now more powerful and with 405nm heads The Panasonic LED UV curing system UJ30/35 is designed for hardening UV-reactive adhesives, sealing compounds, and ink curing. The UJ30/35 is very compact, has lower energy consumption than lamp systems and advanced features compared to other LED UV systems. Moreover, LED technology reduces the thermal impact on components and Contact: temperatureblhnobel.uk@vpgsensors.com feedback control assures stable intensity without any fan cooling.

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The controller can be equipped blhnobel.com with up to four individually controlled LED heads. Besides the UV-LED heads with a wavelength of 365nm and 385nm, Panasonic now also offers heads with 405nm. All heads can be equipped with lenses to adjust the power concentration on the desired area.

-XVW $6. QR SXUFKDVH QHHGHG

With a head size of only 50mm length and a diameter of 12mm, the new 405nm heads work with an irradiation intensity of up to 20900mW/cmÂ˛.

(PDLO VDOHV#DYDQFHUXN FRP

Info.pewuk@eu.panasonic.com www.panasonic-electric-works.co.uk Electronica 2016 Advert_Print.pdf 1 10/6/2016 11:10:40 AM

ÂŠ2017 Vishay Precision Group, Inc.

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Electronica 2016 HALL B1 BOOTH 121 November 8-11th Messe MĂźnchen

CMY

sales@comuseurope.co.uk

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www.comuseurope.co.uk

Tel: 44 (0) 1255 862236

28/08/2015 10:10 20/08/2015 18:19:46

Truly Continuous Availability of Critical Industrial Applications n our increasingly competitive “always-on” world, where doing more with less is the objective, automation is empowering industrial enterprises to be dramatically more productive, twenty-four seven.

You could say that this is a matter of operational excellence; the successful, reliable and consistent execution of a business strategy that yields industryleading performance. We are just starting to scratch the surface of potential gains in efficiency and profitability for discrete manufacturing and process plants through the application of big data and analytics, synchronised in real-time with operations. This is accomplished by using “Edge” computing at the sensors and actuators in order to perform real-time analysis and drive decisions that change operating parameters. This helps to minimise overhead costs, eliminate production steps (thereby reducing transaction and other ‘friction’ costs) and generally optimise business processes. With the stakes so high in an unforgiving economic climate, it is not surprising that business is investing in technology to improve operations. Industrial operators can get a continuous view into key areas such as procurement, production and materials management. They gain the ability to see problems as they happen, which means that they can solve them quickly and guarantee they have minimal effect on performance. Even better, it is possible to see trends developing which allows operators to take proactive measures to counteract problems before they happen. By preventing problems, costs can be reduced, losses prevented, revenues improved, and new business opportunities can be identified. By focusing on the fastest and most efficient ways of doing things, operation excellence is ultimately about delighting customers and setting a new standard of performance in industry. This unwavering focus allows those undertaking automation improvements to grow revenue with existing customers and to attract business away from the competition. Operational excellence requires a modern, ‘smart’ and flexible infrastructure designed to increase reliability.

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However, building or updating the infrastructure for industrial automation requires a unique implementation of technologies designed to increase reliability, efficiency and availability. From process oriented functions to discrete manufacturing and critical infrastructure, there are tried and tested solutions that will modernise your enterprise and reduce the complexity of your industrial control systems. At the core of this digital transformation, hardware and software solutions enable control systems to be consolidated onto one unified platform. These proactive systems automatically diagnose problems, don’t require IT centric specialists to keep them running and can even heal themselves. It is what helps deliver the continuous availability that today’s evolving infrastructures require. The solutions allow new applications to be easily introduced, and can either be deployed as a turnkey solution that includes hardware, software and support, or on standard X86 servers without the need for additional hardware. Configuration and management is centralised; empowering industry managers to access information anytime, anywhere and on any device. The automatic reporting features of the self-monitoring platforms help detect issues before they become problems. This includes not only fault conditions but performance metrics too. Industrial operators want their automation to be future-proof to take advantage of IIoT and Edge computing, and these solutions infuse control systems with new capabilities that also greatly extend the operational life expectancy. The Industrial Internet of Things (IIoT) is undoubtedly the future of automation. This is the vision of the world where smart connected assets (the things) operate as part of a larger system or system of systems that make up the smart manufacturing enterprise. The ‘things’ possess varying levels of intelligent functionality.

They are linked using open standards that enable secure access to devices and information. This allows the ‘big data’ to be processed with new, advanced analytical tools to drive greater business value. What is clear, is that the IIoT will be creating huge amounts of data points. To be useful, that data needs to be centralised and amalgamated into a single repository from which the analytics can be run. For industrial operators to benefit from ‘smart’ manufacturing, this needs to be done in real time. To run in real-time there must not be gaps in the data or any chance that in-flight data can be lost. Lost or incomplete data make a mockery of trying to predict or trend anything that would intelligently help operators to develop new business opportunities or enable greater business control. It simply does not make sense to implement mission critical systems on any infrastructure that is not designed for purpose. By definition, industry must avoid any and all consequences associated with interruptions to critical services and applications that control the automation. Seconds matter and there is no room for any unplanned break in service. Making the most of modern industrial automation and moving operations into the era of the IIoT then, are fundamentally reliant on the availability of the IT systems that enable them. Achieving continuous availability is vital, but it needn’t be complicated. By Andy Bailey – Solutions Architect www.stratus.com

