Process Engineering Control & Manufacturing Issue 30 2018 by MH Media Global

Engineering Process

Control &

MANUFACTURING

PECM

Global Success Through Innovation Issue 30 2018 ÂŁ3.95 www.pecm.co.uk

PLATE HEAT EXCHANGER - 08

SOUTHERN MANUFACTURING 2018 - 36

BURKERT - 51

Plate heat exchanger (PHE) is an important equipment commonly used in refineries and plants.

Southern Manufacturing & Electronics returns to Farnborough from February 6th to 8th 2018 for its 20th anniversary event.

Maintaining water quality standards is an essential process, not only for water supply companies, but also for those who rely on it .

Programmable Logic Controllers

HMI & IIoT Solutions

Sensors, Encoders & Motion Control

Lamonde Automation Ltd The Officersâ&#x20AC;&#x2122; Mess | Coldstream Road | Caterham | Surrey CR3 5QX +44 (0)203 026 2670 | sales@lamonde.com 2

PECM Issue 30

Engineering MANUFACTURING

Sections

Editors Choice

Southern Manufacturing Show

Boilers & Maintenance

Control & Automation

Electrical & Electronics

Facilities Management

Fastners & Fixings

Fluid Handling

Gears, Drives & Motors

Health & Safety

Lifting & Handling Equipment

Machining & Machinery

Measurement & Monitoring

News & Events

Process Technologies

Product News

102

Software & Systems

103

Switches & Sensors

106

Valves & Flow Control

110

Control &

Inside...

Process

Inside Issue 30 THE AEMT ENSURES ENERGY EFFICIENCY IS MAINTAINED DURING SERVICE AND REPAIR An extensive joint research project conducted at the University of Nottingham found that energy efficient motors remained within plus or minus 0.5% of their original efficiency after being repaired by a good service centre. PROLONGING THE SERVICE LIFE OF A CONTROL VALVE THROUGH PROPER SELECTION AND OPERATION Control valve usually known as the final control element is integral equipment in the oil and gas and process industries because they are used to control the flow of fluids.

IMPROVING COOLING TOWER OPERATION AND MAINTENANCE One of most conspicuous process equipment is the cooling tower. The cooling tower is used to cool hot process cooling water streams, which is widely in use in all process plants, so as to recycle it back for use in various temperate units and especially for steam regeneration. QUESTION AND INTERVIEW ON PLATE HEAT EXCHANGER Plate heat exchanger (PHE) is an important equipment commonly used in refineries and plants. It was invented by Dr Richard Seligman in 1923 and soon revolutionized methods of indirect heating and cooling of fluids without the usage of electricity.

Issue 30 PECM

Industry News DOES THE USE OF GENERAL SEARCH ENGINES IN THE RESEARCH PROCESS POSE SERIOUS RISK TO ACCURATE ACADEMIC AND SCIENTIFIC WORK?

UK SPACE AGENCY REBUTS ‘WHITE ELEPHANT’ SPACEPORT FEARS

Leading engineering institution publishes whitepaper which examines the growing trend of using general search engines to locate scientific information.

“Increasingly desirable” orbit access and new rocket regulations will enable the UK’s first commercial space flight services “over the next few years,” a space agency director has said.

Students and early career researchers are becoming too reliant on search tools designed for general and consumer use and are not proficient at using the more complex, high quality scientific search tools and databases that are available to them, a white paper from the Institution of Engineering and Technology (IET) has found.

A new £50m spaceport launch fund could turn “opportunity into a reality”, said Ross James, director of commercial space at the UK Space Agency (UKSA), after a satellite engineer told Professional Engineering the UK could be left with a “white elephant” spaceport.

Research amongst engineering professors, researchers and librarians shows concern that students and researchers may be risking the validity, relevance and complexity of their research in favour of a ‘simplistic attitude to search’. ‘Cookies, fake news and single search boxes: the role of A&I services in a changing research landscape’ examines this growing trend and highlights the continued importance of Abstracting & Indexing (A&I) databases in an open web landscape. The paper also discusses how these groups are helping to equip their students and peers with the knowledge they need to make informed choices about the sources they are citing, and demonstrate that specialist search databases are a faster way to find trusted, subject-specific information.

Speaking to PE yesterday, the founder of satellite company ThumbSat claimed it was not clear the money would be accurately targeted. Other issues could limit the UK’s suitability for major launches, added Shaun Whitehead. “The geographical and legal environment is not ideal in the UK for large scale flights,” he said. “There is a high risk that legal and safety issues, and a lack of tourist market, could leave us with a white elephant spaceport.” However, James told PE that the UKSA’s ambition is for “home-grown launch markets” to help businesses access a market worth £10bn over the next 10 years. “The UK has the right geography to access increasingly desirable orbits, a thriving space industry ready to support and exploit new opportunities and world-class facilities to test,

THE PEOPLE OF BLOODHOUND On a mild October afternoon, crowds massed at a Cornish airfield to watch the Bloodhound SSC’s first major public step towards the land speed record. After a decade of intensive planning, the car leapt to 210mph (338km/h) in less than eight seconds. The team hope it will eventually hit 1,000mph (1,609km/h) in the South African desert,

PECM Issue 30

develop and deliver new satellite technology and services,” he said. Although the UK is far from desirable orbits at the equator, the space agency said it is well placed to access valuable polar and sub-synchronous – gradually drifting east or west – orbits. These are popular for many new small satellite constellations planned for the next 10 years, the agency said. Subject to an approved business case, the agency said its £50m programme will provide grant funding to build the capabilities needed for the first commercial space missions from new UK spaceports. Focusing on small satellite launch and sub-orbital flights, the money will also fund a market strategy to develop a “globally competitive spaceflight sector”. New government regulations will also help enable a “range” of launch technologies, said James. “From vertically-launched rockets to airlaunched spaceplanes and rockets, UK industry has the skills and expertise to participate in all these activities, and over the next few years we expect to see the first of these commercial launch services established in the UK.” The most common types of flights and launches will depend on what companies use UK spaceports, the agency added. Options could also include sub-orbital spaceplanes and very high-altitude balloons.

showcasing the best of British engineering, securing a place in the history books and inspiring a new generation of engineers. But who are the people of Bloodhound, how did they engineer this ambitious project and what does it mean to them? Joseph Flaig finds out… As the fastest man on Earth, Andy Green has to be as much an engineer as a driver. Ask the current land speed record holder how it feels to drive Bloodhound, and after a quick “great” he will tell you about the car’s unique blend of aerospace and automotive engineering.

Industry News MANUFACTURERS END YEAR WITH PLENTY OF FESTIVE CHEER – EEF/BDO SURVEY Britain’s manufacturers are ending the year with a bang on the back of the continued improvement in global demand and increased export performance, according to a major survey published today by EEF, the manufacturers’ organisation and accountancy and business advisory firm BDO LLP. According to the EEF/BDO Manufacturing Outlook Q4 survey, manufacturers are continuing to ignore the ongoing political uncertainty at home as improved global demand, from European markets in particular, and the increase in commodity

prices is feeding growth across the manufacturing supply chain. This is compensating for weaker UK demand as the squeeze on living standards and Brexit uncertainty continues to take its toll domestically. This strong performance, across all sectors and regions, has led EEF to upgrade growth forecasts for manufacturing for this year and next, meaning the sector will outperform the economy overall. Furthermore, the positive conditions in the fourth quarter mean that 2017 will

NEW MANUFACTURING ORGANISATION CEO COMMENTS ON PHASE 2 OF EU NEGOTIATIONS Commenting on the statement by Donald Tusk and progress to phase two of negotiations with the EU, Stephen Phipson, Chief Executive of EEF, the manufacturers’ organisation, said: “Companies are relieved there is progress in the negotiations. But this is one step forward in a complex and long process. So we need to pin down the transition arrangements, which will be in place after March 2019, to ensure it’s business as usual for companies for as long as it takes until a final deal is reached. Until we get to that point, many businesses will need to prepare for any and every eventuality. “Many employers will be relieved that their EU employees have more certainty going forward, and Government must now clarify the rights of EU citizens by Christmas so that they are not concerned about their future.”

BUSINESS GROUPS WELCOME BREXIT PROGRESS UK business groups have today jointly welcomed progress made in Brexit talks but also called for an agreement on a transition deal as soon as possible. The statement says: “We welcome the fact that the European Council has approved the progression of talks to the discussion of a transition period, and a future trade relationship. “It is our collective view that the transition period must now be agreed as soon as possible, to give businesses in every region and nation of the UK time to prepare for the future relationship. Further delays to discussions on an EU-UK trade deal could have damaging consequences for business investment and trade, as firms in 2018 review their investment plans and strategies. “While our members will be particularly pleased that EU citizens currently living and working in the UK now have more clarity, it’s still essential that an unequivocal commitment on their future rights is made whatever the outcome of negotiations.

be the first since the financial crisis when both output and order balances have been positive in every quarter throughout the year. The bounce in business conditions seen over the course of this year is driving the need for investment in more capacity to fulfil increasing customer demands. As such we’ve seen the second successive improvement in investment intentions, with the balance of companies planning more capital expenditure hitting a three and a half year high.

MANUFACTURERS CALL FOR BUSINESS INVOLVEMENT IN TRADE NEGOTIATIONS Britain’s manufacturers are calling for business to be fully involved in negotiations on a future transition deal with the European Union as progress on talks moves into a second stage. The call, made by EEF, the manufacturers’ organisation, comes on the back of Friday’s agreement with the EU and ahead of the European Council meeting later this week. According to EEF, such practice has been the case in Canada and Australia, where business has been fully consulted in the negotiation of free trade deals to ensure that trade negotiators understand the implications of their proposals. According to EEF, it is essential that business is provided with clarity on a transition deal as a matter of urgency if companies are not to trigger contingency plans early in 2018. Despite the successful move to a second phase of talks, there remain considerable hurdles to surmount to provide business in the UK, and across Europe, with the necessary reassurance. Commenting, EEF Chief Executive, Stephen Phipson, said: “Now that the dust has settled it’s time for the Government to bring UK industry into the heart of the negotiations on a future transition or implementation deal, as well as the longterm future trade or partnership arrangements. “This is standard practice in countries experienced in negotiating free trade deals and it is critical that businesses have confidence the UK’s negotiators fully understand the implications of their actions. Issue 30 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 30 PECM

Q&A INTERVIEW ON PLATE HEAT EXCHANGER late heat exchanger (PHE) is an important equipment commonly used in refineries and plants. It was invented by Dr Richard Seligman in 1923 and soon revolutionized methods of indirect heating and cooling of fluids without the usage of electricity. Also called plate and frame heat exchanger, it functions by simply transferring heat from one fluid to another through the use of metal plates. Comparing it with other conventional heat exchangers such as shell and tube heat exchanger or spiral heat exchanger, PHE is favored mainly because the fluids work on larger surface areas and are capable of dispersing on the metal plates, thus greatly increases the speed of the temperature change. It has compact size and could easily fit in narrow spaces in a plant.

In a PHE, the fluid flows through series of walls of alternating chambers usually made of stainless steel having high thermal conductivity to facilitate the interchange. Stainless steel plates are preferred because it has the ability to withstand corrosion, high temperature and noted for its durability and strength. The plates are usually thin in depth,

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separated at their largest surface by a corrugated metal plate. Making each chamber thin ensures that the majority of the volume of the liquid contacts the plate, hence aiding the heat exchange. The plate design ensures that turbulent flow is maintained within the PHE. The plates are arranged with precision together and between them sealing gaskets are placed to contain the fluid within the system. All plate heat exchangers look similar on the outside. The difference lies on the inside, in the details of the plate design, plate arrangements, the number of path and the sealing technologies used. Some PHE are covered with insulation to prevent heat and energy escape. PHE has numerous advantages compared to other heat exchangers. It is always preferred due to its compactness, flexibility and ease of cleaning. Its compactness can be attributed to the fact that this unit operation does not require a large floor space. Its flexibility is seen with its ability to cope with requirements of different types of fluids. The plates are removable thus making it easy to clean. If replacement is needed, the plates may be removed conveniently as well. The

PHE can also be sized up or down. It is just a matter of adding or reducing the corrugated metal plates. Normally, there will be a container underneath the PHE to contain fluid in case of leaking. Leaking may occur due to several reasons but is always possible to avoid if necessary preventive steps are taken. The container will prevent fluid from spreading in the plant floor and provide some time before operators can rectify the PHE problem.

Q1: How has plate heat exchanger technology evolved over the past decade? How is the plate heat exchanger technology of today more effective/efficient than the technology of previous generations? A: Iâ&#x20AC;&#x2122;m not really sure on the evolvement of plate heat exchanger (PHE) although I have used and taken care of it all the time when I was working as a process engineer. I know just a little bit though. PHE has been around since 1923 after Dr. Richard Seligman who was the founder

of Aluminum Plant and Vessel Company Ltd. (famously known as APV) designed it. The earliest PHE was constructed from cast gunmetal plates and enclosed within a frame. It has then become the standard for todayâ&#x20AC;&#x2122;s more advance PHE fabricated by various companies worldwide. Todayâ&#x20AC;&#x2122;s PHE is definitely more effective and efficient after several years of improvements. There have been more in depth studies and improvements on the plate corrugation patterns, plate arrangements, sealing technology and others. Companies like APV, SchmidtBretten, Graham and Alfa Laval have set such high standards. I believe there are more reputable companies manufacturing great PHE outside there.

Q2: When selecting plate heat exchanger, what are some key considerations an end-user should make to ensure success? A: First of all we need to know what we want in our process. We surely need to know the fluid flow, temperature, pressure of both cool and hot fluid passing through the PHE. The important data we can obtain here is the temperature change in the PHE. A process engineer should also identify the cost of the PHE as well as the cost of equipments (pressure gauges, valves, RTD etc), parts for PHE installation.

For a new engineer, thereâ&#x20AC;&#x2122;s nothing to be worried about. If you are not sure what kind of data to provide on the initial planning, just contact the PHE manufacturer and they will normally have a design questionnaire for you to fill up based on your process and application or simply ask you a series of questions. Just answer the questionnaire or questions and the PHE manufacturer will soon provide you with the most appropriate PHE design for your process. Part of the information that needs to be answered will be the details of fluids in your process which are crucially imperative and affect the PHE design. Hence, you need to know the type/name of fluid, specific gravity, specific heat, thermal conductivity and viscosity. Based on my experience, the PHE manufacturers normally have the physical data of fluids their clients run in the plant. Besides that, for an existing plant, a suitable space/area should be carefully selected. A process engineer needs to consider the piping connections for the newly installed PHE in an existing plant. For a new plant, normally, a dedicated location has been allocated for the PHE. Bear in mind to ask the manufacturer to design the PHE based on your requirement but has room for sizing expansion.

Q3: How does plate heat exchanger differ from other types of exchangers? A: A PHE is a very compact equipment that can provide efficient heat exchange compared to other heat exchangers such as shell and tube or spiral heat exchanger. For similar amount of heat exchanged, the size of PHE is smaller due to the large heat transfer area provided by the plates. A significant plus point for a PHE is the fact that the heat transfer area can be scaled up and down easily via controlling the amount of plates. However, a PHE using gasket has limited operating temperature. It can only go up to the maximum temperature the gasket can withstand. Beyond that, the gasket may not be capable of tolerating the high fluid temperature. The shell and tube on the other hand can go to higher temperatures compared to PHE mainly because of its gasket capability and all tubes inside it are welded. The gaskets for shell and tube which uses spiral wound gasket made of stainless steel can hold higher temperatures and pressures. A PHE can easily be dismantled for cleaning, maintenance and replacement of the plates. A shell and tube heat exchanger cleaning normally needs cleaning-in-place (CIP) before being Issue 30 PECM

applied with high pressure jet water pump. Occasionally, the corner point of the shell and tube heat exchanger is the toughest one to be cleaned and cleared. A spiral heat exchanger on the other hand can only be cleaned via CIP only. Thereâ&#x20AC;&#x2122;s no way of it to be dismantled as it is constructed in such a way like a spiral. Each layer of stainless steels is welded and thus if there is a tiny leak, the spiral heat exchanger could not be used anymore.

Q4: What are some best practices you can offer end-users in the areas of

specification, installation and maintenance of plate heat exchanger technology to ensure long-term performance? A: There are a few best practices that have been applied. Among them is to make a preventive maintenance schedule. By doing this we can stop the PHE at certain time and let the process runs on a standby PHE. CIP can be conducted if the scale or fouling is not too bad. A

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CIP need to be carried out in a proper way and the engineer in charge should design a suitable standard operating procedure (SOP) especially for the PHE CIP. Otherwise, a major maintenance service must be carried out which is to dismantle the plates and clean them and then install back the clean plates into the PHE. Another point is to take the inlet and outlet temperature and pressure as well as the flow rate reading of the PHE. This needs to be done consistently on a daily basis. From this exercise, an engineer or supervisor can monitor the trending of temperature drop and detect whenever the PHE performance is deteriorating. For a relatively advanced monitoring, a process engineer can calculate the U-value (overall heat transfer coefficient) of the PHE and assess the performance of the PHE based on it. To make it more interesting, this data can be captured from the PLC/SCADA, program and formulate it and make the U-value appear in the SCADA. Supervisors and plant operators can easily detect the lack of performance when they notice the U-value of any operating PHE is not up

to certain value. An alarm or indicator can also be installed to make notification automatic, instant and efficient. As soon as the engineer and his team identified an underperforming PHE, he or she can assess and instruct the PHE to undergo CIP or plate replacement. If there is other maintenance work to be carried out, it also can be done at that time.

Q5: What are some pitfalls you see end-users commonly encounter in plate heat exchanger applications? How

can end-users best avoid and/ or respond to such application pitfalls? A: There are situations where the hot fluid and cold fluid flow rates are not balanced. This situation normally occurs during plant start up, plant shutting down or plant failure etc. When this occurs, the plateâ&#x20AC;&#x2122;s pressure will not be balanced and leaking can likely occur. The best way to overcome this is to have better control of both fluidsâ&#x20AC;&#x2122; flow rate. The flow rate need

to be gradually slowed down together to avoid imbalance pressure within the plates. Sometimes, there are cases where pressure builds up in one side of the flow. This might due to many reasons. One of the reasons is due to unexpected dirt or particles penetrating into the system and choke the PHE. To avoid this, install a filter/strainer before the PHE. This will help to block unexpected objects from entering the PHE and blocking the flow. Then, periodically check and clean the filters/strainer. Once in a while, leaking occurs due to the tie-bars not tighten properly. The tie-bars are the thick metal rod that holds the plates between the PHE frames. Since the plates are connected by gaskets, the gasket physical property may change after the PHE is in operation for some time. This happens because the gaskets are continuously exposed to hot temperature of the fluid. Therefore, to avoid this, check plate tightening dimensions and the integrity of the frame, tie-bars, etc periodically.

Erosion of plates is another point of concern. Though plates are normally made of stainless steel, there are situations where certain area around the plate becomes thinner and thinner. As a consequence that particular area experiences pitting and resulted to leakages. This happens because some of the plates arranged in the PHE experience more pressure than the others due to its position. These plates become more fragile because of the flow momentum hitting on it continuously. Therefore, PHE operators/engineers need to identify this plate and replace it when it becomes thinner. Another way to prevent this is to avoid flow rate beyond the recommended limit. Consult the PHE design specification for this data.

Q6: What are the plans for the future, from the industry stand point? A: This question is almost similar to the previous one. Anyway, plans for the future include making the PHE capable of tolerating high temperature. This can be done by developing a more strong and durable gasket. This is the challenge for materials and polymer engineers. PHE is already a brilliant piece of heat exchange device and because it depends very much on gaskets, it is the gaskets that need to be further improved. There are also issues of the safety and health of the gasket material. This is a concern especially in food industry. Gasket made of asbestos can be dangerous for health. Therefore, designing and creating a safer and healthier gasket is imperative.

Interviewee Biography Ir. Dr. Zaki Yamani Zakaria has been with the Faculty of Chemical & Energy Engineering, Universiti Teknologi Malaysia since 2008. His main research interests are in catalytic reaction engineering, green related technology and occupational safety. Prior to that, he was a Process Engineer in an edible oil refinery from 2005 to 2008. From 2003 to 2005, he works as a Project / Chemical Engineer with a local oil and gas servicing company. In the faculty, he presently is the Facility Manager since August 2016. He share his working experiences in his website http://fcee.utm.my/zakiyamani and http://chem-eng.blogspot.com. He is also the administrator of Chemical Engineering World, a Facebook Page related to Chemical Engineering with followers closed to 27,000 people.

CMY

PECM Issue 30

New features for pressure sensor The popular PN pressure sensor now features larger display in 2 colours for enhanced visibility of operating condition and output status. Setting is now easier and the unit can be rotated after fitting.

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

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 agri-food. 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 30

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

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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.

PECM Issue 30

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

Colpa Precision Engineering Ltd.

Precision Machined Components About us •

•

Established in 1946 Colpa Precision Engineering has been supplying quality manufacturing solutions for over 70 years.

•

All Materials – Plastics, Stainless Steel, Brass, Aluminum, Titanium

•

We have an array of Turn/Mill machines from Fixed head twin spindle machines to sliding heads.