Software & Systems

AUTOagility; working behind the scenes to intelligently manage and automatically deploy work Agility, the market-leading CMMS/EAM solution from SoftSols Group, seamlessly manages work with the new ‘end to end’ solution, AUTOagility. Based on over 30 years’ experience in managing work across a variety of sectors; AUTOagility uses dynamic, behind the scenes rules to ensure the right detail and quality of information is captured for each work request and then automatically deploys it to the most appropriate resource for completion. Using a dynamic question/response driven helpdesk, AUTOagility ensures all the relevant

information for each request is quickly and completely captured. Nothing can be overlooked or missed out that could prevent the work from being dealt with and completed right first time. AUTOagility then finds the person with the right skills and availability to complete the work. Used in conjunction with Agility Mobile Solutions, work can then be deployed directly

to mobile device of the identified individual, ensuring the work is started and completed as quickly as possible. Work is captured and completed in one seamless process; your team work on jobs appropriate to their skills and savings are made across administration and scheduling. All done automatically with Agility; find out more at www.softsolsgroup.com

The secret ingredient that ensures the bread always rises

Agility is a flexible, dynamic asset and maintenance management platform that maximises uptime and minimises production disruption. Identifying the causes of repetitive maintenance and downtime is essential to reliable production. Agility is delivered and fully supported by SoftSols, a global manufacturing solutions provider, so you have the reassurance of a technology you can trust and rely on. The result is more efficient (and rising) production levels.

Take a look at our case studies to discover Agility in action at www.softsolsgroup.com or call us on 01924 200344 today.

www.softsolsgroup.com Issue 27 PECM

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PNY TECHNOLOGIES EUROPE 15 YEARS OF GPU TECHNOLOGY EXPERIENCE Established in 1985, PNY has been driving the future of computer, imaging and mobility solutions for over 30 years. Our broad assortment of memory, graphics, storage and mobile accessories products deliver solutions to Consumer, B2B and Enterprise/OEM channels of business. Based in Bordeaux in France, the headquarters of PNY Europe houses a production site, a logistics center and a dedicated marketing team, allowing thus to produce, on a timely basis, products 100% adapted to the expectations of the European consumers. PNY has a long history of providing designers, engineers, researchers and visualization clients with cutting-edge NVIDIA® QUADRO® and TESLA™ solutions. PNY understands the needs of its professional graphics clients, offering professional technical support and a constant commitment to customer satisfaction.

NVIDIA® Quadro® — The World’s Most Powerful Visual Computing Platform.

PNY GPU SERVER — COMPACT, POWERFUL and designed for Deep Learning and VDI

Experience the world’s most powerful visual computing platform everywhere—for the ultimate in creative freedom. Whether you’re developing revolutionary products, telling spectacularly vivid visual stories, designing groundbreaking architecture, or creating the most lifelike, immersive virtual experiences, NVIDIA Quadro gives you the performance to do it brilliantly. Support for multiple 5K displays, large graphics memory capacity, advanced physically based rendering, VR-specific features, and flexible multi-GPU configurations give you the power to tackle the most challenging visual computing tasks.

The PNY Server series is a super-computing server designed and optimized for NVIDIA Tesla computing accelerators. This server offers the ability to receive up to 8 double slot GPU cards. With such power, this system is able to offer vast gains in processing time for the most supercomputing intensive applications, from cutting-edge rendering farms to the latest simulations in leading scientific research. The PNY Server Series is the first choice for High Performance Computing, Deep Learning and Virtual Desktop Infrastructure.

NVIDIA® Quadro® GP100 — World’s Most Advanced Visual Computing Accelerator. The NVIDIA Quadro GP100, powered by Pascal GPU architecture, is equipped with the most advanced visualization and simulation capabilities to meet the needs of the most demanding professional workflows. A single GP100 with 3580 FP32/1792 FP64 CUDA cores has incredible power to render photorealistic design concepts interactively, create extremely detailed 3D models, run intensive CAE simulations to validate designs, and evaluate design prototypes in immersive VR. You can even connect two GP100 boards with NVIDIA NVLink™ technology to scale performance with an amazing 32 GB of combined HBM2 ultrahigh bandwidth memory.

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NVIDIA® GRID — Deliver accelerated virtual desktops to any user, anywhere NVIDIA GRID is a graphics virtualisation platform that extends the power of NVIDIA GPU technology to virtual desktops and apps. It delivers an immersive, high-quality user experience for everyone from designers to mobile professionals to office workers. NVIDIA GRID technology lets IT tap into a powerful graphics-accelerated cloud solution to centralise apps and data, with virtual workspaces that offer improved security, productivity, and cost-efficiency.

THE NEW QUADRO GP100 Unmatched Power. Unmatched Creative Freedom

The Quadro GP100 provides the ultimate in workstation visual computing scalability. The Quadro GP100 can run FEA, CFD, CEM, CAD and other GPU accelerated analysis codes faster. With 16GB of HBM memory, larger simulations can fit into GPU memory. Users can connect two GP100 cards with NVLink to provide 32GB of HBM memory to run the largest simulations. •

Compute and graphics tasks simultaneously

•

Combine two GP100 cards for large rendering workloads.

•

Support for multiple displays at up to 5K resolution.