ISO 9001 Approved. •

Industrial Air Conditioning

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

Prototype components

Electronics

•

Large and small batches

•

Kanban & Faxban

•

Mill/Turn Bar Capacity 3mm to 65mm

•

Chucking Capacity up to 250mm

Telecommunications Industry

www.colpa.co.uk

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

Editors Choice BREAKTHROUGH IN FLUID FLOW MEASUREMENT FROM SENTRONICS

Sentronics Limited’s FlowSonic LF ultrasonic sensor represents a breakthrough in the measurement of lowrate fluid flows (0-4 ltr/ min) especially suited to challenging environments. Using proprietary technology proven in Formula 1 and Le Mans competition, the FlowSonic features solid-state design in a super-compact and lightweight package, easy portability between test bench and field operations, laboratory-quality flow data with industry-leading accuracy (+/-0.5%) and repeatability (+/-0.15%),

a 2.2 kHz measurement rate with 500:1 turndown ratio, race-proven reliability and durability, extreme robustness and vibration tolerance, -20°C to +120°C temperature range, compatibility with a wide range of fluid types, internal processing and diagnostics, multiple output formats, and minimal running and maintenance cost. A highflow (0-500 ltr/min) version will be available later in 2018. +44 (0)1725 513703 sales@sentronics.com www.sentronics.com

HAWORTH CASTINGS: A POSITIVE STEP FOR THE FUTURE Haworth Castings is a non-ferrous foundry and machining facility located in Romsey and Basingstoke, Hampshire. Specialising in high integrity cast and machined components for the defence, aviation, marine, medical, automotive, energy and safety critical industries, Haworth Castings provide a fully managed service from initial design to final production. On 31 October 2017 Haworth Castings was acquired by Expromet Technologies Group Ltd. Expromet is a privatelyowned foundry group that also owns Investacast, a leading investment casting business based in Ilfracombe, Devon.

The Con

After 50 years of family ownership, the acquisition is a positive step for the future of Haworth Castings. Joining a focused foundry group such as Expromet, will enable the company to benefit from the resources, investment and management experience of a larger business. It will also be beneficial to Haworth Casting’s customers, who will be able to access a wider range of engineering solutions through Investacast’s UK manufacturing site and its supply chain partners in Asia. For more information: www.haworthcastings.co.uk +44 (0)1794 512685

Leaders in bespoke calibration & test systems

The LOB fixed sid tightene handrail

The LOB into any It can be

With over 40 years experience designing and building high integrity test and calibration systems, Chell’s engineers are ready to design complete solutions for your production calibration needs.

Pressure, Vacuum & Gas Flow Automated Product Calibration All Cal. Standards to ISO17025 All Design & Build to ISO9001 Ask your engineers to call our engineers, they almost certainly speak the same language.

Chell Instruments Ltd www.chell.co.uk . info@chell.co.uk +44 (0) 1692 500555

PECM Issue 30

36 Channel Smart Gas Meter Calibration System

Handrail LOBO Sy

Conformiti

EU: BS EN10

nclusion

APPLICATION â&#x20AC;&#x201C; TIERED SEATING

BO System comprises of trestle legs that vary in size, and adjustable extensions with The system is made from modular steel he Problem Product Benefits de clamps. TSteel tubes can then be passedcomponents, throughwhich the clamps, are easy andwhich quick to are hand assemble It flatbraces, packs for transport and theatres, The LOBO System is scalable, adaptable ed to formPlayhouse a structure tograndstand suit theseating, application. Sway toe boards, wheels, yet is incredibly strong. auditoriums and lecture theatres require and adjustable to meet your on-going ls, out riggers and ateams lifting beam maintenance to safely workcan at be added to enhance the construction. and changing requirements. Simply add Therefore, out sourced scaffolding costs can be substantially reduced, as your own and assembled with ease from maintenance and production teams can assemble the system anywhere required. maintenance staff.

height and reduce scaffold costs in all maintenance and support. System areas canofbe transported from site

BO required Theatre configuration, your for own maintenance by is essential and healthy working e stored inproviding a LOBOa safe Towerstore unit when not in use. environment for staff, students and The Conclusion patrons, from a variety of departments Product Benefits

more components or alter your existing

aconfiguration flat pack,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 who are involved in the inspection, repair The LOBO System comprises of trestle point in the erection process. and scheduled maintenance of all the legs that vary in size, and adjustable The LOBO System is scalable, adaptable and theatre and auditorium facilities. extensions with fixed side clamps. Steel adjustable tobemeet on-going andSystems provides fully certified LOBO tubes can then passedyour through the training for safe assembly, inspection Effective safety management begins with changing clamps, which are hand tightened to form requirements. Simply add more and use. an organisation ensuring that employees a structure to suit the application. have fit for purpose, work at height safetycomponents or alter your existing equipment to use, on which they have For more information and to arrange a Sway braces, toe to boards, wheels, configuration satisfy the demands of the been trained to assemble, inspect and product demonstation please contact us handrails, out riggers and a lifting use correctly. by either email: sales@lobosystems.com next task. beam can be added to enhance the Telephone: +44 (0) 1332 365666 construction.

The Solution

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.

Protect your initial investment with a product www.lobosystems.com The LOBO System can be transported that will all your safely! from site meet and assembled withaccess ease fromneeds a flat pack, into any required configuration, by your own maintenance staff.

LOBO is a rigid and stable product, which meets orstored exceeds current safety It can be in a LOBO Towerstore unit regulations. when not in use. ls can be fitted in seconds, at any point in the erection process. The unique and patented hand adjustable ystems provides fully certified training for safe assembly, inspection and use. clamp, when combined with the tube,

ies

allows the technician or engineer to create a work platform, of any shape or size, without the need for any tools.

004:2004 BS 1139 parts 3 & 4,

www.lobosystems.com

Issue 30 PECM

Editors Choice

Solutions for the Processing Industry

RMIG is one of the world’s most renowned manufacturers of perforated metal. Drawing on decades of skill and experience, RMIG has cultivated a reputation for expert development, rapid supply and unmatched customer service. RMIG has a long history behind it, having first been set up by a young German man named Richard Müller. By 1901, the toolmaker set up his own business, specialising in tool production and materials production, eventually introducing metal perforation in 1906. Today, RMIG stands as the world’s largest perforation company with significant

PECM Issue 30

experience in the chemical, pharmaceutical, paper and offshore industries to name a few. The company offers a wide selection of perforation ranging from small, high precision perforation in thin materials to large holes in thick sheets. RMIG has an extensive choice of different perforation patterns and different metal materials, whether it be carbon steel, stainless steel, titanium or aluminium. Contact RMIG on the number below or go to the company website for more information on products, solutions and services. T: 01925 839 610 www.rmig.com

Newland Magnetics Europe SAS located in France are part of Ningbo Newland Magnet Industry Co. Ltd a Chinese manufacturere of NdFeB magntes and magnetic assemblies with ISO9001:2015 and IATF16949:2016 accreditation. Newland Magnetics Europe was formed to provide technical/design and sales support for our European customers also logistic solutions including consignment or stock holding within our European warehouse. Using simulation software our engineers assist with design/ prototyping of your magnetic assemblies ensuring they meet required specifications and performance. With extensive market/application knowledge within Automotive, Medical, Electronics, Aerospace and Green Energy sectors. Products include electric and hybrid motors, sensors, liner motors and magnetic couplings. www.newlandmagnetics.eu Call us: +33 (6) 21 96 41 12 Email: info@newlandmagnetics.eu

ARE YOU COOL ABOUT YOUR ENCLOSURE CLIMATE CONTROL PERFORMANCE Users of Rittal enclosure cooling technology are being offered free on-site inspection surveys to ensure that their production and process critical equipment is being adequately protected. he offer is available for a limited period and extends to any business with Rittal climate control installations, ranging from top therm, roof mounted fans, to Blue e or Blue e+ cooling units, all of which manage the temperature inside their enclosures. The user does not have to have previously registered with Rittal for their cooling units to qualify.

Excessive temperature or overheating in an electrical

enclosure means that enclosure cooling is very important for a number of reasons:

•

Unplanned interruptions to production due to tripping or failing control components are costly

•

Excessive temperature affects the correct operation and service life of electrical equipment

•

High temperatures that lead to tripping or failing control components are avoidable

80 per cent of control component failures may be addressed with a suitable cooling solution

Marketing Director Simon Kelemen says, “The costs of downtime, loss of production and system shut-down due to equipment running over temperature can easily exceed £10,000 per hour. I don’t know any businesses that would be happy to right that off, particularly as it’s entirely avoidable.”

Hygienic Design Extra cleanliness guaranteed

ENCLOSURES ENCLOSURES

POWER POWER DISTRIBUTION DISTRIBUTION

CLIMATE CLIMATE CONTROL CONTROL

Inspection by Rittal experts For businesses with Rittal enclosure cooling equipment installed the process will involve an engineer conducting the review which will provide: •

Confirmation as to the condition of the devices

•

An assessment of their cleanliness, function and serviceability

•

An asset list documenting status of each enclosure

•

A quotation (if required) based on the most appropriate solution for moving forward

•

On-going service suggestions and offers, tailored to the site itself

To book a survey, users can contact the Rittal team via information@rittal.co.uk or call 01709 704105 to book their survey. Further information on climate control solutions at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

NEW: Hygienic Design

air/water heat exchanger

The Rittal hygiene standards for maximum productivity Significant Significant savings savings on on detergents detergents and and disinfectants disinfectants More More productivity, productivity, thanks thanks to to reduced reduced cleaning cleaning times times Comprehensive Comprehensive system system solution, solution, comprised comprised of of an an enclosure enclosure plus plus climate climate control, control, up up to to aa protection protection category category of of IP IP 54 54 and and IP IP 69K 69K Greater Greater reliability, reliability, thanks thanks to to DGUV DGUV testing testing

IT IT INFRASTRUCTURE INFRASTRUCTURE

SOFTWARE SOFTWARE & & SERVICES SERVICES

www.rittal.co.uk

COMPLETE CONTROL OF PHOSPHATING PROCESSES FOR SUPERIOR CORROSION PREVENTION ith an estimated worldwide turnover of more than 500 million US dollars, phosphating is the most important metal pretreatment process. The phosphating process produces a hard, electrically nonconducting surface coating that adheres tightly to the underlying metal. This layer protects the metal from corrosion and improves the adhesion of paints and organic finishes to be subsequently applied.

The basic phosphating process consists of the etching reaction and the formation of the surface coating. After the thorough degreasing and rinsing of the metal workpieces, the phosphoric acid removes interfering surface-bound metal oxides and increases the surface roughness. Subsequently the alkali phosphates react with the previously generated metal ions at the surface of the workpiece forming a layer of insoluble tertiary metal phosphates. With a coating thickness smaller than 1 µm, iron phosphate coatings provide a basic corrosion protection and are intended for interior use under controlled environments. In contrast, the addition of metal cations such as Zn2+, Mn2+, and Ca2+ to the phosphating bath results in the formation of very resistant zinc phosphates with a coating thickness between 7 and 15 µm. Due to a modified crystal structure these

PECM Issue 30

layers are perfectly suited for outdoor use under hostile environments. Both iron and zinc phosphating occur by the same mechanism. However, the latter process is characterized by the preferential incorporation of zinc cations. The iron cations at the metal surface hardly contribute to the metal phosphate formation. A first-class corrosion protection is achieved by the supplementary addition of further cations (e.g. Ni2+) to the phosphating bath, resulting in even better surface properties. In an at-line system, the analytical unit is positioned directly at the process line, allowing for on-site determination of the parameters required. Sampling occurs manually and if necessary at various sampling points of the production line. All bath-relevant parameters of the phosphating process can be efficiently determined with Metrohm’s modular ADI 2045PL ProcessLab at-line analysis system. The analytical modules are accommodated in a single housing that is impervious to dust and splashes. The user-friendly operation software and the operating unit (TFT screen with builtin membrane keyboard and touch pad) offer straightforward and easy handling. Additionally, a barcode reader guarantees unambiguous sample identification and makes time-consuming and error-prone manual data entry obsolete.

Automation of analytical tasks by means of a sample changer allows to easily manage high sample throughputs, at the same time enhancing repeatability. The ADI 2045PL ProcessLab reliably records, controls and documents all the important process parameters. The analytical data set is stored in a database and can be processed internally or transferred to a process control system. For more information on Metrohm Process Analytics visit www.metrohm.co.uk or email us at process@metrohm.co.uk

INCREASE PROFIT WITH IN-LINE MOISTURE ANALYSIS

s moisture a parameter you measure in your process or products? Do you have a specification limit that your customer demands to be met? Maybe too much or too little moisture in your process leads to processing issues, poor product quality or lower yields. Do you struggle to keep moisture under control?

If this sounds like your process, MPA has the solutions to keep your process in control. In-line moisture measurements using MPA’s Near Infra-red (NIR) Analysers means moisture can wbe monitored directly in your process giving instantaneous results. NIR is a light based instrument that shines on or through a sample directly in the process. The light that is absorbed by the sample is detected in the analyser and moisture levels can be accurately quantified. There is no stopping the process to obtain a sample, no transport of unstable sample to a lab, and hundreds of datapoints can be obtained in the time it takes for one lab result. By measuring directly in-line, high frequency and highly reproducible data is obtained in real time. Any deviations in moisture will be seen instantly and a closed loop system means direct feedback to the process control system to keep the process in check. Not only does this narrow your process fluctuations for moisture, it also means you are in control. You can edge your process closer to your upper moisture limits being confident you won’t go out of spec. Increasing water content means you can increase yield and make more profit on your products. Improving product consistency can mean you can offer tighter specs to your customers locking out your competition

or demanding higher prices. The NIR analyser can also be used to monitor and quantify other key parameters and components within the processed material, meaning multicomponent analysis reducing bottlenecks for lab analysis.

contact such as in flowing powders, spray driers, liquid processes, in slurries, melts plus many more. Our NIR analysers can be multiplexed to offer monitoring of upto 9 process points with one analyser offering flexibility and reduced capital outlay on instruments.

Advantages of in-line process control include improved yield and profit based on:

NIR Analysers are used for monitoring many processes and operations. Examples include

•

Optimised moisture content

•

Moisture in powders during drying

•

Run production closer to specified targets

•

End points of batch reactions

•

Consistent product quality

•

End point and homogeneity of blending operations

•

Higher value products for your customers

•

Steady state parameters in continuous processes

•

Increased energy efficiency

•

Reduced rework

Viscosity, particle size, solids content, chemical components, residual solvents, plus many many more…

An example production process with an output of 30,000 tons per year at £2000/ ton and moisture closer to the upper spec limit by 0.1 % leads to a yield increase worth £60,000, giving rapid payback. With the choice of correct process interface, the analyser can analyse moisture in all matrices including Pastes, Liquids, Powders, Melts, Films and Slurries Because the technique relies on a white light source (Tungsten Halogen Lamp), the analyser can be used in non-contact applications. For example over a conveyor belt, on the output of an extrusion or product winding on a roll. With the use of various probe types, the analyser can be interfaced directly in

Our NIR analysers are ATEX ready and can communicate to your process through choice of analogue/digital outputs, modbus, profibus, or OPC. MPA also offer other means for analysis of moisture on-line with our Karl Fischer analysers, giving the capability to offer moisture measurement from ppm to % level. Metrohm Process Analytics have multiple methodology analysers using the techniques of NIR, titration, colorimetry, liquid chromatography, ion chromatography, TOC and Voltammetry. For more information on Metrohm Process Analytics visit www.metrohm.co.uk or email us at process@metrohm.co.uk Issue 30 PECM

SULZER IN GLASGOW SETS THE STANDARD IN MAINTENANCE AND REPAIRS ncreasing pressure to reduce costs and optimise performance is causing many industries to reassess the way in which they tackle maintenance issues. Sulzer's Glasgow facility has been quick to expand the capabilities and expertise of its staff to ensure additional benefits for customers and help meet these demands.

Scott Tyre took on the Glasgow service centre manager's role in early 2017, after joining Sulzer as Contracts Manager in June 2016. Scott joined from a leading gas turbine repair company, where he completed their International Graduate Rotation Programme and latterly held a position in international client management. This background provided him with an exceptional opportunity to understand the best methods for delivering upon the expectations of customers. With a background in rotating equipment, Scott soon learned about the additional challenges of the electromechanical

PECM Issue 30

sector. The sheer volume of work in the service centre at any one time means that precise organisation and clear communications are essential. Scott comments: "The Glasgow Service Centre is continuously improving to keep pace with its customers' demands and the staff pride themselves in delivering the best possible technical service. Our challenge is to provide expert engineering support along with concise customer communication and dialogue, 100% of the time." Sulzer's Glasgow Service Centre specialises in the repair of electronic drives and controls, such as variable speed drives, power supplies, automatic voltage regulators and printed circuit boards (PCB). However, one of the key customer benefits of the business is its obsolescence management services. Sulzer can provide replacement control hardware where the original manufacturer has deemed the component obsolete. This service offers considerable savings for the customer in terms of both costs and

time, when compared to the alternative of a replacement piece of equipment.

Reducing Downtime In addition to being Sulzer's drives and control repair specialists in the UK, the Glasgow Service Centre offers complete refurbishments of pumps and motors, as well as condition monitoring and preventative maintenance services. As part of the continual improvement process, the service centre has recently completed the purchase of a new PRĂ&#x153;FTECHNIK Optalign kit. This equipment allows the service of the entire customer package, including all installation and alignment services, as well as making the business more reactive, reducing customer downtime. Workshop Manager, Mark McCreadie comments: "Our mechanical engineers are fully trained in the alignment of all rotating equipment, including pumps, motors, gearboxes and pulleys. This ensures that we can get our customers back online as soon as possible."

Maintaining safety In support of customers that operate within potentially explosive atmospheres, Sulzer's Glasgow Service Centre is a BASEEFA approved repairer of explosive atmosphere equipment. This provides confidence that Sulzer engineers have the training and competency to maintain equipment to the highest standard and to the levels demanded by IEC 60079-19. Mark McCreadie explains: "It is the responsibility of the end user to ascertain that the service facility engaged to make a repair can demonstrate compliance with the codes of practice laid out by the Repair, Overhaul and Reclamation standard (IEC 60070-19) for any equipment installed in potentially explosive areas. Our service centre can provide that assurance to all customers seeking repair of Ex d, Ex e and Ex n rated equipment." Working in such a diverse range of industries, Sulzer promotes a companywide culture of safety and the Glasgow Service Centre has recently completed five years without a lost time incident (LTI). Scott Tyre concludes: "I am pleased to inherit a service centre that has such a positive record for health and safety performance. This excellent record can be directly attributed to the positive attitude of our staff and everyone in the business is encouraged to work towards continuing this legacy." Tel: +44 (0)121 766 6161 Web: www.sulzer.com Email: harpreet.suree@sulzer.com

Issue 30 PECM

Editors Choice

THERMASET LTD Thermaset Ltd is one of the UKs leading privately owned architectural approved powder coating manufacturers based in Tamworth, Staffordshire and offers a wide range of stock powders available for next day delivery. Thermaset also offer a bespoke colour matching Made to Order service with a 7-10 working day turnaround schedule. Benefitting from over 30 years in the powder coating industry, Thermaset offer expert advice to provide our customers with the best powder coating solution for their requirements. This year Thermaset have exhibited at Surface World Live and SubCon. Both of these were a huge success, gaining interest and opportunities for us.

The teams at these events were able to meet a variety of new contacts and potential clients. Due to the positive response from these exhibitions, we have already booked 2018 SubCon and Surface World Live. While showcasing at SubCon 2017 we were able to demonstrate Thermasetsâ&#x20AC;&#x2122; new fluorescent range which was released this year. This has generated a huge interest at the exhibition which has continued into the year. The new fluorescent range consists of a variety of colours including pink and green and are all available from stock. This gives customers an exciting alternative from other powder coating manufacturers. For any enquires and sales please contact Thermaset via email, phone, website or social media. T: 01827 55777 E: enquires@thermaset.co.uk W: www.thermaset.co.uk

PECM Issue 30

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.

+44 (0)1908 289 311

sales@koyo.co.uk

Where our expertise lies... + AEROSPACE & AVIATION

+ MACHINE TOOL

+ REPLACEMENT MARKET

+ AGRICULTURE

+ MARINE

+ STEEL

+ AUTOMOTIVE

+ MEDICAL & HEALTHCARE

+ TRANSMISSION & GEAR

+ CONSTRUCTION

+ MOTORCYCLE

+ WIND

+ ELECTRICAL

+ RAILWAY

INDUSTRY LEADING SPECIFICATION SPHERICAL ROLLER BEARINGS

CALL US FOR DETAILS

koyo.eu Koyo UK Ltd, Whitehall Avenue, Kingston, Milton Keynes, MK10 0AX

Issue 30 PECM

Editors Choice

Metrohm UK

RE’FLEKT

Metrohm UK & Ireland are pleased to introduce to you our brand new Metrohm Process Analytics Evaluation Station, dedicated to the process and manufacturing industries it allows easy access to demonstrations and evaluations at your site and can be set up within minutes.

RE’FLEKT launched the latest member to the leading Enterprise AR Suite: REFLEKT REMOTE for real-time expert assistance with Augmented Reality at the Augmented World Expo. REFLEKT REMOTE provides instant access to expert knowledge and connects to a cloud-based incident management system as well as to AR applications created with the REFLEKT ONE content creation platform. Using the remote video collaboration tool, employees and customers can now choose between real-time assistance or on-site guidance with AR-powered instructions in mobile apps for Android, iOS, Windows and smart glasses like the Microsoft Hololens. The fusion of remote expert assistance and highly automated experiences provides enterprises with the most comprehensive AR solution to improve maintenance, operations and training for complex machinery.

If you can do it in the lab, you can do it on-line. Our process solutions can save you money and increase throughput, as well as improving quality, consistency and safety. On board the MPA Evaluation Station we have our latest equipment allowing you to see how our on-line solutions can work for you, showing real times results! If you’d like to find out more would like a free, no obligation demo at your site please get in touch at process@metrohm.co.uk or visit www.metrohm.co.uk

www.re-flekt.com +49 (0) 172 108 06 61

MoVeoTM Repair Levels – Transparent and Predictable With the KARL STORZ MOVEOTM you have opted for a lightweight, portable videoscope for industrial remote visual inspection applications with integrated image and video capture. To maintain the full functionality of the MOVEOTM videoscope, KARL STORZ offers a manufacturer service that restores original performance parameters after each repair. At KARL STORZ, we are constantly advancing all of our products. For that reason, please understand that changes may be made to the scope of supply, design, equipment, and technology. Therefore, the information, illustrations, and descriptions contained herein cannot be made the basis for any claims whatsoever. Phone: +44 1753 503500 Fax: +44 1753 578124 E-Mail: info-uk@karlstorz.com Website: www.karlstorz.com

PECM Issue 30

ds@re-flekt.com

Advanced Valve Solutions UK Ltd Celebrates Their First Successful Training Workshop in Crewe Advanced Valves Solutions (AVS) was established in 1998 to provide solutions to the Power Generation Industry. The first workshop covered the challenges that engineers face in relation to IP and HP bypass stations. It was attended by Power Station engineers and with special guest speakers from both OEMs and end users presenting ‘true-to-life’ case studies. Dave Colston, an engineer with SSE stated: “It was a good day, with excellent subject matter and good presenters.” The next course will be on the 13th February 2018 and will concentrate on de-superheater, PRDS and attemporator issues. For more information contact Sadie Beavis, on 01270 586944 or sadie.beavis@advancedvalvesolutions.co.uk

Light Bearings for Innovation: 3D-Printed housing parts reduce the weight by 90%

OPM Group are Proud to Announce Zero Labels 2 Landfill Scheme Certification Awarded

Due to their characteristics, Franke wire race bearings are predestined for lightweight design. Reduced to the essentials, they enable completely new designs of the bearings and the use of light materials for the housing parts. On the basis of state-ofthe-art production technologies, light-weight bearings are created with substantial weight, energy and space savings with comparable stiffness and highest precision over the entire service life.

OPM Group is proud to announce that it has recently been awarded their Zero Labels 2 Landfill Certification. The certificate was issued by BPIF Labels following Prismm Environmental confirming that OPM’s waste was being treated according to the scheme compliance requirements.

Your benefit: •

low weight

•

high load capacity

•

bespoke design

OPM has worked closely with recyclingled waste management company Prismm Environmental Services. Prismm who offer a total waste management solution to businesses on a national scale commenced with an initial audit of the system, processes and waste streams. Prismm introduced various equipment to accommodate the waste being produced, as well as maximise efficiencies, the aim was to reduce the impact on the environment by utilising the latest technologies to divert waste from landfill sites. www.opmgroup.co.uk

Editors Choice

TME LAUNCH RADICAL NEW LEGIONELLA RISK MANAGEMENT PROBE KS20-S

SAVE OVER 55% ON ENERGY IN PLASTICS EXTRUSION INDUSTRY BluVac units from Speck ABC UK Ltd reduce energy consumption by controlling vacuum required by the process. The highest energy saving is reached using optimised calibration tools with minimal air leakage. 67% savings have been achieved in tests. Sensors continuously measure pressure levels in the system and water levels in the separator tanks. From this data; the Controller automatically adjusts the speed of both vacuum and water pumps.

Speck ABC UK Ltd are also the SOLE UK distributor for Speck liquid-ring vacuum, side-channel, regenerative turbine, hot oil and centrifugal pumps. For further information: Speck ABC UK Ltd, AreenA House, Moston Road, Sandbach, Cheshire, CW11 3HL 01270 753 606 admin@speck-abc.com www.speck-abc.com

UK thermometer manufacturer, TME have launched a radical NEW solution for water temperature testing: the KS20-S dual purpose surface/immersion Probe: stronger and faster than ever before. MD, Tom Sensier: “Temperature probes for combined surface and immersion measurements must balance competing requirements for strength, even surface contact and quick response. The KS20-S delivers a better result on all three fronts.” Conventional surface probes feature a thin steel or copper band at the tip. A thermocouple is welded to the back of the band to react quickly to changes in temperature. Over time, when pressed, fatigue at the weld can result in the joint fracturing. But a heavier gauge band has a longer response time – problematic for ACoP L8 timed temperature tests.

The KS20-S employs a radical design which uses heavy-gauge thermocouple wire, crossed and silicon back-filled for added durability and water resistance. “The KS20-S has a much stronger joint and faster result: in tests, the probe settled in stirred water at 50°C in under ten seconds.” TME specialises in legionella solutions:MM2008 Water Thermometer with integral timer; TC Wall Port remote testing for TMVs and tanks; MM7000 Barcode Thermometer for paperless spot checks. TME When temperature matters +44 (0)1903 700651 www.tmethermometers.com sales@tmethermometers.com

Issue 30 PECM

Editors Choice

Monitor and Control Indoor Air Quality (IAQ) with a PPMonitor

Rittal’s Solutions for Centralised or De-centralised Automation

PPM Technology Ltd is pleased to announce our latest range of IAQ monitoring instruments - the PPMonitor range. The PPMonitor has been designed to give a good visual representation of IAQ in a building. A great number of units may be networked together via the ZigBee wireless mesh system to show precise changes in concentration of selected IAQ parameters over time for an entire building.

We live in a world of rapid change, driven by the growth of ‘smart technology’. Automation components are becoming more compact, both for centralised and decentralised applications, while still delivering considerable computing power. Sensors and actuators are also getting more ‘intelligent’.

Each unit can monitor temperature and humidity as well as up to 5 different IAQ target gases including formaldehyde, carbon monoxide, carbon dioxide, nitrogen dioxide, sulphur dioxide, VOC’s, ozone, ammonia and many more. Please contact info@ppm-technology.com or visit www.ppm-technology.com for more information.

Packing components into an enclosure is a science and an art. The engineer must plan the interior configuration to reduce wasted space and optimise the size of the enclosure, yet avoid issues such as over-heating or problems of future access to any of the components. Further information at www.rittal.co.uk and www.friedhelm-loh-group.com or on twitter @rittal_ltd.

Northern Industrial Takes on Two Old Robots to Help Customers Face Adoption Challenges Blackburn-based automation spare parts and repairs company Northern Industrial has taken delivery of two used robots, previously employed on production lines in Germany, to help ensure the integrity of repair work and spare components before shipping worldwide. Northern Industrial provides reconditioned and obsolete parts and repair services to customers in 132 countries. Sourcing parts from over 1,350 manufacturers, the multiaward-winning company covers over 200,000 part numbers and holds approximately £7m in stock. www.nicontrols.com

Modernising your instrument with a front panel refresh XS Training

Swindens Patents

XS Training Limited deliver the City & Guilds 2356-99 NVQ Level 3 in Electrical Maintenance, Electrical Installation, Panel Building, Instrumentation, Public Lighting and Motor Rewind and Repair.

Swindens is a UK manufacturing company producing the unique range of double-jaw 4’’, 6’’ and 8’’ Swindens revolving head work holders.

These NVQs allow those who successfully complete the qualification the chance to get their skills officially recognised by the JIB and gain their ECS/JIB Gold Card. Candidates can successfully complete the qualification by gaining evidence of their day-to-day activities and uploading photo evidence to their e-Portfolio. The e-Portfolio is very simple to use with full training provided by experienced and qualified training instructors. Website: www.xstraining.com

Swindens come with swivel bases (optional) thus enabling rotation vertically and horizontally through 360 degrees. A range of soft jaws is also available. Swindens solves your engineering problems saving you time and money and practically eliminating back pain. Swindens are made of A2 Steel and SG iron. Our customers include Defence, Automotive, Aviation, Shipping, Oil and Gas, General engineering, Gunsmiths and Jewellery makers, and the individual in the workshop. We are proud to be ISO 9001:2015 accredited. Please see our website for problem-solving videos and testimonials. www.swindens.org

PECM Issue 30

Instrumentation equipment needs to maintain a modern look and feel, in order for manufacturers to maintain their market share in this modern fast-moving world. Does your instrument have a modern look and feel? If not, help is at hand! For companies to commit to a new instrument design or upgrade can be a costly process and a concern in uncertain financial times. Today the trends for user interfaces (UI) are heavily in favour of wide-screen displays with as high as a 90% preference towards the modern touch screen technologies used by almost everyone on mobile phone and tablet computers. So perhaps a “front panel refresh” could be all that your instrument needs to maintain a healthy level of sales? To find out more please either Call us today on +44 (0) 1933 778000 to discuss your front panel refresh or check out our website WWW.SELECTRONIC.CO.UK

Editors Choice

Casella celebrates Intrinsically Safe approval for Apex2 Following a rigorous testing process, Casella has announced Intrinsically Safe approval for its Apex2 personal sampling pump range, with class leading performance and capability. Instruments supplied for application in atmospheres where there is a risk of explosion must be designed with the appropriate safety requirement critical in achieving IS approval; protecting the equipment and ensuring it is safe to use. Achieving the IS certification for the Apex2 range ensures that monitoring and analysis of dust exposure can be carried out safely and effectively in these areas. Please contact info@ppm-technology.com or visit www.ppm-technology.com for more information.

Battery Test Chambers

FluxData, Inc

The UK is at the forefront of the development & testing of the latest battery chemistries and technologies, choosing the right test chambers is paramount. Unitemp supplies the Espec range of test chambers for battery cell evaluation and abuse testing, including NIMH, lead acid and lithium ion batteries from small battery cells & modules to large battery packs.

FluxData, Inc., is a leader in industrial inline color process control and measurement. We offer customizable imaging solutions and services for Fortune 100 customers. Our inline inspection equipment is used by some of the largest consumer electronic companies, offering minimized labor costs while maximizing yield.

All Espec Test Chambers are manufactured to UL, IEC, SAE and EUCAR 1- 6 standards, enabling risk-free testing of the safety, performance and reliability of battery cells. Built-in safety features reduce the chance of an explosion and minimise damaging effects of a spark-induced explosion.

FluxData helps guide customers from camera specification to delivery of the final system. Our multispectral and polarimetric imaging systems offer solutions for aerospace, industrial, medical, defense and scientific markets. The company is headquartered in Rochester, New York, USA.

The Espec range will take a battery through all environmental conditions likely to be encountered by the product during its lifetime.

www.fluxdata.com

Telephone: +44 (0) 1628 850611 Email: info@unitemp.co.uk

FOR HAZARDOUS CONDITIONS

FOR AGGRESSIVE CONDENSATES

BEKO drain where others canâ&#x20AC;&#x2122;t BEKO TECHNOLOGIES are the world leaders in condensate management. BEKOMAT zero loss drains are manufactured for multi-stage compressors, vacuum, hazardous areas and in stainless steel versions to meet the most exact specifications. FOR EXPLOSIVE ATMOSPHERES

Contact BEKO for all your compressed air treatment applications.

BEKO Technologies, Technologies, 22 West West Court, Court, Buntsford Buntsford Park Park Road, Road, Bromsgrove, Bromsgrove, Worcs, 01527 575778, 575778 Fax: www.beko-technologies.co.uk BEKO Worcs, B60 B60 3DX, 3DX, Tel: Tel 01527 Fax:01527 01527575779 575779email: email:info.uk@beko.de info.uk@beko.dewebsite: website: www.bekotechnologies.com

PECM Issue 30

Editors Choice

WORLD’S 1ST LASER TACHOMETER CONNECTED TO YOUR ANDROID DEVICES VIA USB CABLE Compact Instruments have been designing, manufacturing and selling high quality speed measuring instruments since 1976, mainly from its site at Bolton in Lancashire. We have a dedicated team of professionals, and a strong development programme, led by Dr Zhong Wang. We sell to every corner of the globe. Today we are happy to announce our new sensor, which can measure speed, when connected to your Android device. Your device will need USBon-the-GO support The instrument does not have batteries as your device provides the power source. You can store thousands of pieces of data, as your device has the storage capabilities. You can then download back to your office or send by email/text worldwide. The sensor is small, and will fit easily in your pocket We can customise the programming to suit your individual needs. Speeds from 3rpm-100,000rpm Questions/enquiries? Then please don’t hesitate to contact us direct, either by phone/email

Our New MINIVLS 313 optical sensor

The new tachometer is our model

MINIVLS313

Simply connect the sensor to your phone, via the supplied connectors, and begin to take your measurements without delay. All readings are kept in the phone’s memory, for transfer later to another device or simply send via your phone to any pc in the world !!! Your smart phone will need USB-on-the-GO support We can customise the programming to suit your individual needs [a charge will apply] Speeds can be programmed from1rpm – 100,000 rpm !!!! Want to know more? Then simply connect via the link below or

Download and Install the FREE Android APP from Google Play Place your orders now for 2018 http://compactinstruments.co.uk/product/minivls-313usb-tacho-laser-sensor/?preview_id=11065

Compact Instruments Ltd www.compactinstruments.co.uk Phone: +44 (0)1204 532544

Fax: +44 (0)1204 522285

Address: 61-65 Lever Street, Bolton, Lancashire, BL3 2AB, United Kingdom Issue 30 PECM

FARNBOROUGH | Hants | GU14 6XL 6th – 8th February 2018 9.30am – 4.30pm (3.30pm close Thurs)

The UK’s must-attend event for every industrial engineering and manufacturing professional Meet over 800 national and international suppliers under one roof in the brand new Farnborough venue next February at Southern Manufacturing & Electronics (inc AutoAero) 2018.

2018 celebrates the event’s 20th Anniversary with a move to the brand new FARNBOROUGH venue

FREE SEMINARS FREE PARKING

See live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labeling & marking, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment. Free industry seminar programme online @ www.industrysouth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Tuesday 6th February. Pre-register online now for your free entry badge and show preview at www.industrysouth.co.uk

SOUTHERN MANUFACTURING & ELECTRONICS is an ETES event organised by European Trade & Exhibition Services Ltd Tel 01784 880890 email philv@etes.co.uk

Southern Manufacturing & Electronics 2018 outhern Manufacturing & Electronics returns to Farnborough from February 6th to 8th 2018 for its 20th anniversary event, and the first to be held in the brand-new £35m Farnborough International Exhibition and Conference Centre development - the UK’s newest exhibition venue and the biggest built in the UK for 20 years.

Southern Manufacturing is considered by many to be the UK’s premier industrial engineering show; it is certainly the largest annual gathering of engineering firms in the UK, with around 800 companies expected to participate in 2018. The show covers an extremely wide range of products and services from both the electronics and manufacturing production sectors.

Covering both electronics and mechanical engineering, Southern Manufacturing & Electronics is a superlative marketplace for components and sub-assemblies of all descriptions. Nearly half the visitors to the show in 2016 came in search of components, and the diversity of suppliers present means that multiple sourcing issues can be addressed in a single visit. Many of Southern’s familiar faces return for 2018, including igus UK, Heidenhain, Renishaw and many others. Key products on the HepcoMotion stand this year include GFX Hepco Guidance for the Beckhoff XTS (eXtended Transport System). This solution utilises Hepco’s PRT2 and 1-Trak guidance systems to work with Beckhoff’s XTS circuit linear system

to meet the needs of higher duty XTS applications where motion profiles and long-term durability requirements are particularly demanding. Other highlights include the popular SBD Sealed Belt Drive and the HDS2 heavy duty linear motion system designed load capacities up to 68,000N. Kabelshlepp Metool showcases its new Master drag chain system at Southern 2018, designed to meet the demands of Industry 4.0 applications. One of the new exhibitors for 2018 is Fuji Electric Europe GmbH, which will display high performance inverters that offer automatically controlled motor operations for a wide variety of AC drive applications including conveyor systems, pumps, fans, HVAC, lift applications.

The size of the event and its location at the centre of one of the UK’s key manufacturing regions makes it an extremely important one for numerous big-name firms from all over the UK, and, increasingly, from continental Europe and even further afield as well. This international flavour combined with the importance of the event to the myriad of smaller engineering firms across the South, delivers a unique visitor experience; this year made all the more enjoyable thanks to the new, comfortable surroundings and ultra-modern facilities to be found at Hall 1 Farnborough. Issue 30 PECM

Numerous new products will be launched at Southern 2018. CamdenBoss showcases its CFTBN range of fuse holders, which has become one of the first to meet the latest fire safety standard EN 60127-6 that came into force in October 2017. Diamond Electronics showcases a new range of keyboards and accessories designed for use in clean industrial applications including food processing, semiconductor manufacturing, laboratories, PoS systems, public area data input and clinical use medical systems. RF Solutions will be showcasing its brand new battery-less remote control systems, capable of up

PECM Issue 30

to 300 metres range with no additional power source; distances which, the firm claims, are yet to be approached by other companies using similar methods. Utilising a secure, high-speed RF protocol, the KAPBOX and KAPTRAP systems have a myriad of possible process engineering applications.

each year, with its complementary blend of technical and business topics covering a wide range of issues facing manufacturing businesses today. From understanding lithium ion batteries and Industry 4.0, to the forthcoming GDPR regulations and life after Brexit, the sessions genuinely deliver something for everyone.

The showâ&#x20AC;&#x2122;s free seminar programme is another compelling reason to attend. Running in two lecture theatres on all three days of the show, the free seminar programme at Southern Manufacturing & Electronics draws hundreds of delegates

Two of the most perennially popular speakers return for 2018. With examples from manufacturing, service and warehousing, Tim Scurlock, Director of ALC, will guide delegates through the benefits of Lean, include eliminating

waste from existing processes, together the problems and pitfalls in bringing Lean into their organisations. Ailsa Carson of Onsite Insights shares the best practice methodologies and key activities that have made some of the world’s greatest manufacturers so successful. Using real world examples, the sessions look at how top firms remain innovative and produce the best quality product in terms of design, cost, performance, quality and delivery. Dr. John Loftus of HMK Automation & Drives takes a look at the future role of Cobots, collaborative robots intended to physically interact with humans in a shared workplace. Business management and strategy also comes under the spotlight for 2018. The General Data Protection Regulations come into force on 25th May 2018 affecting all personal data, and introducing new requirements and huge fines for transgressions. Dave Smith of Corpdata shares the essential knowledge to help keep your organisation compliant and safe. All in all, the seminar programme for Southern Manufacturing & Electronics 2018 includes an impressive 34 sessions, all of which are completely free to both visitors and exhibitors. A complete listing and the all-important pre-registration form can be found at http://seminars.industrysouth.co.uk Southern Manufacturing & Electronics 2018 opens from February 6th to 8th. Admission to the show is free. More information and tickets are available from www.industrysouth. co.uk. Farnborough Exhibition and Conference Centre offers free on-site car parking and is easily reached by road, air or public transport.

RELIABLE CONNECTIVITY SOLUTIONS See us in 2018 at:

Southern Manufacturing, Stand H130 Drives & Controls, Stand 377 Or contact us today to ﬁnd your solution: Call +44 (0)23 9245 9600 or email Sales@ﬁscherconnectors.co.uk

Fischer Connectors manufactures reliable connectivity solutions for a wide variety of applications to ensure repeatable, accurate connections and data protection. Available options include:  High voltage  Mixed signal  High density  Vacuum, IP69K and IP68 sealing  360° EMC shielding  High temperature  Fibre optic  Hybrid connectors  Common data protocols supported  Custom connector and cable assembly solutions 

NEW

MiniMax USB 3.0  Dedicated USB 3.0 contact block  Up to 10Gb/s data transfer

www.ﬁscherconnectors.com

THE RELIABLE EXPERT

Issue 30 PECM

IF YOU MAKE STUFF WE’LL HELP YOU MAKE IT IF YOU HAVE A WARHOUSE WE’LL HELP YOU MANAGE IT IF YOU HOLD STOCK WE’LL HELP YOU CONTROL IT Sapmanv12 looks to put a comprehensive ERP System into the financial reach of all manufacturing businesses uying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay.

For manufactures looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software! For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be £2,450. Our licencing is £50 per month ( plus VAT) per user licence with no minimum contract obligation. Additional users can be added as required and, indeed, reduced. A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapmanv12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50 and Sage200, and we still have some clients on Sage Line 100 yet to upgrade. One of the great advantages of Sapmanv12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from

At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution. Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution. Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100. Sapman v12 is highly customisable to operate with virtually any business model. With successful installations in a huge range of industry types from manufacturers of medical products to disposable BBQs our customers rely on Sapman v12 to run their businesses. Sponsored development of specific functionality is possible where customers require some modification to allow the software to exactly map their business’s operational model.