•

Create immersive VR environments

•

Deep Learning on a professional workstation

Fueled by NVIDIA Pascal™, NVIDIA‘s most powerful GPU architecture ever, the new Quadro products bring a whole new level of performance and innovative capabilities to visual computing on the desktop. The new NVIDIA Quadro makes it possible.

Learn more and visit www.pny.eu/quadro For more information please contact quadrouk@pny.eu Insight

uk.insight.com Tel: 0844 846 3333

Misco

www.misco.co.uk Tel: 0800 038 8880

Novatech

www.novatech.co.uk Tel: 0239 232 2500

Scan Computers www.scan.co.uk Tel: 0871 472 4747

© 2017 NVIDIA Corporation. All rights reserved. NVIDIA, the NVIDIA logo, and Quadro are trademarks and/or registered trademarks of NVIDIA Corporation. All company and product names are trademarks or registered trademarks of the respective owners with which they are associated.

Storage Handling & Distribution

Efficient drive solutions with a small line-up of variants Specifically designed for intralogistics and baggage handling systems, the new LogiDrive standardized AC vector drives from NORD DRIVESYSTEMS facilitate planning, configuration, and spare part management through a project-based reduction of variant complexity. These drives meet the highest efficiency standards – IES2 system efficiency and IE4 or Super Premium Efficiency for the motor by itself – and reach excellent efficiencies even in the partial load range and at low speeds. They therefore pay for their initial cost within a few years or even only months. Total expenses over the product lifespan are significantly reduced. The systems allow for simple daisy-chaining; short power lines can be connected from one drive to the next.

Modular industrial gear units in additional sizes NORD DRIVESYSTEMS introduces two new gearboxes for nominal torques of 15 and 20 kNm. With these latest additions to the line-up, the series now comprises 11 gearbox sizes that deliver output torques up to 250 kNm. The NORD industrial gear series offers a particularly great variety of configuration options for application-specific drive solutions. The modular NORD product range includes dual-gear setups, auxiliary drives, brakes, torque arms, backstops, swing bases, and – as the latest special feature – extruder flanges. In addition, there are a variety of sealing options and solutions for monitoring and temperature management. www.nord.com

If you knew………………. just how expensive electro smog is and how much it is costing you, you would be in the queue at our door. Absenteeism, high staff turnover, poor communication, low productivity ……. These are all typical symptoms of electrosmog. For a free consultation write to us on the contact tab at www.harmonyunited.co.uk

www.nord.com

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PECM Issue 27

RtTech Software

Innovation in Cyclone Design

RtTech Software is simplifying the Industrial IoT.

The aero cyclone separator can separate solid particles from the gas phase. Several parameters affect the separation: the properties of the gas, the number of particles in the entry gas, the volumetric flow rate and the geometry of the cyclone separator.

By avoiding any unnecessary rip-and-replace, the team at RtTech is able to help companies reduce downtime and eliminate energy waste by leveraging any existing systems with the data collection and analytic power of their IoT platform Cipher.

www.rttechsoftware.com/en/cipher/ product/

We provide now the new version of “Cyclone“, a comprehensive software application for the calculation of cyclone dimensions. This program enables the user to correctly dimension a cyclone. The required parameters are defined, e.g. pressure drop, effectiveness, particle size separation, and the cyclone geometry is calculated. “Cyclone 2” can also determine the performance of a cyclone or cyclone network with predetermined geometry, under specific predetermined operating conditions.

contact: brett@rttechsoftware.com

www.sysmatec.ch

Specializing in areas such as Asset Management, OEE, and Energy Management, RtTech helps companies to remove waste from their process to realize maximum operational efficiency. Cipher’s drop-in approach to IIoT helps companies reduce their deployment costs and makes old equipment tell new tales.

Designed to Meet Your Needs, at Your Convenience Zero-cost valve industry updates at your premises Find new suppliers, products, technical solutions Hassle free, no down time

For more information and to register your interest please contact:

www.bvaa.org.uk/exhibitions.asp

Tools The combination of Master grinding wheels, Cool-Grind nozzles, and Q8Oils on the Micromatic eco 200 machine contributes to achieving optimum grinding performance in application

The eco 200U grinding machine is now up and running at Master Abrasives facility in Daventry

New grinding machine installed in the Master showroom aster Abrasives has been busy setting up a new showroom at its Daventry location for demonstrating precision grinding products including abrasives, dressers, and Micromatic grinding machines. Following the recent visit of an installation engineer from Micromatic Grinding Technologies, the eco 200 universal hydraulic cylindrical grinding machine is now installed and ready for demonstration in the Master showroom.

products, says “Having the eco 200 installed at our showroom facility will be a great aid in showing customers the capabilities of Micromatic machines. Demonstrations of the eco 200 can be arranged on request and we already have many interested customers who have scheduled their visit to see the machine.”

Martin Stevens, Technical Sales Representative for grinding machines and precision

The high-performance brand of MASTER® grinding wheels and dressers will be available to use in demonstration of the eco 200 to provide efficient grinding and surface finishing. The showroom machine is set up with a coolant application nozzle system by Cool-Grind Technologies, providing accurate

Plastic media

Liquid compound

coolant flow and pressure to the process. This gives visitors the opportunity to see Grind-Loc nozzles in action and understand how they can help to achieve optimum performance from grinding processes. Q8Oils has worked with Master Abrasives to supply the suitable oils and cutting fluid for the eco 200 U demonstration machine. The team of technical experts has provided products to improve the operational efficiency and optimise the production process. www.master-abrasives.co.uk

Ceramic media

Improve productivity with new MASTER® Premium Finishing Consumables aster Abrasives has launched a new premium range of finishing consumables for mass finishing under the MASTER® brand. This includes plastic, ceramic, argo (dry), and special media and a range of compounds to facilitate the finishing process.