Sage50 to Sage200. This is an additional cost saving benefit We’d be delighted to visit you to demonstrate the product, or you can arrange to visit our demonstration suite in Bristol

For more information on Sapmanv12 please visit our website at Sapmanv12.co.uk Email us on info@sapmanv12.co.uk Or please telephone us on : 0333 456 12 12

COME AND VISIT US AT SOUTHERN MANUFACTURING IN FEBRUARY ON STAND E105

Ashley Garratt Senior Consultant

SAPMAN V12 AND SAGE 50 IT111 ALL t 07415 610STARTS WITH A SALES ENQUIRY! SELL IT Quotations: Quote ( including price breaks)& Drawings & Pricing : v12 can attach drawings to the Quote SoP : The Sales Order Processing gets underway

MAKE IT Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock? If not it may generate a Purchase Order for more Stock If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works

e ashley@sapmanv12.co.uk Stock values from v12 update Sage50 wNominal www.sapmanv12.co.uk Ledger

Machine Variances & produce management reports -

Sapphire Manufacturing Systems Ltd. 10 Harts Croft Yate Bristol BS37 7XE Every stock issue is linked to an original Bristol - Loughborough - Dundee

PoP Purchase Order Raised

Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT

GRN - ensuring full Serial Number and Batch Traceability

Stock Finished item is booked into Stock

WoP The confirmed order has to be manufactured & v12 produces the works order

v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors

BOM V12 produces the BoM : tree-view with collapsible/expandable nodes

Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

SFDC Shop Floor Data Capture : using barcodes v12 manages the job though the shop floor

SEND IT

WiP With Shop Floor Data Capture SFDC v12 knows :

Stock Stock records updated, Despatch note raised; Certificates of conformity produced

What Material/Subcomponents have been used, Who has worked on the job and on what machine - Get Material, Labour &

Sales Invoice raised & Sage 50 updated for Nominal Codes, Sales Ledger & VAT

WHAT THEY SAY “We really like the Shop Floor Data Capture

“V12 offers us greater productivity, improved

“V12 was a complete transformation for our

system which enables us to see the current

communications with third parties and the

business back in 2014, with the added bespoke

status of any Works Order live and onscreen.”

interconnectivity between the various menus

service and repair package designed by the

and our Sage Accounting software makes

SMS team the customer input and traceability

operating our company infinitely easier.”

became seamless.”

Colin Mallard, Finance Director,

Mike Perkins, Managing Director, Encoders UK Ltd

Alan Saitch, Managing Director, Lada Engineering Services Ltd

Lakeland Laboratories Limited

Come and visit us at Stand: B215

Southern Manufacturing Show

uPrint SE PLUS Powered by GrabCAD PrintTM Software GrabCAD Print simplifies the traditional 3D print preparation workflow and provides intelligence around printer usage so your team can get quality prints, faster. Print directly from CAD, organize print queues, monitor material levels and work with detailed views of your model.

Models can be made within hours and then sanded, painted, tapped & drilled and even chrome plated to give you a reliable representation of the actual manufactured product. Perfect for End use parts, Rapid Proto-typing, Jigs & fixtures and Drill Guides. With it's heated chamber the SE plus is ideal for first time adoptees who want accurate fit for purpose parts.

Desktop Replicators including the MakerBot Print Software MakerBot Print is free software that optimizes and streamlines the 3D printing process for any workflow. It allows you to discover, prepare, manage, and share 3D prints Prepare: Import design files in native CAD and fine-tune their settings for optimal results when printing MakerBot is setting the standard in reliable and affordable desktop 3D printing and scanning. Engineers and Designers are using the Replicator range of 3D printers to innovate and create right in their workshops, offices and studios. The printer delivers fifth generation ease of use and connectivity offering a simple and versatile way to get from 3D model to 3D print.

Manage: Keep your projects organized by automatically arranging models across one or several build plates Monitor: Kick-off prints, control your printer, and monitor print progress remotely

For more in-depth product information, and to arrange a product demonstration, please contact Gordon Lewis at GTX Europe Ltd—Phone: 01256 814444—E-mail: gordonl@gtx.co.uk—Web Site: www.gtx.co.uk Issue 30 PECM

IMPROVING COOLING TOWER OPERATION AND MAINTENANCE ne of most conspicuous process equipment is the cooling tower. The cooling tower is used to cool hot process cooling water streams, which is widely in use in all process plants, so as to recycle it back for use in various temperate units and especially for steam regeneration. The tower is located in the utility section and is a large size humidification structure consisting of draught fans at the top and transfer pump at the bottom.

The process employed in cooling tower is known as evaporative cooling. When one cools his hot cup of tea by inter spraying it between two cups in applying the said process. Usually, water is cooled by exposing its surface to available moving air. Cooling of water on the surface of a pond and spraying of water into slow moving or forced air are other known processes. The cooling of water of varying degrees involves heat transfer process in the form of latent heat transfer as well as sensitive heat due to the differences in the

PECM Issue 30

temperature of the water and air. Cooling by air depends on the moisture content of air that is indicated by the wet bulb temperature of the air in the surrounding. The wet bulb temperature is the lowest theoretical temperature of which the water can be cooled. Theoretically, enthalpy potential difference is the driving force for the cooling tower heat transfer process. It is assumed that there is a film of air on each particle of water. And the enthalpy potential difference between the films on each particle of water and the surrounding provides the driving force for the cooling process. Cooling tower cools stream of water by controlling the humidity of the air passing through it. You will thereby experience mist or carry over of moisture around the tower. However, this should be relatively very small because the adequate engineering design will reduce the mist level substantially. In the forced draft tower the fan is mounted at the base forcing air upwards whereas in the induced draft towers the fan is at the top

polling the air below it. It has counter flow and cross flow design depending on the flow direction of water and air. The air velocity, cross sections for air passage as well as the length of the tower play important roles in tower design. Operational personnel can manipulate the fan speed as well as the water rate to achieve provisional temperature drop. The cooling tower is therefore defined as the equipment used to cool down the temperature of process cooling water so as to recycle it for reuse by controlling the air humidity surrounding it.

It has two main types; 1.

Mechanical draft towers; Forced and Induced draft towers,

Natural draft or Hyperbolic type towers; Atmospheric towers, Spray ponds etc.

It can be assembled independently from below grade where the water falls to meters, and above grade where the water is poured.

Cooling Tower Operation

Temperate process water is ready for cooling.

â&#x20AC;˘

How to commission cooling tower

The associated instrumentation is in good condition.

â&#x20AC;˘

Routine checks on cooling towers

â&#x20AC;˘

Cooling tower maintenance

To Commission Conventional Cooling Tower

Process plant operators need to ensure that. i.

The below grade basement is free or clear of foreign bodies and particles.

ii.

The below grade basement is water clean.

iii.

The draft fans motors, blades, belt are in good condition.

iv. The tower slap containers are well fastened to prevent water spill. v.

vii

viii

Commission the air fan and stabilize the speed and louver position if provided.

Line up the supply and return water lines to the process by keeping the supply crack open and the return line fully open.

Open the minimum flow line to provide a spill back to the tower basement.

Start the water supply pumps to the tower and stabilize the flow pressure by controlling the supply line valve opening to the process.

Maintain adequate water return rate by adjusting the by pass lines provided.

The feed and transfer pumps are ready in good condition.

vi. The minimum flow lines/spill back from the pump to the below grade / basement is lined up

These are few of the routine checks that operator needs to confirm before advancing the start up of towers. You will certainly find other importance activities to ascertain. When these activities are carried out you can proceed to start the tower.

The process lines are lined up by checking the isolation valves position

Power is available.

Routine Checks on Cooling Towers Routine checks associated with towers are very little. Towers do not need a lot of operational activities or depict problems. Once adequate operations are carried out as, and when due and parameters controlled operators can remain distance away from the tower without any fear. However, here are few things to do; 1.

Monitor the feed water temperature.

Monitor the outlet water temperature.

Control the transfer water flow a rate.

Control the draft fan speed and louvers position.

Check for brake away cross sectional partitions, louvers or fence and fix any loose part.

Check for leakage and arrest any.

Maintain the slap covers in good condition to minimize water loss.

Maintain the below grade water level.

10.

Control the feed water flow rate and monitor the status of the distribution nozzle.

Monitor the associated instruments performance. Issue 30 PECM

Know that air flow through a natural draft cooling tower is due largely to the difference in density between the cool inlet air and the warm exit air. The air leaving the stack is lighter than ambient air, and a draft is created by chimney effect without the need of mechanical fans. Spray ponds cool by evaporative cooling so it occupies less area compared to cooling ponds. A spray pond uses a number of nozzles that distribute water into contact with the available air in the surrounding. Sufficient distance between the spray nozzle and the basin should be provided to keep the spray nozzle and the basin should be provided to keep the spray from being carried over to the sides of the pond basin.

PECM Issue 30

Cooling Tower Maintenance Cooling tower maintenance requirement is no doubt very minimal. The following are essentially the basics to be carried out. 1. Electric Fan Motor: Where draft is provided by fan mechanism the motor bearings need to be greased regularly of prevent noise while the belts are checked for broken and loose ones. 2.

Transfer Pumps: The same maintenance requirements applicable to all pumps are applied and have been discussed earlier under pumps.

Louver Fence: Loose ends are to be replaced to contain all water and to prevent

water loss. In some designs louvers are formed with woods whereas in others of metal plates. In any case always check the interlocks bolts tightened any loose ends.

Distribution Nozzles: Nozzles could be blocked and will cause uneven water spray or distribution across the tower, which may result to tower inefficiency. Good distribution is very necessary. Blocked nozzles could result from fouling effect due to deposits of scales formed by minerals salt available in the water. Blocked nozzles should be freed.

Boilers & Maintenance

‘REAL TIME’ REMOTE MONITORING FOR THE BOILERHOUSE Benefits include: • • • • • •

Cost savings through optimal performance. Instant alerts on failures – ‘when it matters’. The ability to determine both maintenance and investment strategy. Predictive maintenance to prolong equipment life. Minimal downtime resulting in increased revenue. Calculate and improve efficiencies, reliability and

•

availability. Anticipate service requirements and reduced risk of further damage. Reduced labour costs.

For details see ‘www.jbcindserv. co.uk/halo-real-time-remotemonitoring-system’ JBC Industrial Services Ltd. Branches nationwide. T: 0113 220 3830 E: info@jbcmail.co.uk W: www.jbcindserv.co.uk

The UK’s longest-standing steam expert Trusted experts

Product innovation

We’re the trusted steam specialist for hundreds of companies across tens of industries, all of whom receive quality-engineered, high performance, reliable and energy-efficient steam and hot water solutions. Our credentials for technical excellence and engineering expertise are renowned in the industry, as is our genuine commitment customer service and satisfaction.

Manufacturing class-leading products is in our blood; we were the first steam boiler specialist to manufacture a superior, energy-saving four-pass steam boiler. And we’re the minds behind an innovative reverse osmosis unit which delivers high performance for around half the cost of alternative products on that market. www.steamboilers.co.uk

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

• • • • FD-C high turndown oven/

FD-E low cost high turndown

dryer air heating burners.

oven/dryer air heating burners.

FD-GA modulating gas + air process air heating burners.

TX Series Gas Fired Process Tank Heating Systems High efficiency (80%+) heating of all types of spray and dip process tanks Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space Accurate performance modelling using Lanemark TxCalc design software Heat Input Range: 15 kW (1½") – 1150 kW (8")

• • • •

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

• • •

Midco HMA high efficiency,

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

TX high efficiency small diameter immersion tube tank heating systems.

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

X4620 Lanemark Ad SDAW.indd 1

•

COMBUSTION ENGINEERING

Issue 30 PECM

31/08/2016 09:04

THE UK’S LONGEST-STANDING STEAM EXPERT here's only one steam boiler company that can boast over 120 years of operation, class-leading energy-saving solutions, and UK-manufactured steam boilers - CFB Boilers.

Trusted experts We're the trusted steam specialist for hundreds of companies across tens of industries, all of whom receive qualityengineered, high performance, reliable and energy-efficient steam and hot water solutions. Our credentials for technical excellence and engineering expertise are renowned in the industry, as is our genuine commitment customer service and satisfaction. Product innovation Manufacturing class-leading products is in our blood; we were the first steam boiler specialist to manufacture a superior, energy-saving four-pass steam boiler. And we're the minds behind an innovative reverse osmosis unit which delivers high performance for around half the cost of alternative products on that market. Quality manufacturing As well as manufacturing our flagship steam boiler at our purpose-built facility in Essex, we are the OEM partner for the Bosch range of horizontal boilers, and also supply a wide variety of electric and hot water boilers, ancillary equipment, reverse osmosis (RO), plant rooms and skid assemblies. An independent company, we have complete control over our product range, ensuring the highest standards of equipment manufacturing. Experienced engineers CFB Boilers is a family-owned business that’s been established more than 120 years. All of our engineers benefit from experience that’s been collated over more than a century - expertise that then becomes the advantage for our customers. Complete steam solutions CFB Boilers offers a complete range of specialist steam services, from design and installation to maintenance and repair. We pride ourselves on delivering exemplary customer service, fast quotation response, quick order turnarounds, and competitive pricing as standard.

PECM Issue 30

MANUFACTURERS & DISTRIBUTORS OF STEAM BOILERS & ANCILLARY EQUIPMENT

Complete Steam Solutions • Boiler ranges from 128 – 55,000 kg/hr • Steam, electric and hot water boilers • Ancillary equipment • Fully packaged plant rooms INDUSTRY-LEADING DESIGN, INSTALLATION, MAINTENANCE AND ENERGY SAVING SERVICES

T: 01255 224500 E: boilersales@steamboilers.co.uk www.steamboilers.co.uk

or almost 20 years KFS have been using Computational Fluid Dynamics (CFD) as part of the design process for combustion systems used primarily in rotary kiln applications. The experience gained with this difficult application combined with recent investment in new high performance hardware has allowed KFS to become a leader in combustion and flow modelling in a wide range of applications. KFS have expanded their capability and now offers CFD modelling as a consultancy service to the wider market.

KFS apply a solutions-based approach to projects, developing representative models and using our in-house expertise to identify solutions for existing problems or to optimise designs and operation. Every model developed is bespoke and created using the most appropriate technique for the application. Examples where this approach has been successfully applied by KFS include: • Boilers • Cyclones • Process Ductwork • Fired Heaters • Burners • Furnaces • Dryers • Calciners CFD Modelling previously carried out by KFS has looked at a range of issues beyond combustion including: wear analysis within systems to increase life of components, air flow analysis in process ducts and burners where poor air flow and distribution affect performance, solid distribution and particle dropout in cyclones, dryers and ducting. The mod-

PECM Issue 30

elling techniques used can be applied to similar applications and systems. KFS work with the customer to develop a full understanding of the system to be modelled. This allows us to create the most representative model to assist in problem resolution. The modelling output is then post-processed to analyse the system parameters prior to use of the model to help develop solutions. KFS will not only model your system but also put together a package of solutions developed by their experienced engineering team. This can include conceptual design through to detailed engineering, as appropriate.

The correct application of CFD modelling can take the guesswork out of process design and product development, or replace time-consuming, expensive or impractical physical modelling. It also provides a powerful tool to help overcome ongoing process problems, optimise existing operations and reduce running and maintenance costs. KFS have successfully used our solution-based CFD approach to provide technical support to a range of organisations from small independent operators to large multinationals, as well as to specialist equipment suppliers. If you would like to explore how KFS can use its powerful CFD modelling capability to help resolve design or process problems then please call our team to discuss how we can help.

KFS Ltd

Unit C Brow Business Centre Copyground Lane High Wycombe Bucks, HP12 3HE UK T: +44 1494 450539 F: +44 1494 530518 info@kilnflame.com

www.kilnflame.com

MORE FUNCTION MODULES FOR COMPACT WATER ANALYSIS SYSTEM aintaining water quality standards is an essential process, not only for water supply companies, but also for those who rely on it for their commercial process applications.

Analysing and recording various water quality parameters using the compact and modular solution from B端rkert Fluid Control Systems now has increased functionality thanks to new 'cubes' that add more test options. Since introducing the Type 8905 Online Analysis System for water treatment processes, Burkert has continued to work on new functions and testing capabilities that increase its functionality. The latest developments include new test cubes for Chlorine dioxide and iron as well as a hand-held cleaning and calibration module. Furthermore, the ability to adapt the basic principle of the analysis system into a bespoke sampling station that can accommodate any number of sample streams will be of particular interest to larger water treatment facilities.

Flexible design The original premise was to create a multi-channel, multi-function unit that could communicate using the majority of existing protocols and provide a precise record of water quality, based on the needs of the application. As such, the Type 8905 is already capable of measuring pH, reduction potential (ORP), conductivity, free chlorine and turbidity. Each parameter is measured using a specific sensor cube that fits into the analysis machine. Each cube, irrespective of its capabilities, has the same dimensions and connections and can be plugged in, or removed, from the unit while it is operational, thus providing a hot swap facility. The design of this product allows the customer to start with an initial set of parameters to be analysed that can be added to at any point, without affecting the existing system. When a new sensor cube is plugged into a free slot, it logs in with the system and makes its features available to all of the other modules that are present.

One analysis unit can be used to measure properties of two independent sample lines, reducing costs where more than one sample needs to be analysed. In situations where multiple samples require comprehensive analysis, Burkert can develop custom-built designs, if necessary in one cabinet and linked to a single touch-screen display.

New features In addition to the existing sensor cubes, Burkert has added two more: Chlorine dioxide and iron. The former is an important characteristic to measure in the disinfection process as it is widely used as an effective microbicide, disinfectant and sanitiser. The effective control of this popular chemical is very important and B端rkert has now added a sensor cube that can be used in both new and existing analysis stations. Just as important is the removal of iron deposits from water used for processes that demand a minimum of contaminants. The iron analysis cube can be set up to measure and record iron levels as well as initiate warnings when pre-set levels are reached. The compact FIA colorimetric system houses three bottles above the iron measuring module - which include the iron colouring reagent, as well as calibration and cleaning fluids, all of which are automatically controlled by the base Type 8905.

All three bottles feature barcode-locators to ensure correct replacement and weigh scales to monitor consumption as well as alerts in good time when topping up is required. B端rkert has also developed an autocleaning process for the sensor cubes that uses a solution of clean, filtered water and mild citric acid, primarily to flush the turbidity sensor cube. The process can be set up on a timed basis by the customer to suit the needs of their application and can be used to clean any of the sensor cubes and other wetted parts. Once the cleaning procedure is complete, the fluid is sent to drain to avoid contamination of the main process. To help customers maintain the accuracy of their water analysis equipment B端rkert has also designed a hand-held cleaning and calibration module that connects to the Type 8905. This enables operators to follow step-by-step maintenance instructions and procedures for using calibration fluids. All the while, the base unit is constantly monitoring the process and recording the necessary data. The Type 8905 can communicate with existing control protocols and with personnel both on and off site, ensuring that any deviation from the water quality criteria is notified immediately. Furthermore, research with customers is ongoing into their future requirements and Burkert will continue to develop additional features and capabilities.

Issue 30 PECM

Control & Automation

VELDEN: RELIABLY INNOVATIVE BRITISH ENGINEERING

elden has been manufacturing precision engineered components since 1973,

earning a sound reputation for quality, exceptional service and innovation and has become one of the best British subcontract engineering companies for machined components, fabricated assemblies and system builds. 2017 was a positive year on many fronts for Velden. The arrival of new machinery has added to an already extensive portfolio and increased our flexibility; a change of management structure has seen the arrival of both a new Production and Purchasing Manager; we have gained several new blue-chip customers; further advancements to becoming a true Industry 4.0 smart factory have been

made plus we are involved with some exciting development work for the future. Success has arrived by differentiating ourselves from competitors, by consistently exceeding expectations and through having an innovative approach to solving our customer’s procurement challenges. “I appreciate the effort that went into the response. If only all suppliers!” [Design for product manufacture support] STA Engineer Mercedes AMG HPP

years, advancing our ERP system, live machine monitoring and KPI dashboards, secure enterprise grade network and cyber security. In an uncertain business climate, Velden offer reliability, innovation and a willingness to build and nurture partnerships with our customers. To discuss your requirements, contact us on 01204 520620 or email: enquiries@velden.co.uk. Website: www.velden.co.uk

A key strength of Velden has always been our foresight: we were the first sub-contract engineering company to become certified to BS5750, ISO9002 and EN29002. We have consistently invested in the latest machinery and have been anticipating and developing Industry 4.0 practices for several

01204 520620 enquiries@velden.co.uk

PECM Issue 30

Control & Automation Composites 4.0 – Cevotec’s Fiber Patch Placement automates the production of complex CFRP components Cevotec enables manufacturers to build complex fiber composites in high volume and quality – by smart process automation based on Fiber Patch Placement technology. With SAMBA Series, Cevotec offers tailored, automated fiber layup systems for challenging 3D geometries and laminates with complex fiber orientation. Given its easy scalability, Fiber Patch Placement adjusts to requirements of high-volume production with throughputs of 100 kg per hour as well as flexible batch production, prototyping and R&D. ARTIST STUDIO is the matching CAD-CAM software for generating patch-based fiber laminates and automated robot programming. A plug-in for commercial FEM software allows for efficient structural simulation. Phone: +49 89 2314 165 - 0 advantages@cevotec.com www.cevotec.com

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What did you want to be when you were young? Your ambition has led you to the fast-changing world of engineering. And your ideas are shaping its future. But to do what you do best, you need the time to focus on what really matters. For 80 years we’ve been helping customers achieve their goals through our extensive range of industrial maintenance and electronics products, and world-class service. We’re here

| High stock availability | Expert technical help | Next day delivery

Issue 30 PECM

Control & Automation

Your dedicated specialist for factory automation. For the last 60 years the worldâ&#x20AC;&#x2122;s No. 1 in factory automation has been at the forefront of innovation, continually pushing back the boundaries of automation to increase productivity and drive down costs across a whole range of industries. Boasting 99.9% reliability, a customer-centric approach, world-class service and infinite solutions for industrial robots, CNC systems and purpose-built machines for wire cut EDM, electric injection moulding and milling and drilling, weâ&#x20AC;&#x2122;re there to help you make the most of your automation. All you need is yellow.

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PECM Issue 30

17/08/2015 12:18:40

Electrical & Electronics Electrical & Electronics

MachineryMate™ handheld vibration meter

Guhring Drill Is The Top Prize For Robot War Warriors Over the summer months Robot Wars has been back on our TV screens with 40 distinct combat robots battling it out for the prestigious accolade of being crowned the 2016 champion. Self-built by the competitors and ﬁghting in a purpose-built arena, the six-episode series has been watched by over 2 million people each week. The Grand Final was won by Apollo, a robot captained and driven by Dave Young. As one of the House Robots that featured in the Series, Sir Killalot is a 740kg robot with a 2.5tonne pincer grip and a top speed of 10mph. On one arm is a 300kg arm lift that outweighs all competitors and on the other arm is a 2inch taper shank drill from

Wilcoxon’s handheld vibration meter helps find machine faults before Guhring. The Guhring 245 Series Taper Shank Drill they impact has been used throughout the series as operation a tactical or feature in battles with contestants. Manufactured cause catastrophic failures. by Robo Challenge, a Birmingham based company The MAC200 can increase of enthusiastic, creative and downright whacky productivity and lower engineers, Sir Killalot is just one of many maintenance costs prestigious projects that Robo Challenge has by identifying vibration delivered. problems and bearing As well as featuring heavily in the hit TV show with in earlywith and late Sir Killalot, Robo Challenge conditions was also tasked stages of failure. The designing and manufacturing the coveted trophy. simple, easy to use A trophy that has another iconic masterpiece at meter, its centre, the Guhring 245 Series Drill. analyzes and displays records,

ODU-MAC®

vibration signals and comes with built-in band filters for unbalance, misalignment, and looseness. The low Hertz range allows readings on machinery running as slow as 120 RPM. The meter assists in condition monitoring for industries including commercial and industrial. 01767 651058 www.kdpes.co.uk

THE ALL-ROUND SOLUTION FOR AUTOMATIC DOCKING

Compact modular connector system

The intelligent path to customer-specific connections: ODU-MAC – our versatile modular connector solution enables the transmission of power, high current, high voltage, coax, high-speed data, fiber optics and other media such as air or fluid. For your made-to-measure connection.

Fail-safe performance thanks to outstanding contact reliability 6 standard docking solutions High packing density 30 different high-speed inserts in the field of data technology Up to 100,000 mating cycles Stable low contact resistance ODU-MAC strain relief housing for optimal protection

New ODU-MAC® strain relief housing

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

Issue PECM55 51 Issue 30 23PECM

PNY PREVAILPRO WORKSTATIONS PRO PERFORMANCE. ANYTIME. ANYWHERE. Until now, mobile workstations really weren’t very mobile and simply couldn’t keep pace with desktop offerings. PNY’s thin and light PREVAILPRO series resets expectations by delivering the ability to interactively work with large and complex models or scenes, drive up to four 4K UHD displays simultaneously, generate stunningly realistic and immersive professional VR environments, or generate photorealistic renders on the road, without straining shoulders or breaking budgets – all with unmatched NVIDIA Quadro performance, features and ISV compatibility.

MOBILE PERFORMANCE EVERYWHERE PNY PREVAILPRO integrates NVIDIA® Quadro® P3000/P4000 to deliver desktop-level performance with great mobility, allowing visual computing professionals across various industries to work with large, complex designs, render photorealistic imagery, and develop intricate and life-like VR experiences. 7th generation Intel® Core™ i7-7700HQ quad-core Kaby Lake processor in PNY PREVAILPRO provides both speed and performance with HyperThreading and TurboBoost.

CONNECTIVITY AND MOBILITY A full complement of I/O ports, including HDMI 2.0, 2x mDP 1.3, 3x USB 3.1 Gen 1, 2x USB 3.1 Gen 2 Type-C, 1000BASE-T Ethernet, Wi-Fi, Bluetooth, audio input and output and a versatile media card reader are all provided. A full size English keyboard and numeric keypad, both with LED backlighting, and a touchpad with a built in fingerprint sensor deliver superior ergonomics and security. Weighing only 4.8 lbs (2.2kg), with dimensions of 14.95” x 9.8” x 0.73” (380mm x 249mm x 18mm), this system is fuelled by a 4 cell Li-Polymer 55WH battery pack good for up to 300 minutes in UMA mode. This system is optimized for and features Windows 10 Professional 64-bit.

COMPACT, MOBILE AND PERFORMANT PREVAILPRO lets you experience the world’s most powerful visual computing platform everywhere – for the ultimate in creative freedom. Whether you’re developing revolutionary products, telling spectacularly vivid visual stories, designing transformational architecture, or creating the most lifelike, immersive virtual environments, PREVAILPRO gives you the performance to do it brilliantly. Phone Number: +33 (0)5 56 13 75 75 Email: quadrouk@pny.eu Website: www.pny.eu

PECM Issue 30

AUTOMATIC SELF-CLEANING ELECTROSTATIC PRECIPITATOR SYSTEM REDUCES COSTS AND BEATS EMISSIONS STANDARDS FOR POLYFLOR ooking to minimise the TCO on a replacement electrostatic precipitator (ESP) system, flooring manufacturer Polyflor has chosen an innovative new design from ThermTech. Judged to be the most cost-effective option to remove plastisol emissions from flue gases, the new ESP unit incorporates a revolutionary cleaning system that effectively eliminates downtime for maintenance.

Polyflor is a leading producer of PVC flooring and has been manufacturing in the UK since 1915, as such the company takes its environmental responsibilities very seriously. It is constantly looking to improve its carbon footprint and that of its suppliers as well as minimising its impact on the environment. ThermTech was involved in installing a 16,000 CFM, triple-stage air pollution control (APC) unit at Polyflor's site in Manchester over 25 years ago. Over the years ThermTech has continued to provide technical support for that unit, which had now reached the end of its service life. The quality and engineering support aspects of what ThermTech could provide were therefore well established, the decision came down to which technology suited the application best. Regulations and standards relating to air pollution have been tightened since the original APC installation and now Polyflor needed to find a replacement unit that would meet future standards. There were essentially five options available: a high efficiency Venturi scrubber, a biological scrubber, a coalescing candle filter, an incinerator or a new ESP. The venturi scrubber, coalescer and the incinerator have very high energy costs associated with them while the biological scrubber requires a large area for the installation.

PECM Issue 30

In the past ESPs had developed a reputation for being very efficient to run and very effective, but costly to maintain due to the cleaning requirement. In fact, ESPs have the highest collection efficiency for sub-micron particles, the ability to recover the captured products, and the lowest electrical running cost per unit volume of air throughput of any of the five pollution control devices. However, the efficiency with which ESPs can remove solids, moisture and thermal degradation products from flue gases causes the precipitator and its associated gas cooling equipment to eventually become blocked. This requires them to be cleaned, sometimes off-site, which until now, resulted in downtime for the manufacturing process they are associated with. ThermTech had completed a considerable amount of research into solving this problem and now there was an opportunity to prove the theory. ThermTech approached Polyflor with a proposal to install a pilot plant that could be used to evaluate the technology. Successfully winning a government development grant, ThermTech manufactured the prototype equipment and installed it at Polyflor's Manchester site, where it was connected to a stream of flue gas. Over a period of several months the process was fine-tuned until the ESP cells could be washed periodically, or on demand, automatically and be brought back online within 2 minutes of the cycle ending. Lionel Macey, Technical Director at ThermTech, comments: "The process was closely monitored and found to remove 99.5% of contaminants from the flue gas stream, while the new automated cleaning process enabled this to remain a continuous process.

By removing the need for periods of downtime to disassemble the unit to manually clean it, ThermTech has reestablished ESPs as a prime low energy abatement plant (LEAP) product." Following the successful conclusion of the pilot scheme ThermTech has applied for a patent for the technology in the cleaning process, which was one of the conditions attached to the government loan. It has also designed, built and installed a full-

Tel: +44 (0)161 339 3049 Web: www.thermtech.co.uk info@thermtech.co.uk

scale, 20,000 CFM, triple-pass plant for Polyflor. The new system uses a full wash cycle every 6 hours and has been operational 24 hours a day, five days a week, for the last 14 months, without any loss of performance. The system includes a range of sensors that continuously monitor the emissions from the flue chimney and provide real-time data to the Polyflor maintenance team.

The data from the sensors is also monitored and logged remotely by ThermTech to ensure continued performance of the cleaning system. Furthermore, the local council has carried out independent environmental monitoring of the flue chimney and agreed completely with the data provided by the ThermTech installation. Lionel Macey concludes: "This country needs efficient cost-effective

manufacturing facilities to remain competitive on a global scale. We also must meet targets for environmental protection. This project has made a major contribution to reducing the cost of pollution control equipment for those using PVC in their manufacturing processes. The technology that we have developed has proven its reliability and Polyflor is keen to see it used in another site very shortly." Issue 30 PECM

TRANSTHERM TOP 5 MAINTENANCE TIPS FOR YOUR COOLING SYSTEM

ou’d be surprised if we compared a cooling system to a human!

But in fact they aren’t too dissimilar – especially when you think that both man and machine need regular exercise, a proper looking after, the right food and good rest to be on top form. With that in mind, here are our top tips for keeping your cooling system in topperforming shape. 1.

Dress for the occasion

We’ve all been caught out with our (un) reliable British weather. Thankfully, even if we fail to get the weatherman’s memo and get drenched or boiled by our choice of outfit, we can make sure that our equipment doesn’t follow suit, and works perfectly despite its location. There’s no grinding to a halt because of rain or snow – our machines are specified correctly right from the initial design stage so they run smoothly whatever the weather. If equipment is going into a corrosive environment, then we’ll choose hardwearing construction materials. If it’s going to be shipped to a coastal or desert location, then we’ll use a wider fan spacing so that sand can pass through the heat exchanger without clogging everything up.

PECM Issue 30

If the system will be situated in an area with a lot of debris swirling around, then we’ll advise on leg meshes. Preemptive planning will make on-going maintenance a lot easier. 2.

Don’t overdo it!

Despite thinking machines are indestructible, they also have a shelf life and if worked too strenuously, they will collapse – just like if we were forced to run a marathon every day – there’s only so much both of us can do! Just as a personal trainer will give you a tailored routine so as not to push you over your limit, you need to pay attention to manufacturer’s operating and maintenance requirements which will stipulate how hard and how regularly the system can be operated and how often the process can be shut down for heavy maintenance. 3.

Everyone needs a workout, even machines!

Yes even cooling fans need to have the odd gym workout. If your equipment is only used intermittently then keep it ticking over well by rotating the moving fan and pump motor parts so you don’t get any system failures because of seized up bearings.

It’s not only humans who need a clean

You can’t get them in the shower, so ensure you air blast coolers and pump sets are kept spick and span by monitoring them regularly for debris. A blocked up heat exchanger in a cooler or a clogged up strainer within your pipe work can massively affect efficiency and the life span of fans and pumps. Lift the strain off and let them run like a dream instead! 5.

Eat the right things

We wouldn’t go overboard on the chemicals, and neither would we omit important vitamins in our diet. The same goes for cooling equipment believe it or not! If your system needs special fluids, like glycol anti-freeze to protect it from frost damage, then check and maintain the required amount. Frost damaged cooling equipment can be costly to repair or replace. If you need any advice on how to look after your air blast coolers or pump sets, then don’t hesitate to ask us. We will be happy to help you bring them back to full health. TEL: +44 (0)24 7647 1120 Email: sales@transtherm.co.uk www.transtherm.co.uk

200+ EER (Energy Efficiency Ratio) Achievable with oversized heat exchange coils

ErP certified EC fans, save more than 30% of energy

Adiabatic Cooler - Water consumption that is less than 1% of cooling towers and 2% of wetted surface hybrid dry coolers

Supplying High Quality Heat Exchange Solutions Since 1989

2-year warranty, including parts and labour in UK mainland, parts only elsewhere â&#x20AC;&#x201C; extendable to 5 years* **Subject Subject to to Terms Terms && Conditions Conditions

Air Blast Cooler

Adiabatic Cooler

Tel: +44 (0)24 7647 1120 Email: sales@transtherm.co.uk www.transtherm.co.uk

Packaged Pump Sets

EFFECTIVE HUMIDITY CONTROL IS ESSENTIAL IN INDUSTRIAL ENVIRONMENTS FOR PROCESSES AND PEOPLE. John Barker of Humidity Solutions explains

Pharma dehum – desiccant dehumidifier being installed into a pharmaceutical application to provide low humidity control “20%rh)

umidity control is essential in any indoor environment for the health of the occupants and the building fabric. In a manufacturing environment it can also affect the integrity of stored materials and impair the reliability of machinery.

In terms of measuring humidity, we use the term ‘relative humidity’ – or RH - to describe the relationship between the temperature of air and the amount of moisture it can hold. When there are problems with RH in UK industrial environments it is usually because the RH is too low, potentially leading to dehydration and drying out of eyes and respiratory surfaces. Low RH also increases the spread rate of pathogens such as the influenza virus and has been linked with the intensity of chemical pollution caused by gases from materials used inside the buildings. These issues are reflected in the environmental variables identified in HSE Guidance note 194 (4) - in relation to maintaining workplace health, safety and welfare. Low RH will also cause various materials (e.g. timber) to dry out very quickly. Additionally, it makes occupants feel colder, so they turn the heating up, which increases energy consumption. Ironically, raising the temperature reduces the RH even further, exacerbating the problem. Taking control Therefore, it makes commercial sense to ensure effective humidity control

PECM Issue 30

Hydrojet – Airtec high pressure water humidifier installed at a plastic production facility to prevent static

in industrial environments, with a view to maintaining RH between 40% and 60%. This will usually mean using humidification to raise the RH and choosing the right system is essential. Energy consumption, maintenance requirements and location of the humidification plant should all be considered. Traditionally, the solution has been to heat water to produce steam and this is still an appropriate option for some projects. However, high pressure, low energy systems using cold water are becoming increasingly popular in industrial applications. Steam humidification

SKE – Steam humidifier installed in a clean room air handling unit to provide sterile humidity control

Another consideration is where to locate the humidification plant. Gas-fired units tend to have a relatively small footprint and can be skid-mounted for installation outside the building. Electric units can also be weatherproofed. Low energy, high pressure A lower energy alternative to steam generation is to spray water through nozzles, at low or high pressure, directly into the space or into ductwork. Such systems also need to incorporate antibacterial measures such as ultra violet disinfection and can be combined with demineralised or reverse osmosis water.

There are several ways of generating steam for humidification and the optimum solution will depend on the project. For example, electrode boilers will not supply more than 90kg/hr. of steam, while resistive generators can provide up to 120kg/hr for a single unit and modular gas-fired humidifiers will deliver up to 400kg/hr.

All forms of adiabatic humidification use less energy than self-generating steam humidifiers. Low pressure nozzles use pressurised air, so energy is consumed by the air compressor. High pressure nozzles take the energy for atomisation from high pressure water, so the high pressure pump is the main energy consumer, albeit very low.

As a rule of thumb, it takes 0.73kW of heat to produce 1kg of steam, though distribution and other losses might add as much as a further 20%. In most cases, gas-fired humidifiers will offer higher efficiency with a lower carbon footprint, compared to mains electricity. Gas fired units may also prove less costly to install because electric humidifiers have heavy cabling requirements.

Summary

In hard water areas the potential for limescale formation cannot be ignored and demineralised water is often recommended.

Further information: www.humiditysolutions.co.uk

Given all of the factors discussed here, it is clear that achieving acceptable humidity control depends on addressing a number of variables within each project. For that reason, it makes sense to team up with companies that have a comprehensive range of different humidity solutions and the expertise to apply them to optimum effect.

Add humidity expertise to your skill set... Steam Humidifiers

Dehumidifiers

Adiabatic Humidifiers

...and with our help grow your business. • Design and support • Equipment to suit all applications • Full technical back up • Adds value to projects • Increases profit www.humiditysolutions.co.uk

138x108mm advert_new2.qxd:Layout 1 03/06/2015 23:06 Page 1

Facilities Management

Dura Grating Fibreglass Floor Riser Decking

LIP SURFA IS HTWEIGH IG

AN T

CORROS I ON

LIP SURFA IS

CE L

HTWEIGHT IG SPARKIN ON

CORROSI

+44 (0)1255 423601 enquiries@duracomposites.com www.duracomposites.com

Can be cut on-site Gritted surface prevents slips, trips & falls Quick & easy to lift and install No hot works permits required

Permanent Riser shaft installation

SPARKIN ON

Fibreglass Dura Grating Floor Riser shaft decking makes an ideal replacement for metal decking. They can be installed at any multi-storey construction as permanent riser shaft decks or as as temporary lift shaft deck covers. They are lightweight, anti-slip and non-sparking reducing the need for hot works permits.

...designed for the future Industrial

Rail

PECM Issue 30

Marine

Landscaping

Architectural

Fasteners & Fixings

ENGINEERING EXCELLENCE CREATES REMARKABLE NEW FRICTION GUIDES Using engineering expertise gained from the development of class-leading telescopic slides, a new range of linear friction guides is launched. Friction guides use a plain bearing surface with no rolling elements. The lack of exposed moving parts makes this solution ideal for harsh environments where dust, sand or dirt particles might be present. Compared to equivalent recirculating ball bearing slides, they are lighter, easier to use and engineered to minimise stress and wear on the friction elements; a durable and reliable system. The new linear bearing guides showcase all the benefits that customers have come to expect of Accuride products from JET PRESS - ease of use, superior performance and designed-in reliability. The strong engineering pedigree has delivered a friction guide that, thanks to its

extratough anodised aluminium track and superior polymer guide, is hardwearing and long-lasting. This longevity adds to the low total cost of ownership and also makes it an attractive alternative to applications that might be over-engineered with costlier solutions. Three variants of the new friction guide are available; non-adjustable, manual adjust and auto-adjust. The height, width and

hole pitches all comply to ISO 12090 standard to ensure compatibility to existing systems. Tracks are available in two standard lengths of 1 or 2 metres and seamlessly fit together to form a track of any length for the bearing blocks to traverse freely along. Available from stock at JET PRESS for next working day delivery. Contact our sales team on 01623 551 800, sales@jetpress.com or visit www.jetpress.com

jetpress.com

YOUR GLOBAL SOURCE FOR

FASTENERS & COMPONENTS

• Extensive stocks available for rapid delivery! • Vast range of proven solutions to choose from • First class technical support & customer service • Bespoke design, development & manufacturing

Find your solution at jetpress.com sales@jetpress.com • 01623 551 800 Issue 30 PECM

www.elaflex.de/en/configurators

Many options, fast choice. ELAFLEX hose assemblies, nozzles, rubber expansion joints and couplings reflect the decision for premium quality. They ensure safe operation and long-term optimisation of the total cost of ownership.

Due to the large number of product options we have complemented our catalogue with online configurators. These configurators offer a fast and efficient overview or can be used for your enquiries.

nozzleconfigurator.elaflex.de

hoseconfigurator.elaflex.de

ervconfigurator.elaflex.de

manntekconfigurator.elaflex.de

ELAFLEX - Gummi Ehlers GmbH · Schnackenburgallee 121 · 22525 Hamburg, Germany · Tel. + 49 40 540 005-0 · info@elaflex.de · www.elaflex.de/en

Fluid Handling

SPX Flow Inc. appoints AxFlow UK to distribute APV components

Aquaflow Aquaflow, a division of T-T Pumps Ltd, introduces their range of new liquid turbine flow meters. Acuflux is designed with reliability, durability and practicality in mind to incorporate the required features of a flow meter with manufacturing expertise to produce a flow meter that operates efficiently in demanding media conditions. The Acuflux’s durability is demonstrated in its diverse temperate range, allowing a flow of liquid from -40°C to

+85°C and a 40 bar maximum working pressure. Not only is the Acuflux reliable in terms of its robust design of corrosion resistant stainless steel, it is also reliable in terms of its data capture with the readings guaranteed to achieve accuracy within one per cent. If you wish to know more about the Acuflux or any more of Aquaflow’s range please visit www.aquaflowvalves.com or call 01630 647111.

AxFlow UK Limited has announced its appointment by SPX Flow Inc., (NYSE: FLOW) as its primary distribution partner for APV brand process components and parts in the UK food and beverage market. The agreement includes APV pumps, valves, homogenisers, mixers and sanitary heat exchangers. This is a major step forward for both companies and follows the long term successful partnership between SPX Flow and AxFlow representing the Waukesha Cherry-Burrell (WCB) brand in the UK. Announcing the agreement, AxFlow UK Limited Managing

Director Tony Peters said: “Our reputation as a successful distributor with great customer service, strong technical knowhow, extensive stockholding capacities at our European Distribution Centre and comprehensive after market support service capabilities in the UK makes distributing SPX FLOW’s APV brand components a natural fit.” Based in Charlotte, North Carolina, SPX FLOW have recognised the success that AxFlow has achieved with the WCB brand in the UK and see them well placed to partner and replicate this success with the APV brand. www.axflow.com

SMART DOSING PUMP (SDP). A progressive cavity pump with integrated controls for optimum dosing performance SEEPEX’s SDP has an intelligent inverter drive programmed locally via an HMI or centrally via a fieldbus interface. The SDP can be controlled by analogue or digital I/Os either locally or remotely by a PLC. The flow rate is controlled entirely from the pump drive which adapts to variations in operating conditions ensuring accurate repeatable dosing of thin to highly viscous products.