Mass finishing is a process that automates the mechanical and chemical finishing of parts. The benefits of this stage in the manufacturing process of components are savings in costs and time, as it allows large numbers of parts to be finished

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simultaneously. Mass finishing can be used for a variety of applications, such as deburring, removal of machining lines, descaling, radiusing, polishing, and superfinishing in many industries including medical, automotive, aerospace, hospitality, and manufacturing. The range of Master finishing consumables has been developed to provide the desired finish for various applications. This new product category includes Master argo, pretreated, plastic, ceramic, and special media, all to suit the numerous challenges in different industries.

Master also offers environmentally friendly and biodegradable liquid compounds, vital to the cleaning and finishing process, as well as powders and pastes which contribute to the grinding and polishing of materials. After 50 years of successful trading, Master Abrasives continues to diversify and adapt to meet customer needs. Mass finishing is now another solution Master Abrasives offers for the manufacturing process. www.master-abrasives.co.uk

Values & Flow Control

Download Dixon’s Quick Connect Interchange App Finding the right Dixon quick release coupling is now quicker and easier thanks to the free App which allows a user to enter a part number of their existing coupling and be given the Dixon equivalent.

Quick release couplings from Dixon comprises of a full range of interchange couplings for both hydraulic and pneumatic applications, engineered to the highest specification in order to flawlessly fit existing hoses and couplings. The range of manual quick release couplings is ideal for applications where full and smooth flow paths need to be maintained. Dixon specialise in the bespoke design of speciality couplings to meet the requirements of our customer including miniature and high pressure automatic connect couplings.

A wide selection of materials including Steel, Aluminium, Brass, 316 & 303 Stainless Steel are available; thread configurations including BSP & NPT and body sizes ranging from 1/8” through to 2” ensure compatibility in a variety of installations. To ensure you can find the correct interchange required Dixon has the developed Dixon Quick Coupling Global Interchange App which allows the user to quickly cross reference Dixon Quick Coupling part numbers with those of other manufacturers. This free app is available to download on your iphone/ipad or android mobile devise. To find out more about the Dixon range ask us for our Quick Couplings brochure today by contacting our customer sales department on 01772 323529. Contact Gill Platt @ Dixon Group Europe Ltd T: +44 (0) 1772 323529 E: marketing@dixoneurope.co.uk

MAKE THE RIGHT CONNECTION WITH DIXON QUICK COUPLINGS

Dixon Group Europe Limited 350 Walton Summit Centre, Bamber Bridge, Preston PR5 8AS Telephone: +44 (0)1772 323529 Fax: +44 (0)1772 314664 marketing@dixoneurope.co.uk

www.dixoneurope.co.uk

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PECM Issue 27

The Dixon Family of Quick Release Couplings offers complete Interchanges to all major manufacturers. • Sizes from 1/8” to 21/2” • Full Interchange Guide Available

For further information please contact us now on:

01772 323 529

Values & Flow Control

RotaVal to attend Bulkex 2017 Rota Val will be exhibiting at the Bulkex Show in Nottingham 18-19th October. Registration for tickets are available at www. bulkex.co.uk The event is organized by the Materials Handling Engineers Association (MHEA) and will also include a programme of eminent speakers At the show Rota Val will be launching a new range of â&#x20AC;&#x2DC;How Toâ&#x20AC;&#x2122; videos to help customers to overcome any common industry problems. On show will also be the new website with demonstrations on the improved features.

To help customers work out what size valve they need, an app has been developed which when populated by industry, throughput and cleaning method, it will indicate what is needed. For customers more aware of their requirements there is a search by industry, where the search results will show the options available. There is a section clearly showing the accreditations that Rota Val have for their valves which include ATEX, ISO 9001 and the

latest EHEDG certification which ensures that Rota Val can support food manufacturers with the strictest hygienic requirements to enable safe food production The product pages offer concise information which includes brochure downloads, ability to print the page or email the page to a colleague, the ATEX accreditation and a video in action where available. For quick help and advice we have direct links to our engineers and customers can also keep up to date with recent news and social media links.

Web: www.rotaval.co.uk l Tel: +44 1249 651138 l E: sales@rotaval.co.uk

Issue 27 PECM

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BROCHURE AVAILABLE

Contact Gill Platt @ Dixon Group Europe Ltd T: +44 (0) 1772 323529 E: marketing@dixoneurope.co.uk

Values & Flow Control

www.dixoneurope.co.uk

High Flow Model VBP Series Volume Booster Delivers System Stability

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stock of control valves, instrumentation and spare parts for The range functions with a working pressure range of 2 to 10 bar g, the Masoneilan product range.

with maximum inlet pressure of 20 bar g and operates at a working

As a valve stockist, principles include Cameron temperature of -20ÂşC toother +180ÂşC. Douglas Cheroand forged gate valves fromvisit Â˝â&#x20AC;?our to website 2â&#x20AC;? in A105, For innovative reliable valve solutions, LF2 and Stainlesswhere Steel, NEWCO valves and and Alfa www.bifold.co.uk more detailedcast information Valvole ball valves, floating and trunnion design up to 6â&#x20AC;?a PDF brochure can be down loaded. 600 .