BENEFITS  Easy implementation of complex dosing in continuous and batch modes  Minimal pulsation and high accuracy  Easy integration into higher-level controls and automation systems  Temperature /pressure sensors protect the pump  Conveying capacity: up to 2,000 l/h  Pressure: up to 48 bar SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com

Issue 30 PECM

Gears, Drives & Motors

Solid. www.enemac.org

ENEMAC distance couplings – simple connection of far distant shafts As the ENEMAC customers wanted a simplification when connecting two widely spaced shafts, the different types of distance couplings have been developed by the drive technology specialist from Kleinwallstadt, GERMANY. Labor costs and material costs for intermediate bearing are no longer required.

Distances from up to 6 m can be bridged, the intermediate pipe is getting modulated after customer’s requests. In many cases the distance coupling can be installed as clearance-free connection, drive line or synchronous shaft and replaces therefore complex additional intermediate bearing. Tel.: +49 6022 7107 0 www.enemac.de

Power Transmission Clamping Technology Made in Germany

23-01-16_Anz-PECM-RZ.indd 1

24.02.16 10:04

Cross + Morse

Power Transmission Manufacturing Specialists in the UK Since 1984

◊ Manufacturing up to 1450mm diameter ◊ Turning - CNC lathes, Vertical Machining Centre ◊ Gear Cutting - Hobbing, Planing, Shaping Gears ◊ Bevel Gears, Helical, External & Internal cut Spur Gears ◊ Worms & Worm Wheels ◊ Rack Shaping, Broaching, Keywaying ◊ Vertical Boring, Centreless & Rotary Grinding ◊ Bore Honing ◊ Induction Hardening ◊ Drilling & Tapping ◊ Large stocks of Transmission Drive components ◊ CAD - CAM Design & Development

Yes we can make it.

Cross + Morse. Shady Lane, Great Barr. Birmingham. B44 9EU sales@crossmorse.com Tel: +44 (0)121 360 0155 Fax: +44 (0)121 325 1079 www.CrossMorse.com

PECM Issue 30

Health & Safety

JSP’s new range of Sonis® Extra Visibility Ear Defenders with market leading attenuation Since the PPE Regulation update reclassified hearing protection to a category 3 risk product, it is now more important than ever for employers to provide their staff with the correct hearing protection and to fully understand that employees are adequately protected. JSP are strongly committed to safety innovation and are aware workers who need to protect their hearing also need at times to be extra visible so they have developed a range of Sonis® Extra Visibility Ear Defenders peaking at an unbeaten SNR of 37. More information is available from www.jsp.co.uk, by emailing uksales@jsp.co.uk or calling +44 (0)1993 826050.

Snickers New Body-Mapping Micro Fleece Jacket It’s advanced workwear made from a stretchable micro fleece fabric with an advanced body-mapping design - just the job for the fast paced professional, who’s always on the go. Warm, light and flexible, the jacket is made from a quick-drying ‘AIS’ (Advanced Insulation System) material, which is high-functionality and ideal as warm first layer garment or lighter second layer protection. The jacket delivers an effective balance of insulation where it matters and ventilation for your body when it’s needed. What’s more, with its innovative natural anti-odour treated and quick-drying fabric, it’ll keep you dry, fresh and comfortable all day long. To get more information on the Snickers range of Fleece Jackets is easy - call the Helpline on 01484 854788; check out www.snickersworkwear.co.uk and download a digital catalogue; or email info@snickersworkwear.co.uk

WeeTect Successfully Multiplied Anti-fog and Hydrophobic Coating on the Same Hockey Visor WeeTect, a global leader in manufacturing and designing helmet visors, today announced that they have successfully applied anti-fog coating and hydrophobic coating on the same hockey visors. This is yet, another significant milestone in protecting and ensuring safety of hockey players as required by the International Hockey Federation. “We have formulated a technology that is effective, environmentally friendly and guarantees safety of all players,” said Mr. Taylors Lei, WeeTect Product Manager. “Using hydrophilic anti-fog coating and hydrophobic coating on the same visor has been my greatest challenge at WeeTect Material Ltd. so far.” www.weetect.com/hockey-visor/

Issue 30 PECM

Q-BALL – THE MINIMUM WEIGHT SOLUTION FOR FLAMELESS EXPLOSION VENTING

s a pioneer in developing systems for flameless explosion venting REMBE® GmbH Safety + Control has fundamentally changed the world of explosion protection already in the eighties. With Q-Ball the German engineers are now presenting a new development, which possesses the potential to revolutionise the flameless explosion venting once again.

This is because the Q-Ball is going to set a new benchmark in venting effectiveness and weight. Primary designed for elevators and screens the principle of contour parallel venting -developed by REMBE engineers- applies with the Q-Ball. A maximum venting effectiveness is guaranteed and at the same time the required vent area is reduced to a minimum. The design is characterised by another new feature: The extreme low weight of the Q-Ball, enabled by construction related setting aside of outer frame profiles.

PECM Issue 30

Competitive products with comparable performance will easily reach more than double weighting. Because of its minimum weight the Q-ball is ideally suited for components with a low strength. The dimensions of the four available Q-Ball sizes are designed to fit perfect to elevators. Moreover the integrated signalling enables a reliable monitoring and maintenance. An optional available sanitary cover protects the Q-Ball in a perfect way against wetness and dust indoors and outdoors. Retrofitting of existing vent panel installations is easily possible. Nowadays it is a common industrial standard for systems of flameless explosion venting that in closed rooms and spaces neither flames, nor pressure or dust can exit the unit. The dangerous effects of explosions need to be reduced to a harmless level; the noise of the explosion bang shall be minimised to an acceptable level. In ideal case production downtimes can be avoided or significantly reduced.

REMBE meets these requirements with explosion-proof housing structures that will stay stable even during extreme dynamic explosions. Additionally filter inlets made of a special stainless mesh material developed by REMBE cool down hot flame gases (up to 3000 °C) extremely efficient within only 500 milliseconds. This reduces the volume of ejected gas and extinguishes the explosion – heat, dust and pressure remain in the facility. Proximity to an external wall is not required, so this simple protection solution can even be used in the middle of production halls. The optimised production process remains in the building.

T: +49 2961 7405-0 F: +49 2961 50714 info@rembe.de www.rembe.de

T +49 2961 7405-0

Made in Germany

Your Specialist for PRESSURE RELIEF and EXPLOSION SAFETY

Hydraulic power & control worldwide Industrial

Energy pFBK-065 a mid-sized, highpressure, dualdischarge pump.

Defence

Mobile

Subsea

SSr-05 a subsea regulator, without the ocsillation. The Oilgear Subsea Pressure Regulator is a robust, precision device that controls the pressure within a given circuit by serving as both a pressure reducer and as a pressure relief. The SSR is available in various sizes and control options (pilotoperated, mechanicallyset, and electricallycommandable).

pVG-048 an extremely responsive high-speed pump. The PVG is a variabledisplacement, axialpiston pump with fast control response. The PVG thrives on low viscosity fluids and is available in a variety of control and porting options. It is designed to be a highperformance solution for your demanding applications.

pVV-200

pFBa-4

the flagship, highhorsepower pump.

a compact, highpressure pump.

The PVV line of Oilgear pumps represents the pinnacle of performance in a variabledisplacement, axialpiston pump. Pressure and flow demands continue to rise for our customers. The PVV is a pump that rises to the challenge.

The PFBA pump has proved itself successful for use with high water content and lowviscosity fluids. These axial piston pumps are used in a wide variety of applications, including oil and gas die casting and injection molding machines, high pressure test rigs, civil and marine projects, intensifier systems, extrusion presses, forging presses and high pressure forced lubrication systems for long turbines as well as metal forming machines.

Wide variety of applications: high pressure test rigs, civil and marine projects, intensifier systems, extrusion and forging pressure and other heavy duty metal forming machines.

introducing the pVV-180 and pVV-355 New additions to the ultra high performance line of PVV variable displacement pumps.

BEST UNDER PRESSURE The Oilgear Company provides robust hydraulic solutions for customers who prefer a partner not a vendor Our vision is to be the No.1 choice for hydraulic solutions in our target markets Oilgear engineered hydraulic solutions are amongst the most reliable and cost effective on the market. We drive the reduction of life cycle costs through innovation and engineering excellence We pioneer multi-fluid testing to promote the use of alternative hydraulic fluids As a partner we value customer satisfaction and being easy to work with Oilgear promote customer confidence through qualification

E: enquiries@oilgear.com T: 0113 394 7300

OILGEAR OFFER AN EXTENSIVE RANGE OF MULTIFLUID, HYDRAULIC PRODUCT RANGING FROM 70 TO 1000 BAR ENERGY

OILGEAR ENGINEERING SOLUTIONS & CAPABILITY

INDUSTRIAL

TESTING & AFTERMARKET CAPABILITY • Hydrostatic Testing up to 1000 Bar • 6000 Bar intensifier rig

• Offshore Motion Compensation

• Pump dynamic performance testing (1000 Bar)

• Subsea Pumping Control • ROV Control

• Multifluid trials

• Blow-Out Prevention

• Rapid response emergency repair

• Hydraulic Press Control

• Routine service checks

• Electrical Amplifier Control

• Preventive maintenance • System performance diagnostics • Remote condition monitoring • Trouble shooting • Retrofit of new technology • System optimisation audits

• Sluice & Bridge Control • Transfer Barrier Control

MOBILE

• Finite Element Analysis • Computational Fluid Dynamics – System Simulation (SimulationX)

• Power On Demand life cycle cost reduction

• Variable displacement pumps • Fixed displacement pumps Hydraulic intensifiers • Bespoke hydraulic control systems • High pressure check valves • Pressure regulating valves • High pressure logic manifold valves • Subsea function valves • High speed relief valves • Screw-in cartridge valves

Visit our website to find out more about our products & solutions!

W: www.oilgear.com

Lifting & Handling Equipment

Handling with ease:

Expanded range

Demag Manulift for loads of up to 500 kg

Sidetracker Engineering has expanded its product range including the addition of two man â&#x20AC;&#x201C; up machines said to be particularly useful when steel stockholders receive orders for mixed quantities of light duty sections, which can then be bundled, trade weighed and labelled at height.

The DC Manulift, used in conjunction with a Demag DC chain hoist, may be used for simple and safe horizontal and vertical movement of loads with minimum operator effort. Loads may be manoeuvred with the operator using just one hand, leaving the other hand free to operate the crane control system. This provides ergonomic advantages over the use of conventional chain hoists, where the operator often needs to use both hands to lift and position loads. The DC Manuliftâ&#x20AC;&#x2122;s control unit is rigidly connected to the load handling attachment, allowing the operator to guide the load with a central handle and, at the same time, lift and lower the load via integrated rocker switches, without having to change the hand position. www.demagcranes.co.uk

Lubricants

This saves time bringing bulk stocks down to ground level, to pick one section and then returning it back into the racking. The truck can be specified to handle bulk stocks in and out of the racking. Sidetracker Engineering also now offers heavy duty electric platforms with high capacity platforms, railed or free â&#x20AC;&#x201C; standing, suitable for transferring materials between buildings where craneage is not available or for moving stocks long distances to despatch rather than using a forklift. www.sidetracker.co.uk 01246 810655

Intelligent drive tailored for conveyors Nexen Lift Trucks â&#x20AC;&#x201C; the designer, manufacturer and supplier of forklift trucks and warehouse equipment â&#x20AC;&#x201C; has supplied a 3-wheel electric X-Range lift truck to Three Oceans, a privately-owned business that, founded by Tim Rose in 1992, recognised a niche in the industry for the supply of high quality whitefish, primarily to the foodservice sector. With application advice and support from Nexenâ&#x20AC;&#x2122;s Yorkshire-based dealer MH Group, one of the UKâ&#x20AC;&#x2122;s leading suppliers of forklifts and materials handling systems, Nexen was able to meet the requirements of Three Oceans with its new electric-powered Nexen FBXT 18 counterbalance forklift, which was supplied with additional weatherproofing and IP protection to ensure it could make trips between the customerâ&#x20AC;&#x2122;s two processing facilities in Hull. www.nexenlifttrucks.com info@nexenlifttrucks.com

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PECM Issue 30

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Machining & Machinery

Gasparini Industries

Automated bending line Gasparini developed a new type of a 4.0 automated press brake with extremely innovative characteristics that enable mass customization.

CMY

Stats and prevention Production statistics and cycle times help us determine costs and bottlenecks. A network of sensors allows for predictive maintenance. Characterization We monitor plate variations, managing springback accurately and in real time. This reduces the need for samples and tells us whether the raw

material is in accordance with what we are expecting. 360Â° interfacing This bending line can be integrated with other smart machinery. It can be interfaced with ERP, NAS, CAD, and CAM systems, uploading programs and drawings via LAN. Top-notch automation It can be equipped with automatic loading, pickup, thickness check, part handling and tool change. 0039 0422 835 800 info@gasparini.it www.gasparini.it

News & Events

Issue 30 PECM

The Brand of Choice for Vibration Control The Historyâ&#x20AC;Ś For over 60 years, TICO has been the brand of choice for vibration control. From our manufacturing site in Cornwall, we have been supplying elastomeric vibration attenuation solutions across the world. With an on-site laboratory, technical unit and research team, we have been offering unparalleled service and tailored engineered solutions to all aspects of industry. TICO is the generic brand name for a range of products that are used for a variety of purposes including: Machinery Mounting, Vibration Attenuation, Plant Levelling, Pipe Supports, Movement Joints, Low Friction Supports and Impact Absorption. With a wide range of off-the-shelf and bespoke manufactured solutions, all backed with technical excellence and an assurance of quality, we are able to make recommendations on all vibration and related problems.

The Scienceâ&#x20AC;Ś TICO supply a wide variety of products, the most common being a rubber bonded cork compound; this compound is vulcanised to create three dimensional bonds. This procedure delivers great strength and toughness when compared to glued rubber crumb products or air-filled elastomers; it also gives a higher resistance to break up during the life of the products. A significant benefit of our rubber bonded cork compounds is that they can compress within their own volume and have limited creep or bulge outside of the loaded area. TICO is only manufactured in the UK at the Tiflex facility, where it has a quality controlled production process and end of line testing. This testing verifies performance against product data sheets, giving confidence of product reliability and consistency. For over 60 years the TICO brand name has been recognised Worldwide as sign of reliability in many diverse applications. TICO products are designed to operate in a variety of environments under a wide range of operating conditions.

With a wide range of offthe-shelf and bespoke manufactured solutions

Anti-Vibration & Noise Isolation Solutions For more information please contact Tiflex Limited Email: tico@tiflex.co.uk Tel: +44 (0) 1579 320808 Web: www.anti-vibration.solutions

Machine Mounting

Structural Bearings

Slide Bearings

Pipe Supports

High Duty Resilient Seatings

A division of

STREET CRANES INSTALLED AT WORLD-LEADING SPACE FACILITY world-leading space facility is using 14 new overhead cranes from Street Crane to help lift and manoeuvre highly specialist equipment around the 80,700 sq ft site.

The RAL Space facility in Oxfordshire forms a key part of the Rutherford Appleton Laboratory, which is operated by the Science & Technology Facility Council (STFC). Involved in more than 210 space missions, RAL Space is home to one of the most sophisticated space design, production and research facilities in Europe. It comprises thermal vacuum chambers, 15 cleanrooms and low vibration chambers, which recreate conditions in outer space and at blast-off. Working with main contractor Willmott Dixon, Street Crane designed and installed 11 new overhead cranes with lifting capacities ranging from 0.5 tonnes to 10 tonnes. These are used throughout the building for lifting and moving scientific

PECM Issue 30

equipment and instrumentation and other specialist materials used by RAL. Two larger cranes have since been installed, each featuring speciallydesigned dual hoists that are integrated into common hoist trolleys for independent lifting operations. The main 50-tonne hoist is used for infrequent heavy lifts and the 15-tonne hoist offers a faster lifting speed intended for smaller loads and regular use. The other crane is similarly configured with a 30-tonne lifting capacity and with an auxiliary 5 tonne hoist fitted. This 30/5tonne crane spans the full 35-metre width of the facilities hall and will be used to transfer space instrumentation and equipment across to the hall’s clean rooms for assembly and testing. Chris Lindley-Smith, sales director at Street Crane said: “We’re really proud to have played a part in RAL Space’s worldclass space research and technology development facility.

“The larger cranes’ dual hoists have been designed specifically to suit the operation’s requirements on quite significant structures that both span over 35m. “The other smaller cranes will ensure that space instruments weighing up to 10 tonnes can be lifted and moved very effectively, reliably and safely. Our ZX hoists improve performance and safety while at the same time reduce the need for maintenance. These benefits are essential in such a demanding environment, which has to meet the exacting needs of customers and collaborators.” This is the second STFC facility that uses overhead cranes designed and installed by Street Crane. Two overhead cranes also form part of the Boulby Underground Laboratory, a world-class £1.7m science facility located 1,100m underground in Yorkshire. www.streetcane.com

Street

WISEMAN THREADING TOOLS LTD SPECIALISTS IN TOOLS & GAUGES FOR SCREW THREADS. e have been supplying threading tools and gauges since 1987. Together with supplying plain plug and ring gauges this is all that we do, we therefore consider ourselves to be specialists in this field. We supply worldwide.

Our real time stocks can be checked and purchased online at www.threadtools. com Just enter the thread details into the search box on the home page. You will be directed to the item, if stocked, or to our specials, (custom manufacture), sales team. who will quote to supply at competitive rates, in good time.

We hold extensive ready stocks that include all of the standard stuff that others offer, but also includes taps, dies, die nuts, die head chasers, thread rolls and gauging for threads not normally available 'off the shelf '.

As an account holder you can also order online from our listed in stock items, at your normal terms.

PECM Issue 30

We realise that you need the right item at the right price and quality, and in a reasonable time frame. We are geared to provide that.

We can ship stocked items same day. Our experienced sales staff can assist and advise you on any technical issues. We welcome enquiries from resellers and can offer terms to suit. WISEMAN THREADING TOOLS LTD 11 Padgets Lane South Moons Moat Redditch B98 0RA UK 0044(1527)520580 sales@threadtools.com www.threadtools.com

Threading Tool Specialists

HSS DIES & DIE NUTS Large shelf stocks for all Standard and many Special Threads. Check our stocks online.

THREAD CUTTING AND ROLLING HEADS and parts and repair service

THREAD ROLLS FOR ALCO & FETTE HEADS. READY STOCKS CUSTOM MANUFACTURURE

HSS TAPS Huge Stocks for all Standard threads CUSTOM MADE taps our SPECIALITY! We stock taps for many non standard (SPECIAL) threads

Thread Gauges all types. Large stocks for standard and SPECIAL threads. Any non stocked can be quoted for custom manufacture.

CHASERS FOR COVENTRY & LANDIS TYPE DIE HEADS Ready stocks for most size heads most standard and some special threads Geometry available for most materials. Custom manufacture our speciality!

All types; Spiral flute and point, Fluteless, Left Hand, etc, etc.

Wiseman Threading Tools Ltd 11 Padgets Lane, South Moons Moat. Redditch B98 0RA Worcs UK 004(0)1527520580 sales@threadtools.com www.threadtools.com Issue 30 PECM

THE AEMT ENSURES ENERGY EFFICIENCY IS MAINTAINED DURING SERVICE AND REPAIR n extensive joint research project conducted at the University of Nottingham found that energy efficient motors remained within plus or minus 0.5% of their original efficiency after being repaired by a good service centre. This is within the specification tolerances of the label and efficiency banding. These tests were backed by a number of leading international industrial organisations and Government Departments in the UK and USA. Tim Marks of the Association of Electrical and Mechanical Trades (AEMT) reviews the projects and their findings.

Sometime ago, members of the AEMT and the American Association EASA worked together to establish "The Good Practice Guide to Maintain Motor Efficiency" after repair. The Good Practice Guide has since been used by members of the AEMT and EASA internationally to ensure that any repairs carried out retain their rated efficiency. The Good Practice Guide and research details are freely available from the AEMT Website. The first Best Practice Guide to maintain Energy Efficiency was produced by the

PECM Issue 30

AEMT in conjunction with Department of the Environment, Best Practice Programme on Energy Efficiency. It was led by Professor David Walters, who had previously led the Brook Crompton design team on their ground breaking W range of energy efficient motors. The project remains the largest study of its kind with tests being carried out on 34 electric motors. These were 5.5 kW D132S machines supplied by manufacturers. They included 13 old design aluminium motors, 13 original design "Energy Efficient" motors, and 8 "higher efficiency" motors. A major difference between the machines was the quality of their stator laminations. The "Higher Energy Efficient" machines were some of the first to use a high grade steel coated with an inorganic based L3 film. This heat resistant varnish film increased the ability of motors to withstand annealing temperatures, and withstand multiple burn out temperatures without any detriment to the core laminations, as shown by tests during the project. Improvements in the electrical steels using L3 or better have formed the basis of new energy efficient machines over the past 20 years. This is shown in figure 1 extracted from the original project.

A few years later the original research programme was expanded to include larger machines up to 225 kW. Several Government Departments, electrotechnical companies and industry groups - both domestic and international - were approached to join a wide-ranging project to broaden the base of the next research project. Sufficient machines were included to give statistically reliable results, which increased the cost of the exercise. To mitigate this, the AEMT invited representatives of the US Department of Energy and through them the US repair trade association (EASA), both of whom agreed to join the project. The AEMT then approached their own national government for support and further sponsors were encouraged to join. The final list of participating organisations was impressive, and included the UK Energy Efficient Best Practice Program, UK Ministry of Defence (Navy), UK Water Industry Research Centre, and British Nuclear Fuels. Ten motor manufacturers also became partners to the project providing motors, technical data, and assistance for the study. These included ABB, Siemens,

Brook Crompton, GEC (now GE) and VEM from Europe, and Baldor, Leeson, Reliance, US Motors and Toshiba from the USA.

on another 11 machines (Group B).

Twenty-four 2-pole and 4-pole motors rated between 5.5 kW and 225 kW were used in the trial; these included 50 Hz IEC and 60 Hz NEMA machines with IP23 and IP54 enclosures.

There are four basic contributors to the accuracy and repeatability of motor tests:

The testing regime was devised by and conducted at the University of Nottingham. Importantly they were independent of the motor manufacturers and the repair industry. They were also recognised as having some of the best researchers and one of the best equipped labs for such work. A 30 kW motor was also tested on a "Round Robin" basis, the same machine being tested at Nottingham and three other reputed test centres in America. Using the IEEE 112B test standard for efficiency testing, the variation between test stations was within plus or minus 0.5%, which was a good result. Tests used the calorimeter method for loss segregation at no load and full load. Finally, a 75kW machine was kept at Nottingham as a calibration machine to ensure the repeatability of test results over the period of the project. It should be appreciated that accurate testing of motor efficiency to this required accuracy is difficult, and takes time, 24 hours may be required just to stabilise the machine so that 3 constant readings can be taken and averaged. They can only be achieved in a suitable laboratory. The readings below show those taken for a new machine test, and the same machine after repair, this machine gained 0.2% efficiency after repair. After stripping and rewinding 5 machines up to three times each, the effect on efficiency ranged from +0.7% to -0.6%. No room for an error in testing, when the Round Robin Results between the test centres varied by plus or minus 0.5%! Figure 2 shows the results of these multiple repairs. After three rewinds, the third rewind was still very close to the original efficiency of the machine and well within the required efficiency band. This is probably more rewinds than most motors will go through over their 15 to 20 year life span in a clean modern factory. Similar test results ranging from +0.2% to -0.2% were noted for a single rewind

The Association of Electrical and Mechanical Trades (AEMT) was founded in 1945. It is an International Association representing leading companies in the electrical and mechanical service and repair industry.

the power supply, mechanical loading system, accuracy of instrumentation, and the test procedures. The research team made certain all of these were consistently maintained for each motor. All tests were conducted in accordance with the internationally recognised IEEE 112 B guidelines, with test procedures, time between readings, and thermocouple location on the winding, all optimised to provide accurate results before the test sequence started. The tests collated data using both the American IEEE 112B method and the IEC 60034 2 readings. Due to the greater accuracy of the IEEE method at the time of the test, these were used for the project and the IEC 60034 2 readings taken to show the difference between the two standards. Recently IEC 60034 2 has been updated to be more in harmony with IEEE 112B. Recent tests have shown that the difference between the two standards is now minimal. Each motor was tested as new and then sent for stripping, rewinding, and tested again. Some machines were rewound and retested multiple times as per figure 3. Comparisons could then be made between the motor 'as new' and after each repair and rewind. Motors were sent to a repair workshop, who used the original AEMT Best Practice Guide; others were sent with specific instructions concerning winding configuration, copper section, mean length of turn (MLT) and other design characteristics, the results of these were then used to update to the new Good Practice Guide to Maintain Energy Efficiency. Tim Marks is convenor of the maintenance team reviewing an update of the International Standard IEC 60023 34 for Rotating Machines: Repair, overhaul, and reclamation. All the hard work from the initial two projects above has been incorporated into the new IEC International Repair Standard, which is on schedule for publication in 2018. The new standard includes all the

recommendations that came out of the above extensive projects to ensure that repairs to the new standard will maintain the rated efficiency of machines after repair. It is not surprising that the repair process maintains the efficiency of modern machines. Generally a repair will re-use the majority of the machine sent in for service and repair.

Items that ensure the efficiency is maintained are: Bearings: Normally the only wearing parts of an electric motor are the bearings and seals. Most AEMT members use high quality bearings during a repair, which are as good as, and sometimes better than, the original specification. Energy efficient bearings may be fitted which are rarely used in the manufacture of standard machines. Cooling: the fans are rarely damaged and are normally refitted. Good practice ensures a fan of the same size as the original is refitted. This maintains the same level of cooling and energy efficiency. The Rotor: Although a shaft may become worn and require reclamation, the electrical properties of the rotor and the air gap between the rotor and stator are not normally items that alter during overhaul and repair. A damaged shaft may be replaced with new after a critical failure, or the shaft reclaimed on larger machines. The energy efficiency of the rotor will be maintained during repair. The stator: Stator laminations fitted to machines over the last twenty years and used in energy efficient machines are designed to be able to withstand a burnout and rewind, and as shown throughout the projects the laminations now meet higher standard specifications designed to withstand even higher temperatures. Insulation and varnish materials have improved by leaps and Issue 30 PECM

bounds over the past 20 years and now workshops use materials as good as, and sometimes better than those used during manufacture. With products as good as the original going into the stator repair as when originally manufactured, the efficiency of the machine is going to be maintained, as shown in the above projects. This is equally true for the first, second, or third repair. The same quality of materials goes in as came out, so the same efficiency rating is maintained before and after repair.

Figure 1

The repair process is also very environmentally friendly, the cast iron or aluminium end shields and stator housing are cleaned and reused, steel laminations, and steel and aluminium rotor reused. The steel bearings are virtually always replaced and the steel bearings returned as pure steel to be recycled. If the windings are burnt out, they are normally removed by hand as pure burnt copper wire, which does not require separating from any other materials when returned to a copper refinery. Considering it takes hundreds of tonnes of spoil, and a large amount of water and chemicals, to get one tonne of copper out of a good copper mine, this is a huge environmental saving. Interestingly 85% of an average copper refineries production is supplied by mined copper and just 15% recycled copper. With current known reserves able to supply the world's copper requirements for around 60 years, it is not an infinite resource. Weight for weight the service industry returns to copper refiners the same weight of copper removed as it uses, and could exist without mined copper. So the repair of equipment should have a very valuable place in a company's ISO 50001 policy document.

Figure 2

Good repairers and service centres use materials that are as good as or better than the original specification, the machine designs are also to a much higher standard to enable a much longer service life. Most AEMT Service Centres will sell, service and maintain electrical machines and can give an unbiased view as to why a machine failed and whether to repair a machine or buy a new replacement. Tel: +44 (0)1904 674895 Fax: +44 (0)1904 674896 Web: www.theaemt.com Email: thomas.marks@aemt.co.uk

PECM Issue 30

Figure 3

Measurement & Monitoring

TINYTAG DATA LOGGERS: Accurate Environmental Monitoring he Tinytag range of data loggers includes rugged devices designed for monitoring in industrial, manufacturing, process and engineering applications. Compact, accurate and versatile, Tinytags help ensure that conditions can be measured, recorded, analysed and validated. Tinytag data loggers record:

•

Temperature

•

Relative humidity

•

Single and three phase power usage

•

Carbon dioxide

•

Low voltage

•

Current

•

Count inputs

Loggers are set up, and recorded data displayed in the Tinytag Explorer software, an easy to use Windows program. Results from separate logging runs can be combined for comparison and analysis, and data can be exported into popular desktop packages for use in reports and spreadsheets etc.

A range of units is available to suit specific applications: •

Standalone, network enabled or wireless devices

•

Dual channel loggers to simultaneously monitor two parameters e.g. temperature and RH

•

Rugged, waterproof and dustproof units

•

Units with displays showing current readings as well as recording data

•

Fully submersible, high temperature loggers

•

Range of accompanying thermistor probes, PT1000 very low temperature probes, and PT100 very high temperature probes

•

Voltage, current and count input loggers for connection to third party sensors for specialist applications

Tinytags are cost-effective with an established reputation for accuracy and reliability, and have been designed and manufactured in the UK by Gemini Data Loggers since 1992.

Tinytag Data Loggers:

The Tinytag Energy Logger is an easy to use, non-invasive device for monitoring power usage in high consumption facilities

Gemini Data Loggers (UK) Ltd Scientific House Terminus Road Chichester PO19 8UJ T: +44 (0)1243 813000 info@tinytag.info www.tinytag.info

Tinytag Plus 2

Energy Logger

Rugged outdoor/industrial temperature/RH logger From £95 +VAT

Non-invasive single & three phase power monitoring Full kit £795 +VAT

Radio and LAN loggers

Tinytag Ultra 2

Robust Environmental Monitoring Solutions Data loggers for indoor, outdoor and industrial/process applications • Rugged and compact • Easy to use • Dust, splash or waterproof

Manufactured in the UK

• Data downloaded to PC • Cost-effective Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework. Automatic data collection Bundles – 3 loggers/receiver/ software from £1000 +VAT

For sites requiring remote data access, Tinytag Radio and LAN loggers gather data automatically for viewing on a PC, across a LAN, or remotely across the internet. temperature

humidity

Gemini Data Loggers (UK) Ltd Scientific House, Terminus Road, Chichester, West Sussex, PO19 8UJ, England

power usage

co2

count

Indoor temperature & RH From £69 +VAT

voltage

current

Telephone: +44 (0)1243 813000 email: info@tinytag.info www.geminidataloggers.com www.tinytag.info

Issue 30 PECM

Measurement & Monitoring

High-resolution pyrometers with rugged remote sensor head Fluke Process Instruments expands the Endurance pyrometer series by models with a remote sensing head that tolerates ambient temperatures up to 315 °C. This design is ideal for applications with tight space constraints and for mounting near a heat source and in harsh environments. The sensing heads also offer improved immunity to electromagnetic interference. They are connected to a rugged IP65 electronics box via fiber-optic cable over a distance of up to 22 m. Various medium and high-temperature models cover a 250 °C to 3,200 °C measurement range. Monochrome and ratio pyrometer version are available with a 1 µm or 1.6 µm spectral response. www.flukeprocessinstruments.com

NEW COMMUNICATION PROCESSOR FROM HBM OFFERS AN INTELLIGENT SOLUTION! HBM – a market leader in the field of test and measurement - is pleased to introduce its new CP52 Communication Processor (CP), which has been exclusively designed for use with the widely acclaimed MGCplus Data Acquisition System. Successor to the CP22 and CP42, the updated CP52 which features built in intelligence, comes with a variety of flexible functions which offers users added value, such as two native interfaces. This enables users to utlise one of the interfaces for data acquisition and the other to drive the control system, for example, by a User Datagram Protocol (UDP). For further information, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com

LEADING MACHINE MANUFACTURER SPECIFIES HBM LOAD CELLS FOR SOPHISTICATED CHECKWEIGHING SOLUTION A leading UK multi head weighing machine manufacturer in Hampshire has specified PW12C load cells from HBM – market leader in the field of Weighing Technology for its latest range of checkweighers. Designed to accurately weigh a wide range of rigid packs, from 10g to 60kg, in the food and packaging markets, the latest range of sophisticated weighing machinery, which incorporates the PW12C load cell, offers a simple and reliable solution, even at very fast speeds. For further information, contact HBM on +44 (0) 20 8515 6000 or via email: info@uk.hbm.co.uk or visit the HBM website at www.hbm.com

Miniature CANopen encoders with redundant Hall sensor Grow your sales, reduce your costs, improve customer service, reduce commissioning & warranty & SLA costs. Too good to be true? Not with the easy connectivity of our hardware to your devices, the power of the CDL SmartHub to tell you what is happening and where, with graphs, alerts by email or SMS, reports, audit trails, downloads, and much much more! We’ve supplied literally thousands of systems into 15 countries, including many iconic installations, as well as working for major global blue chip clients AND local specialists. Check it out at www.captiondata.com or call 01905 754078 or email sales@captionmdata.com

Oil Condition Monitoring for Industrial Applications Tan Delta is the global leader in oil condition monitoring technologies. Unique full spectrum holistic oil monitoring allows owners/operators to improve the performance of their equipment, and increase operational reliability and safety. Tan Delta have developed application specific kits which are quickly and easily fitted to industrial engines, hydraulics and gearboxes enabling oil to be monitored and tracked continuously in real time. •

Significantly reduces maintenance costs

•

Increases equipment efficiency

•

Extends equipment life

T: +44 (0)845 094 8710 E: info@tandeltasystems.com W: www.tandeltasystems.com

Mydax Offers Liquid Chiller System Solutions for Industrial Temperature Control Needs Mydax stands apart from other chiller manufacturers by providing the elite chiller system on the market, utilizing Advanced Temperature Control Technology 0 to 100% proportional process cooling and heating control, rugged tubular steel frames and state of the art touchscreen controls. Expert use of flowmeters, pressure transducers, pulse width modulated valves and variable frequency drives allow precise temperature and fluid flow control. The Mydax CryoDax series of low temperature chiller systems can deliver process control fluid temperatures as low as -70°C and are utilized in Industrial applications including Hydrogen Fuel Cell Fueling, Semiconductor Manufacturing and Test, Thermal Vacuum Chambers, Space Simulators, Environmental Test Chambers, and Biotech Pharmaceutical applications. 530-888-6662 www.mydax.com

PECM Issue 30

Electromagnetic Flowmeter -All metal design-

M-Zert ISO 9001:2008 Registered Company

Stainless steel version

°F °C

NEW

Flow and temperature measurement

Monitoring function

∑

Total and partial quantity counter

2 configurable outputs

Display operation also with gloves

90°

Rotating colour display

Space saver

www.kobold-direct.co.uk

KOBOLD Instruments Ltd 8/9 Brunts Business Centre, Samuel Brunts Way, Mansfield, Nottingham, NG18 2AH Tel: 01623 427701 Email: info.uk@kobold.com

Custom-built robotic inspection solutions OMS is a double Queen's award-winning company that provides innovative measurement and inspection solutions to a range of businesses all over the world. For more than 10 years we’ve carried out projects in some of the most inhospitable regions on the planet, often working in challenging conditions to meet critical deadlines. Our processes and systems have been field-tested in both freezing and scorching temperatures, within confined locations or offshore aboard vessels. We utilise the diverse skill sets of our people to create robotic inspection technology which can navigate to hard to reach locations inside pipes that humans simply could not reach. Once the necessary hardware has been deployed, which includes UT, location, visual and measurement technology, we can report asset condition such as corrosion, cracks or erosion using our own custom-made software. Then, if required, we will carry out in-situ activities such as grinding, cutting, welding or polishing. Here's how a typical project scenario often occurs...

PROBLEM

Our clients constantly challenge us with questions like: we know you provide unrivalled visual and laser inspection inside pipes, but can you? • • • • • • •

Explore around pipe bends Up sloped surfaces and vertically Operate up to 1,000 metres away Navigate obstacles / size changes Work in hot or cold locations Or in inhospitable conditions Can you make it happen yesterday?

SOLUTION

Our experienced, multidisciplinary team create technology to work on projects in some of the most challenging places on earth where operations are testing both physically and mentally. We develop tools, techniques and operations that allow us to deploy solutions quickly, safely and eﬃciently. Then, we can explore, inspect and report, often from seemingly impossible to reach locations to provide detailed asset reports to the client.

Go ahead, challenge us! +44(0)1279 656038 info@omsmeasure.com www.omsmeasure.com

PECM Issue 30

BENEFITS

Our solutions oﬀer a range of advantages, such as tried and tested technology, and operational experience. OMS deliver: • • • • • • •

Custom-made solutions Award-winning technology High-quality camera / video detail Remote / ranged access solutions Repeatable data reporting Global knowledge and operations Project time and expense saving

Challenge the inspection specialists!

AWARD-WINNING TECHNOLOGY

We are an award-winning company that has been established for more than 10 years providing innovative measurement and inspection solutions to a wide range of businesses all over the world.

Detailed reporting: ® cracks ® corrosion ® geometry ® features

UP, DOWN, AROUND BENDS

RANGE OF INSPECTION MODULES

VARYING PIPELINE DIAMETERS

We utilise the broad skills of our people to create

We’ve carried out projects in some of the most

technology that can travel to locations humans cannot

inhospitable regions on the planet, working in

reach and report asset condition in detail.

challenging conditions to critical deadlines.

CUSTOM-BUILT ROBOTIC INSPECTION SOLUTIONS

THE QUEEN'S AWARDS FOR ENTERPRISE: INNOVATION 2007 & 2014

INNOVATION

INSPECTION

Optical Metrology Services Ltd Offices in the UK, USA and Brazil

REPORTING

+44 (0)1279 656038 info@omsmeasure.com www.omsmeasure.com

Q&A INTERVIEW ON ‘FLOW METER TECHNOLOGIES’ Q1) How has flow meter technology advanced over the past 10-15 years? A: In the past ten to fifteen years, we’ve seen advances in the amount of intelligence – that is to say diagnostic capability and signal processing – in flow meters. This increase in intelligence enables functionality such as meter diagnostics and remote meter verification. Meter verification allows end users to confirm that the meter is still performing within its original specifications without interrupting the process. This leads to less downtime, more accuracy, and fewer trips to the field

Q2) What are the major products available in market today in terms of flow meter? A: The major technologies available for process flow measurement are Coriolis, differential pressure, magnetic, and

PECM Issue 30

vortex flow meters. We also see ultrasonic, turbine, and positive displacement in some applications. Each of these technologies has its place and each one has a specific set of benefits – in some cases these benefits overlap, which can make the choice between technologies more subtle.

Q3) How does flow measurement methods break down in terms of their relevance and usefulness for different applications? A: In general, Coriolis flow meters measure mass and density directly. These meters have very high turn-down ratios. The Emerson Elite Coriolis meters can also detect two phase flow and maintain highly accurate liquid flow measurement so long as the gas phase is less than 10 – 12% of the volume. Coriolis is a often a good fit for custody transfer and control applications.

Differential Pressure (DP) is often a lower cost flow measurement approach. Traditionally the trouble with DP Flow measurement was a requirement for twelve pipe diameters of straight pipe, although newer technologies have reduced this to four. Pressure drop depends on whether an orifice plate or an Annubar is used. More than 50% of flow measurements in the process industry use differential pressure. Magnetic flow meters measure volumetric flow with no pressure drop. These meters are ideal for conductive liquids and slurries. Vortex flow meters are a good choice for measuring liquids, gases steam. They offer less turn-down than coriolis meters, so the user should be careful when sizing the meter, especially if the application may have occasional low flow rates.

Q4) When selecting flow meter, what are some key considerations an end-user should make to ensure success? A: End-users need to know:

If it’s safety then either a SIL rated device or proven-in-use criteria will come into play. •

Finally, what are the lifecycle considerations? What reliability is required? I would think that reliability would always be required ????) What is the cost of installation, commissioning, testing and maintenance of each option, and how do these factors offset different instrument costs?

•

The reason for installing the measurement in question. Is it control, custody transfer, batching, or indication? These reasons determine the value of the measurement which, in turn, influences the budget for the measurement point.

•

The properties (viscosity, pressure, temperature, conductivity) of the fluid to be measured. Also the required turn-down ratio and what is required in terms of accuracy. What repeatability and response time are needed? These factors will rule some technologies in, and some out.

As this high-level list of requirements suggests, selecting flow measurement technologies is not simple, so we recommend that you speak to an expert if you are not sure.

What the requirement of the physical installation are (e.g how much space / straight runs are available) and what is the maximum allowable pressure drop?

A: The meter should be installed in such a way that it is always full of product. For liquid application wherever possible the meter the meter should be installed in a vertical line with the flow in an upward direction.

•

Are there environmental and personnel safety considerations that would make a design with fewer leak points preferable? Is this a process control or process safety application?

Q5) What is the best location of a flow meter in a piping system?

Pumps , pipe bends, reductions etc can cause disturbances in the flow profile , and the designer should be careful to take these into account so as to minimise these effects.

Q6) What are some pitfalls you see end-users commonly encounter in flow meter applications? How can end-users best avoid and/or respond to such application pitfalls? A: The pitfalls we see the most often are a lack of process detail, or incorrect assumptions about the application. This leads to poor specification, which in turn leads to meters of the wrong size being installed. The most common consequences are high pressure drops across the meter and lower accuracy than the end user expected. It is also critical that the person specifying the meter understands the reason for the measurement point. Batch control has different requirements from utility flow monitoring, which is different again from Custody Transfer or simple indication. Ensure you have accurate process information and a clear functional specification to avoid these pitfalls. If in doubt, talk to a flow measurement expert.

Q7) How does the industry intend to expose the applications that did not meet expectations? And what is the procedure for achieving that? Issue 30 PECM

A: The best place for this is user forums. In a good user forum there will be a range of activities that will help a flow measurement professional. There will be training courses, where they can learn the latest technologies and how to apply them. There will be userpresented workshops, where successes and lessons from practical experience can be shared. There will be industry forums, where users and industry leaders can gain a common understanding. And in all of these, the end users can frankly discuss the issues they have seen in the real world, understand best practice from each other, and have the manufacturer acknowledge product short-comings and commit to addressing them.