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Our experienced engineers can support all your valve needs from manual isolation to the most critical serve for Flow measurement service and emergency shutdown applications.

special requirements

Valvenco supply various types of valves and instrumentation including: SCHMIDTÂŽ ďŹ&#x201A;ow sensors meet

the highest requirements for â&#x20AC;˘ Control Valves, Instrumentation and Levels. measuring precision, temperatures â&#x20AC;˘ Safety Relief Valves and Safety Valves. and compatibilities with media. â&#x20AC;˘ Manual Valves â&#x20AC;&#x201C; Ball, Gate, Globe and Check. Due to their operating principle, â&#x20AC;˘ Actuated Valves â&#x20AC;&#x201C; Electric, and detection of theyPneumatic allow direct Hydraulic. standard velocities and standard volume ďŹ&#x201A;ows off without â&#x20AC;˘ ButterďŹ&#x201A;y Valves â&#x20AC;&#x201C; Eccentric, Double set and requiring additional of pressure and temperature. Their high Triple measurement offset. measuring precision and repro-ducibility is documented with â&#x20AC;˘ Liquid Level Indicators Levels (tanks). ISO calibration certiďŹ cates. Depending on the variant, they can also be used inLIMITED dusty or aggressive gases, with extreme VALVENCO - TELEPHONE 01844 201105media temperatures andto at glenn.kemmery@valvenco.com high overpressure. ENQUIRIES

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The Chemical En Jobs Board

PECM July/August 2012

PECM712.indd 66

27/07/2012

WESTINGHOUSE

he Chemical Engineer is published by the Institution of Chemical Engineers (IChemE) and read by over Servicing & Repairs 30,000 members across the world. IChemE is the only global institution to of Rotary Valves and Diverter Valves accredit chemical engineers, making Free of charge assessment by a DMN engineer The Chemical Engineer Jobs board the best place to look for vacancies in the Genuine spare parts used to the original manufacturerâ&#x20AC;&#x2122;s specification process engineering sector, anywhere in the world, by far.

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Issue 27 PECM

141

The Total Answer To Waste Management Burden he man who said there were only two certainties in life - death and taxes – got it wrong. He forgot waste. It’s an inevitability of pretty well all human activity from domestic to commercial, industrial to agricultural, on the sea and even in space.

There’s just no escaping it – or the cost of dealing with it. Indeed, this year’s latest rise in the Landfill Tax means that it now costs £84.40 to dispose of one tonne of waste in one of the UK’s burdened landfill sites. Annual tax hikes, and other Government efforts to boost industrial recycling and materials reuse - including a raft of new regulations - have been designed to persuade companies to tighten up the way they manage their waste. Waste creation remains one of industry’s top environmental impacts, and the pressure is on to handle industrial by-products more sustainably than in the past.

Once, of course, waste collection, storage and disposal was a relatively simple business fairly low down on a facilities manager’s priorities and probably regarded as no more than an inevitable nuisance; an unwelcome intrusion. Remember what it was like? The company skips or yard area would be filled up with a hotch-potch mixture of wastes and a designated waste haulier would turn up and take it away. What happened to it then was of little importance. It was gone and that’s all that mattered. Its potential for pollution and its value as an often reusable resource was seldom considered. But those days are gone and won’t be coming back. Now you must assess your waste according to an official Hierarchy - a set of options for managing waste in terms of what is best

Testing for water content in recovered oil at a CSG laboratory

for the environment (with disposal right at the bottom) – •

Prevention

•

Re-use

•

Recycling

•

Recovery

•

Disposal

This, in turn, is presenting specialist waste management companies with new waste treatment challenges, inspiring them to

TWM can help reduce, or even eliminate, the cost of sending waste to landfill

develop innovative technologies designed to boost their customers’ recycling and resource recovery rates, diverting waste from landfill rather than concentrating on mere disposal as a first option. Fareham-based CSG, a multi-award winning independent waste management specialist operating from 27 sites across the country, seeks to act as a ‘green partner’ to its customers by providing them with a customised programme of waste management measures designed to minimize adverse environmental impact in the heavily regulated eco-aware 21st century. These are called Total Waste Management (TWM) programmes, and more and more companies are taking this corporately responsible route in order to contribute to resource sustainability and reduce costs. That word partnership is the key, here. Together with its commitment to real sustainable waste management in which recycling and reuse are its primary goals, CSG has made partnership in a Total Waste Management programme the cornerstone of its offer to customers. So how does a TWM programme work, and what are the benefits? Naturally, all waste streams are removed from a customer’s site for legal disposal, or

preferably treatment, in compliance with the regulations. CSG values even the most hazardous waste as a potential resource, and the amount of reusable components recovered is one of the company’s key performance indicators. As one of the UK’s oldest waste management companies, CSG have the knowledge to identify a huge range of recyclables – some of them not obvious on first sight. By expertly auditing a customers’ waste, and providing the technology to deal with it, CSG can ensure that any customer in a total waste partnership can expect to see a marked increase in the amount of its waste being recycled. This, of course, ensures a more sustainable waste management process which is essential for companies holding, or aspiring to, environmental accreditations. It also puts the company in a stronger position when dealing with its own customers seeking to green their supply chains and dramatically reduces the amount of waste going to landfill. In turn, this reduces waste disposal costs. CSG handles a huge range of waste streams at its processing plants and have invested tens of millions of pounds in new plant, machinery and processes specifically

designed to maximise the recovery and recycling rates of a number of particularly problematic wastes. Many of these developments have been in response to a customer’s individual requirements. In other words, waste partners can rely on creative bespoke solutions to particular problems when a standard disposal route isn’t appropriate. A co-ordinated waste management programme requires routine management and daily oversight, especially in the case of major waste producers. As part of its Waste Partnership offer, CSG can provide constant technical support in which an expert representative is based on the customer’s site to advise on all waste management matters. The other good news is that while facilities managers will probably never view waste management as the most exciting of their many duties, an expertly-managed TWM can drastically reduce the increasing time and effort they’re required to put into managing this now complex function. Tel: 0800 048 0622 Email: technicalsales@csg.co.uk Web: www.csg.co.uk

Issue 27 PECM

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When thinking small pays big “To make a meaningful invention; discover what all experts agree is impossible and then do it” - Arthur C. Clarke When, in 1986, a young German engineer, Joachim M. Wagner Dipl.Ing (FH) (rough English equivalent MSc), decided to do the impossible of making the internal combustion engine produce more power with less fuel and cleaner exhausts, all at the same time! He was constrained to think ever smaller until he identified that the prime cause of the chronic inefficiency is the wildly erratic nature of the spark which ignites the fuel. This, he discovered, is, in turn, caused by the chaotic nature of the electricity being fed into the spark plug and so he set about removing this chaos. The way to do this, he discovered, is to return the natural order to the electron stream delivering the energy to the spark plugs. This, after some years of experimentation, he discovered is best achieved by building a nonconductive resonance mirror which, using the energy already present in the system needing correction, supplies a constant correction. This “ordering” stops the chaos which normally grows with the distance travelled and replaces it with an increasing order. The result is that the spark igniting the fuel is no longer random but precise in quantity, timing and position. This sketch gives an idea of the energy flow before and after status within a power cable:

A nice side-effect is a very considerable reduction in the amount of heat and other chaotic energies being radiated by cables etc. Motor manufacturers were not wildly excited about this invention due to the “unfortunate” side-effect of making the entire vehicle last much longer and need fewer replacement parts. The invention found its initial prime market in tuning shops, especially in Taiwan. In 2002, Mr. Wagner joined forces with the British researcher, Karma Singh, not merely because of Mr. Singh’s marketing skills but also to look at other possible applications of the technology. The technology does not deal with the elementary particles themselves but with the informational structures which causes them to coalesce out of The Field. All material, be this mechanical or biological, is made out of the same elementary particles! Although a TCM doctor in Taiwan had already noted this in 1993 and carried out many successful experiments upon his patients, it was not until Mr. Singh, who has considerable

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expertise in this area, joined the team that this area of application was developed. To understand what then follows, we must revisit the work of James Clerk Maxwell who, in the 19th century, wrote the equations describing the electro-magnetic field. Merely eight of his 24 equations are, however, taught in engineering schools because, until very recently, nobody had the vaguest idea what the “scalar waves” described in the other equations were or what possible use they could be. It was only towards the end of the 1990’s that it was finally discovered that biological systems use not electricity (as had been believed for a century and more) but scalar waves for their internal communication and control!

How can it be so cheap? Because, instead of trying to suppress the symptoms (the effects) of the problem, the Harmony United technology works to remove the CAUSE! This is always much, much cheaper. Disharmonic proportions; conventional solution: Either move or re-build premises. Harmony United solution: Apply devices which order the space and the disharmonic frequencies will be rapidly eliminated.

Although the practice of putting powerful sources of electro smog next to our brains (mobile ‘phones) has, finally, created public awareness of the problem, the problem is not the ‘phone but the electricity which powers it! Chaotic electricity causes mobiles to throw this off as wild electron bundles to prevent damage to the ‘phone. Not only do all electrical systems produce wild scalar waves which can cause major problems for human and other biological systems, but even rooms which have proportions inimical to basic human energy frequencies can feel very uncomfortable and will certainly cause problems with communication and productivity. This has, in recent years, proved to be of considerable importance to the well-being of the people within it and, consequently, the well-being of the business run there. The growing number of companies employing the services of Feng Shui experts to tackle such problems evidences the growing awareness. So, what does the Technology offer here?

Harmony

United

In short, it lets you tackle all of these problems at a fraction of the expenditure. Electro smog; conventional solution: Wrap all cables in additional sheathing. Although this will significantly reduce microwave and magnetic radiation at the cost of increasing the temperature in the cable core, it has virtually no effect upon the scalar waves which will pass through all materials presently known to man. Harmony United solution: Apply ordering devices to the source of the electricity. This eliminates all chaos, including chaotic scalar waves (ordered scalar waves do not produce any problems) and can even reduce the temperature in the cable core(s). Cost, dependent upon the size of the installation, can be as low as £750.00 rising to, perhaps, £9,000 to £10,000 on very large installations.

How rapidly? A 4000 M2 exhibition hall in Munich took 31 minutes to eliminate the aggression caused by the heavy electro smog. A 43 room hotel in which parts of the top floor had been unusable due to a mobile ‘phone mast on the roof was cleared completely in 4 ½ hours. A nine story office building which had stood empty since completion 18 months previously due to extreme electro smog, took 1 ½ days to install all the necessary Harmony devices. Four days later 60% of it had been let! To ask “how far do the Harmony devices reach?” is a question with no answer as they do not have any output of their own. The technology is passive and only corrects that which is already present, i.e. it does not and cannot add anything. So the answer is “how large is your installation?” That is the usual effective limit of functionality. What problems would you like us to solve? For a free consultation please use the contact form on the website:

www.harmonyunited.co.uk

BOLLFILTER Automatic Type 6.18 Automatic filter for treatment of industrial process water

here here aa large large amount amount of of cooling cooling or or process process water water is is re-used re-used in in open open or or closed closed circuits, circuits, the the Bollfi Bollfilter lter type type 6.18 6.18 off offers ers reliable reliable fi filtration ltration for for those those liquid liquid distribution distribution systems. systems. We We are are talking; talking; cooling cooling water, water, potable potable water water and and waste waste water. water. These These three three types types of of water water are are ideal ideal applications applications or or this this fi filter. lter. Liquid Liquid fi filters lters must must off offer er the the operator operator at at least least three three key key benefi benefits: ts: •• Reliable Reliable day day to to day day use use without without interruption interruption and and disruption, disruption, as as aa result result ensures ensures effi efficiency ciency of of the the complete complete system. system. •• Precise Precise liquid liquid fi filtration ltration to to ensure ensure aa defi defined ned degree degree of of purity purity once once treated. treated. •• Low Low maintenance maintenance with with minimal minimal operating operating costs costs resulting resulting in in little little need need for for manual manual involvement. involvement. Why Why the the Bollfi Bollfilter lter Automatic Automatic Type Type 6.18 6.18 is is best best The The Bollfi Bollfilter lter Automatic Automatic Type Type 6.18 6.18 is is the the best best industrial industrial process process water water fi filter lter available, available, this this is is not not aa hollow hollow claim, claim, because because there there are are three three key key advantages: advantages: •• Robust Robust and and durable durable construction construction based based on on in-house in-house research research and and development development over over many many years’, years’, plus plus the the in in depth depth experience experience in in aa wide wide range range of of industries industries gained gained in in the the last last 63 63 years years •• Precision Precision fi filter lter media media and and aa unique unique cross-fl cross-flow ow scouring scouring backfl backflush ush action action •• The The 6.18 6.18 is is designed designed to to last last up up to to 20 20 years years and and has has few few wearing wearing parts. parts. As As aa result, result, operators operators can can enjoy enjoy low low maintenance maintenance costs costs throughout throughout the the fi filter’s lter’s life. life. The The fi filter lter made made for for today’s today’s operator operator Continuously Continuously operating operating systems systems in in remote remote areas, areas, or or plants plants without without on-site on-site staff staff are are ideally ideally suited suited to to the the Bollfi Bollfilter lter due due to to the the current current trend trend of of minimum minimum manning. manning. This This is is likely likely to to continue continue and and the the reliability reliability of of the the 6.18 6.18 is is aa must must for for operators operators of of water water fi filtration ltration systems. systems. The The 6.18 6.18 off offers ers the the operator operator many many advantages advantages over over conical conical or or expanding expanding type type fi filter lter elements. elements. Featuring Featuring cylindrical cylindrical fi filter lter elements elements open open at at both both ends, ends, with with aa throttling throttling plate plate to to develop develop turbulence, turbulence, creating creating the the scouring scouring eff effect ect in in backfl backflushing. ushing. Technology Technology that that takes takes fi filtration ltration to to aa new new level. level. Less Less operator operator costs costs in in man-hours man-hours and and spare spare parts parts because because the the eff effective ective backfl backflushing ushing continuously continuously prevents prevents

146PECM PECM Issue 162 PECM Issue Issue 22 22 27

fi filter lter element element blockage. blockage. Lower Lower dynamic dynamic stresses stresses result result in in longer longer life life over over other other types types of of fi filter lter element. element. •• More More reliable reliable separation separation of of solids solids than than conical conical or or expanding expanding elements. elements. Original Original fi filter lter fi fineness neness is is constant constant but but that that cannot cannot be be guaranteed guaranteed with with other other types. types. •• Better Better cleaning cleaning when when process process water water is is contaminated contaminated by by fi fibrous brous material. material. •• Special Special profi profile le fi filter lter elements elements with with longitudinal longitudinal surfaces surfaces in in direction direction of of backfl backflush ush have have proven proven to to be be very very eff effective ective in in the the pulp pulp & & paper paper industry industry with with high high fi fibre bre content. content. Also Also eff effective ective in in the the water water treatment treatment industry industry with with weed weed & & algae. algae. Design Design of of the the Bollfi Bollfilter lter Automatic Automatic Type Type 6.18 6.18 Robust Robust components components make make this this water water fi filter lter design design aa simple simple option option for for today’s today’s fi filtration ltration buyer buyer or or specifi specifier, er, therefore therefore suitable suitable for for many many situations situations including including these these four four applications: applications: •• Potable Potable water water pre-screening, pre-screening, in in water water treatment treatment plants. plants. •• Final Final effl effluent uent recycling, recycling, in in sewage sewage treatment treatment plants. plants. •• Paper Paper and and pulp pulp manufacture, manufacture, for for nozzle nozzle protection protection from from process process water water contamination contamination in in paper paper mills. mills. •• Cooling Cooling water water fi filtration, ltration, in in continuous continuous casting casting and and cooling cooling nozzle nozzle spray spray bars bars in in steel steel & & aluminium aluminium making. making. Filter Filter body body construction construction The The bearings bearings and and fl flushing ushing bushes bushes are are made made of of high high carbon carbon Polytetrafl Polytetrafluoroethylene uoroethylene better better known known as as PTFE. PTFE. The The fi filter lter housing housing is is made made of of ductile ductile iron, iron, fabricated fabricated carbon carbon steel, steel, stainless stainless steel steel and and super super duplex duplex steel. steel. The The fi filter lter elements elements and and internals internals are are made made from from stainless stainless steel steel grade grade 316 316 or or better better as as suits suits the the application. application. The The only only moving moving parts parts are are the the fl flushing ushing arm, arm, cover cover arm arm and and the the fl flushing ushing bushes bushes that that are are spring spring loaded loaded to to automatically automatically adjust adjust to to wear. wear. Depending Depending on on the the conditions conditions of of the the system system and and characteristics characteristics of of the the liquids liquids to to be be fi filtered ltered aa number number of of alternative alternative options options are are available. available. The The Bollfi Bollfilter lter Automatic Automatic Type Type 6.18 6.18 is is available available in in diff different erent sizes sizes with with connection connection diameters diameters 50 50 to to 1000 1000 mm mm for for fl flows ows up up to to 10,000 10,000 m3/h m3/h in in aa single single unit. unit. Low Low pressure? pressure? You You may may need need our our low low pressure pressure option. option. High High level level of of contamination? contamination? You You may may need need our our heavy heavy duty duty option. option.

Bollfi Bollfilter lter UK UK supply supply BOLL BOLL & & KIRCH KIRCH products products to to Great Great Britain Britain and and Ireland Ireland The The water water fi filters lters by by BOLL BOLL & & KIRCH KIRCH are are the the most most important important safety safety components components in in aa water water treatment treatment plant. plant. BOLL BOLL & & KIRCH KIRCH develops develops its its water water fi filters lters based based on on its its own own research research and and ensures ensures their their compliance compliance with with all all current current technical technical standards standards worldwide. worldwide. The The automatic automatic water water fi filters lters deliver deliver the the strongest strongest performance performance even even in in extremely extremely polluted polluted water water and and under under the the most most diffi difficult cult of of circumstances circumstances long long and and maintenance-free maintenance-free service service lives lives ensure ensure that that operating operating costs costs remain remain at at aa minimum. minimum. Additionally, Additionally, our our water water fi filters lters guarantee guarantee interruption interruption and and disturbance disturbance free free operation. operation. John John Dow Dow Managing Managing Director Director Bollfi Bollfilter lter UK UK Limited Limited Tel: Tel: +44 +44 (0) (0) 01206 01206 589620 589620 Filters Filters & & Capital Capital Equipment: Equipment: fi filters3@bollfi lters3@bollfilter.co.uk lter.co.uk

The 6.18 offers the operator many advantages over conical or expanding type filter elements.

An extensive range of explosion protection equipment. From supply to full turn-key solutions Visit our new website

Flash 2 Explosion Suppression System The latest version of the industry leading StuvEx Flash suppression system has many advanced features.

* www.stuvexuk.com * Earthing Control

There are two Earthing Monitors within the StuvEx range for Gas and Dust applications.

Gas Version

· Single and multipoint injection suppressors capable of

· · · .

handling 4 ducts from one suppression bottle New Master Control Unit can handle up to 16 Zones. A range of explosion detectors for various applications. New Gas Generator - no pressure vessels used. Atex Certified.

Explosion Isolation Isolating an explosion is vital. There are five different explosion isolation devices in the StuvEx range.

· NOREX valve. Designed for filter inlet ducts, though can be

used elsewhere. · Ventex Valve. For installation to a filter air intake. · Fast Shutting Gate Valve. The most efficient way to isolate an explosion. · Diverter Valve. Used to divert a potential ignition source to a safe area. · Fire Trap Valve. Protects ‘Down-Stream’ machinery in the event of a fire or vexplosion.

· Competitively priced. · Very easy to install. · Failsafe operation – visual confirmation of correct earthing through green/red lights. · Automatically recognises the object to be earthed. · Atex Certified.

Explosion Venting StuvEx supplies a range of explosion venting devices.

· StuvEx Explosion Vent. A 100% efficient vent for silos, bins, filters etc. · StuvEx DQS. A maintenance free, flameless vent for installation to an internally located vessel. · StuvEx Flameless Indoor Vent. Allows an explosion to safely occur inside a building.

StuvEx Safety Systems Ltd, Abbey Studio, Church Walk, Chertsey, Surrey, KT16 8RE - United Kingdom Tel: +44 (0)1932 571303 - Fax +44 (0)1932 570548

Email: info@stuvex.com - www.stuvexuk.com

Global engineering, manufacturer and distributor of industrial fastenings and Cat C products.

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