Q8) What is on the prospect in terms of flow meter technology? How is the flow meter technology of today more effective/efficient than the technology of previous generations? A: The trend to more intelligence in the device will continue. This will allow signal processing to be further enhanced. In addition weâ&#x20AC;&#x2122;re seeing devices made of increasingly exotic materials, like Coriolis

PECM Issue 30

meters with super duplex stainless steel measuring tubesl, and in a wider range of sizes. Wireless measurement has the ability to drastically reduce the installation and maintenance cost of installing a flow meter and, with four or two-wire meter technology, Wireless can bring the intelligence from a meter connected to a legacy control system to the maintenance shop.

Q9) From your viewpoint, what are the high-level best practices you typically propose?

A: Understand the purpose of the measurement and its value. Make sure you know the properties of the fluid youâ&#x20AC;&#x2122;re measuring, as well as the physical installation requirements and how fast, repeatable and accurate you need the measurement to be. Take environmental and safety considerations into account and make sure that the balance between capital and lifecycle costs is sensible. Now choose the right technology, the right materials of construction, and install it correctly, away from equipment that will affect the measurement. And, if in doubt, ask an expert!

Measurement & Monitoring

HBM and Kyowa Electronic Instruments Agree on Mutual Sales of Sensors and Measuring Instruments •

• •

HBM complements its product portfolio with a selection of Kyowa sensors which meet the requirements for high temperature ranges and miniaturization Customers can benefit from the extended product portfolio of two leading Test and Measurement Companies Start in April 2018

Kyowa Electronic Instruments, based in Chofu-city, Tokyo, Japan, and HBM (Hottinger Baldwin Messtechnik GmbH) with its headquarters in Darmstadt, Germany, have agreed on a strategic sales cooperation. Both companies will offer selected products from the respective partner to extend their own portfolio of precise, high-quality transducers and amplifiers. HBM customers especially will benefit from a greater choice of measurement applications with higher temperature ranges or strong space restrictions. HBM is going to sell pressure and force transducers, strain gauges, and accelerometers from Kyowa Electronic Instruments. Kyowa will in turn add torque transducers, optical FBG measuring solutions and piezo-electric sensors

PECM Issue 30

from HBM to its portfolio. Those products will be available from April 2018 onwards. Customers will be served by their known contact persons in the sales department of the respective companies. “Both Kyowa and HBM are renowned for the high quality, reliability and accuracy of their products”, says Andreas Hüllhorst, President of HBM. “I am glad that the collaboration allows us to complement our offering and to serve our customers even better.” www.hbm.com

Measurement & Monitoring

SOCOTEC To ensure water systems are safe, efficient and meet compliant health and safety standards, SOCOTEC offers advice and consultancy, covering an array of process systems. Following the assessment and identification of any potential improvements, SOCOTEC can outline solutions and enhancements for plant specification. Ozone is the most effective method of controlling bacteria and biofilms in process water systems with no risk of resistance build up or immunity. Packaged bespoke Ozone systems,

G E S

purpose designed for process water can be supplied from SOCOTEC’s in-house manufacturing facility. Reduction in CIP procedural timescales can, without question, reduce downtime as the only by-products are water and oxygen, thus negating the requirement for a neutralisation cycle. SOCOTEC’s technical experts can support clients in overcoming any water hygiene and treatment challenges through innovative compliance management. www.socotec.co.uk salesuk@socotec.com 0845 603 2112

Gas & Environmental Services Ltd

Unit 1 & 3 Little Ridge Industrial Estate Welwyn Garden City Hertfordshire AL7 2BH

The Next Generation of Flame Ionisation Detection

GES Gas-Tec MK5 FID Hydrocarbon detection from 1 - 10,000ppm in under 2 seconds. Data and event logging: Gas-Tec allows users the ability to download full survey information.

GPS: Enhances record keeping by assigning latitude, longitude and sea level to data readings. Users are also able to view the current location, offering the precise location to back-up crews for immediate leak management. Intuitive functionality: LCD and soft keys offers full sequence instruction, in-operation options, service and calibration set-up and alerts. Tried and tested: Based around the original Gas-Tec ‘engine' detection method.

* Gas-Tec now manufactured, serviced & calibrated by GES * Website: www.gesuk.com Email: sales@gesuk.com

Tel: 01707 373751 Issue 30 PECM

News & Events

CE Certification Opens EU Market To Six Cortec® MCI® Concrete Protection Products! Cortec® Corporation is now certified to use CE marking on six Migrating Corrosion Inhibitor™ (MCI®) products for the protection and repair of concrete structures: MCI® CorrVerter®, MCI®-2018, MCI®-2019, MCI®-2021, MCI® Architectural Coating, and MCI® Wall Defense. The marking certifies that Cortec® meets the 2+ certification system requirements for assessing and verifying the constancy of these products under the EN 1504 standard and allows the products to be sold freely across the European Union. To qualify for CE certification, Cortec® sent the six MCI® products for extensive testing at an independent lab in Spain. To learn more about Cortec’s innovative MCI® products, please visit: www.cortecmci.com

2017 Alberta Exports Award Winner Solex Thermal Science Inc. (Solex) is honoured to receive two awards at this year’s Alberta Exports awards ceremony. Solex was awarded both the Exporter of the Year Award and the Clean Technology Award. The Exporter of the Year Award recognizes Solex as the Alberta exporter who has excelled in international market penetration as well as being a key contributor to improving the economic development of Alberta through job creation and investments in research and development. The Clean Technology Award recognizes Solex as the Alberta exporter who exports goods or services geared towards sustainability through the reduction of carbon emissions, renewable energy, and water conservation. www.solexthermal.com

PECM Issue 30

Climatic Packaging Solutions

Clad Metal Specialties

Protective Packaging Ltd is a specialist in Dried Product Protection and Corrosion Prevention, with over 30 years experience. They design, manufacture and supply climatic packaging solutions to suit their customer’s requirements.

Long before smartphones and smart devices were ever imagined, the world of “wireless connectivity” was achieved through smoke signals, drumbeats and the drone of bagpipes.

Aluminium Barrier Foils are a flexible barrier laminate, that protects atmospherically sensitive during storage and transportation due to its extremely low Water Vapour Transmission Rate (W.V.T.R) which as well as its barrier properties to oxygen ingress and other gases. Protective Packaging Ltd is an ISO accredited manufacturer that supply and export climatic packaging solutions globally to over 50 countries and have recently opened production facilities in Orlando, FL trading as 3D Barrier Bags Inc. For your bespoke climatic packaging solutions – Call 0161 973 2006 or visit www.protpack.co.uk

SolidLux Lack of demarcation between traffic and pedestrians is a major contributory factor to accidents in the work place. SolidLux can help. An industrial grade, coloured floor coating that cures instantly when exposed to UV light and is immediately resistant to intensive mechanical and chemical stresses. An ideal solution in any situation where floor maintenance or renovation work inevitably will disturb the regular activities with associated loss of income and other expenditure. Drying and curing is contained within a single process. The coating is exposed to UV light with a portable UV lamp. Instant curing and a smart working sequence means the floor coating can be applied while business continues with minimal disruption. Ian James 07818 001141 ijames@solidluxcoating.com www.solidluxcoating.com/en

Now, we stay connected in the Cloud, through satellite technology and through the integration of miniaturized components that send and receive signals communicating data and instructions to other connected devices. You can remotely turn your house lights on or off with your smartphone, learn a bit about how “fit” we are with a wristband tracking device, or wear a tiny sensor that sends biometrics data to your physician (blood pressure, heart rate, etc.). 1516 Fifth Industrial Ct., Bay Shore, NY 11706 P: 631.666.7750 or 1.800.666.0670 | info@cladmetal.com | www.cladmetal.com

Thermal Endurance Test Rig at BAE Systems Relies on Heraeus Infra-Red System Premier Coatings Ltd received a Royal Visitor last month when HRH The Duke of Kent K.G presented an official certificate and commemorative crystal bowl to recognise the company’s achievement of a 2017 Queen’s Award for Enterprise in International Trade over the past three years. A ceremony was held at the company’s Smarden, Kent, premises, where His Royal Highness was joined by HM Lord Lieutenant of Kent, Viscount De L’Isle MBE, and other guests including the Mayor of Ashford, Kent. The guests were received by Terry Capps, Premier Coatings Managing Director. A tour of offices and factory included a practical demonstration of some of Premier Coatings protective tape systems. e-mail: mail@denso.net web: www.denso.net

News & Events

Successful first year for Bilfinger Tebodin United Kingdom The UK office of global consulting and engineering firm, Tebodin, part of Bilfinger, has celebrated their first year of operations with new projects within the industrial and food sectors which will pave the way for further expansion in 2018. Ian Dunkley, Managing Director of Bilfinger Tebodin United Kingdom, who was appointed in December 2016 commented, ’It’s been a fantastic year for us with a ten-fold increase in staff numbers, a move to a new office in Warrington and an increasing order book that bodes well for next year when we plan to open a North East England office on Teesside.’ www.tebodin.bilfinger.com

Riley Gear Between the two fully equipped locations, Riley Gear has about 75 employees and operates over 95,000 combined square feet of manufacturing space, providing design consulting and engineering services to AGMA specification; reverse engineering; and prototype to production and production automation support to its customers mainly in the U.S., but overseas as well. Some of our customers have been with us for 35 to 40 years or more. And Riley Gear’s quality management system provides assurance that all gears are manufactured to blueprint specifications. It is capable of producing gears from 0.25 to 50 inches in pitch diameter to AGMA Class Q15 or DIN 2 specifications. Whether it’s speed, power, noise, torque, or accuracy of motion, the team at Riley Gear works with the customers to find a solution to their gearing requirements. We can provide immediate quotations and expedited manufacturing lead times. Riley Gear prides itself on the quality www.rileygear.com

Probably the Most Environmentally Friendly Double Skin Tank Lining System in The World Fuelvac® solvent free double skin lining system provides around the clock leak detection for above and below ground storage tanks of any size, utilising Class 1 vacuum pressure monitoring. The World’s only double skin liner that uses solvent free coatings throughout the system alongside non-hazardous materials.The system has been independently tested to conform to EN13160-7:2016 by TUV NORD and has completed all testing successfully. For more information please visit: www.abfad.co.uk Email: info@abfad.co.uk Tel No: 0191 543 7166

Stainless Band Supplying to manufacturing companies worldwide, Stainless Band is a UK-based producer of stainless steel coil processed products. Quality is assured by testing, which is carried out on material in both in raw state and before leaving it’s facilities after processing, as well as multiple spot-tests throughout the production process. A £250,000 recent investment allows Stainless Band to store more raw materials, increase processing capabilities, streamline logistics and reduce its impact on the environment. A wide range of in-house processing services including slitting, shearing, coating, finishing, edge dressing and more is available, so there’s no wonder that Stainless Band are a preferred supplier to so many manufacturers worldwide. For more information on Stainless Band, please call +44 (0) 1274 566 831 or visit www.stainlessband.co.uk.

TRINAMIC Motion Control GmbH & Co KG

A milling cutter for perfect surface quality in stainless steel

TRINAMIC Motion Control announces the TMCM-1633-CANopen, a new compact 300W BLDC servo controller module with sinusoidal commutation compatible with the industry standard CANopen protocol. The TMCM-1633-CANopen is a cost-efficient module embedding advanced motor control and motion control functions, as well as PLC features. The new drive (92mm x 50mm) is equipped with a CAN interface, CANopen (CiA-402) protocol stack and Trinamic’s free TMCL-IDE. The module provides a flexible, cost-effective solution to decentralized coordinated control of BLDC or BLAC motors of up to 10A RMS continuous current at 48V supply voltage. Featuring field-oriented control using a/b/n incremental encoder signals, the BLDC servo controller allows for precise and dynamic positioning and trapezoidal ramping. The firmware supports hall sensor inputs for faster initialization.

CrazyMill Cool is a new carbide ball mill for finishing operations in titanium and superalloys. This coated end mill with four teeth is available in diameters from 1 - 8 mm for milling depth up to 5xd, each with a cutting depth of 2xd. Two more versions are available specially for medical applications (implants) with usable milling lengths of 3xd and 4x d.

Site: www.trinamic.com Email: tmc_info@trinamic.com

A unique geometry with progressive flutes enables vibration free milling. This provides excellent surface quality when milling in radius areas or cylindrical areas. Integrated cooling channels provide the cutting edges in each position continuously with coolant avoiding overheating and allowing highest cutting speeds and maximum performance. Chips are flushed out of the machining area. The result is a surface quality equal to a grinding finish. Phone. +41 91 610 40 00 info.mto@mikron.com www.mikrontool.com Issue 30 PECM

Kecol Pumping Systems Kecol Pumping Systems offers solutions to many product transfer problems – read on to find out more.

ecol ecol Pumping Pumping Systems Systems Ltd Ltd are are manufacturers manufacturers of of Air Air driven, driven, Positive Positive Displacement Displacement Piston Piston Pumps Pumps and and Priming Priming Devices Devices in in polished polished stainless stainless steel steel or or carbon carbon steel, steel, for for transferring transferring high high viscosity viscosity nonnonflowable flowable products products from from drums drums and and containers containers as as used used in in the the cosmetic, cosmetic, food, food, pharmaceutical, pharmaceutical, chemical chemical and and general general industries. industries. Products Products in in drums drums or or similar similar sized sized vessels vessels that that normally normally need need to to be be heated heated in in order order to to reduce reduce the the viscosity viscosity -- can can be be transferred transferred cold. cold. Products Products with with aa viscosity viscosity up up to to 10,000 10,000 Poise Poise can can be be transferred transferred (cold) (cold) using using the the Kecol Kecol Maxiprime Maxiprime Pump Pump and and follower follower plate plate system system and and is is also also used used to to transfer transfer pastes pastes and and products products that that stick stick to to the the inside inside of of an an open open top top drum, drum, wiping wiping the the inside inside of of the the drum drum or or vessel, vessel, eliminateliminating ing product product waste. waste. Kecol Kecol Air Air Powered Powered Drum Drum Pumps Pumps and and transfer transfer systems systems are are suitable suitable for for all all standard standard size size closed closed top top or or open open top top drums drums and and can can be be adapted adapted to to suit suit open open top top containers containers with with an an internal internal diameter diameter up up to to 1200mm. 1200mm. Non Non contact contact parts parts as as well well as as concontact tact parts parts are are available available in in polished polished stainless stainless steel, steel, clamp clamp -- type type conconstruction struction is is also also available available for for hygienic hygienic applications. applications. Typical Typical applications applications in in the the food food industry industry include include transferring transferring tomato tomato

The The inside inside of of aa standard standard 200 200 litre litre Open Open Top Top Drum Drum is is wiped wiped clean clean –– as as the the drum drum is is empemptied tied –– with with minimal minimal product product waste waste

PECM Issue 30

puree, puree, concentrated concentrated fruit fruit juice, juice, honey, honey, fruit fruit pastes, pastes, biscuit biscuit creams, creams, jams, jams, butter, butter, margarine, margarine, sweet sweet mince mince meat, meat, sausage sausage meat meat and and meat meat pie pie fillings fillings with with cooked cooked vegetables. vegetables. Applications Applications in in the the pharpharmaceutical maceutical and and cosmetic cosmetic industries industries include include transfertransferring ring mascara, mascara, petroleum petroleum jelly, jelly, face face creams, creams, base base creams, creams, magnesium magnesium hydroxide, hydroxide, alualuminium minium hydroxide, hydroxide, toothtoothpaste, paste, lip-gloss lip-gloss waxes waxes and and suntan suntan lotions. lotions.

Kecol’s Kecol’s articulated articulated pump pump systems systems

The The Kecol Kecol Follower Follower plate plate system system will will also also work work on on 200 200 litre litre Open Open Top Top Drums Drums fitted fitted with with an an aseptic aseptic bag bag –– wiping wiping the the bag bag clean clean

Applications Applications in in the the chemical chemical and and general general industries industries include include the the transfer transfer of of paints, paints, resins, resins, adhesives, adhesives, polymers, polymers, latex, latex, high high viscosity viscosity grease, grease, mastic’s mastic’s and and inks inks –– all all pumped pumped cold cold without without pre-heating pre-heating the the products. products. As As manufacturers, manufacturers, Kecol Kecol Pumping Pumping Systems Systems can can offer offer solutions solutions to to your your particular particular product product transfer transfer problem, problem, by by offering offering aa bespoke bespoke system system designed designed to to exceed exceed your your particular particular production production requirements requirements for for single single drum/vessel drum/vessel use use or or multi multi drum drum use. use.

Kecol Kecol Pumping Pumping Systems Systems Ltd Ltd Faraday Faraday Drive Drive Bridgnorth Bridgnorth Shropshire Shropshire WV15 WV15 5BJ 5BJ T: T: 01746 01746 764311 764311 E: E: sales@kecol.co.uk sales@kecol.co.uk www.kecol.co.uk 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 World’s leading pharmaceutical, cosmetic and food manufacturers. Kecol equipment is used to transfer flowable & non-flowable materials from drums, IBC’s, mixing vessels and process vessels of various shapes, sizes and designs, without heating the material. Kecol’s extensive range of equipment is designed to transfer products from triple concentrate Tomato Paste through to Petroleum Jelly and Mascara, quickly, cleanly and efficiently from standard 200 litre drums, tapered or conical drums fitted with an aseptic bag, tote bins and IBC’s. Our vast experience has shown there are never two applications the same and that’s why we also offer bespoke systems designed and manufactured to suit your specific vessels and production requirements.

System for IBC’s

System for 4 x pallet mounted drums

Trolley Mounted Vertical or Horizontal pumps

NOW ATEX APPROVED

Tel: 01746 764311

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

www.kecol.co.uk

E: info@reftrade-uk.com W: www.reftrade-uk.com ARL-1.4 14/4/14 20:38 Page 1 Process Technologies

Total Process Protection

Applied Rubber Linings Ltd Process Plant Liners

Flameless Venting

Explosion Venting

serving the Mining, Quarrying, Aggregates and Materials Handling Industries Bursting Discs

Dust Detection

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

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

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

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

Inspecting a large rubber lined pipe at Applied Rubber Linings

■

Abrasion and chemical resistant rubber linings for slurry pipes, sand washing plant, mixing tanks, conveyor chutes, cyclones, discharge buckets and dredger pipework.

Tel: 01452 381849 www.applied-rubber.co.uk

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

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

3715 - Hazardex July14 Edn.indd 33

Leaders in surface engineering Increasing the performance and life of critical components

l Shot peening l Peen forming l Thermal spray l Engineered coatings l Analytical services l Approvals: AS9100 Rev C l NADCAP l ISO 9001:2008 l FAA

www.cwst.co.uk/aerospace | eurosales@cwst.com | +44 (0) 1635 279621 100

PECM Issue 30

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.

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 Our bellows and expansion joints commercial spacecraft, and in 27/06/2014 09:53 countless other applications. are designed to absorb and reduce

PECM Issue 23

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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Product News

Unleashing a new world of possibilities - launching the FCP4 High Production Drill Grinder that can produce a completed drill in 20 seconds A new entry to the market, the High Production Drill Grinder will service the highvolume commodity drill market typically used by tradespeople and handymen. ANCA is again first to market with the FCP4 High Production Drill Grinder (FCP4). Producing drills from 0.8 to 4mm the new technology provides an exciting opportunity for drill makers, with important efficiencies and cost benefits by manufacturing a complete high speed steel drill on a single machine. From a blank piece of raw material, the FCP4 grinds the Flute, Relief and Point producing a finished drill. www.anca.com/Home

Portable Rigging Kit Moves Materials and Equipment Up to 34,000 lbs AeroGo Inc., offers a portable rigging kit to move machinery, material, and equipment up to 34,000 lbs. The compact and portable kit accommodates load configurations up to 40’ long and 34,000 lbs., and stores easily in an included waterproof wheeled case. Load placement is safely performed over nearly all flat surfaces with the use of compressed air and lightweight overlays. Satisfied customers have commented that ‘Rigging and setup are streamlined’ and ‘The system greatly reduces safety exposure.’ The kit includes four load modules and accompanying air hoses along with a flat supply hose. For more information, call (206) 575-3344 or email info@aerogo.com. Equipment can be viewed online at www.aerogo.com/products/portable-rigging-kit/.

Fiber Optics For Secure IIoT The Industrial Internet of Things (IIoT) is here. [See Fiber and the Industrial IoT]. In industrial environments, fiber-optic transmission provides outstanding network security and reliability. Transmitting monitoring and control signals over a private fiber-optic circuit protects sensitive traffic against the vulnerabilities of the public Internet. Snoopers and hackers may tap copper lines, but fiber connections cannot be tapped without breaking the circuit. Most industrial devices offer an external access port—serial RS-232/485/422, Ethernet, or GPI/O. When connecting to a fiber network you’ll need an interface converter that transforms the electrical representation of the ones and zeroes into to an optical (light) signal stream. To learn more, get the ebook: The 8 Pillars of Fiber Optic Transport http://fpx.lc/8PillarsPE

Huck® Fasteners infinite solutions Star Fasteners offer product innovation and fastener expertise! As well as stocking the standard Huck fastener range, Star have become experts in solving problems and are flexible enough to adapt to the needs of its customers. As the use of lightweight panel and materials evolves in the manufacturing industry, Star Fasteners have tailored their Huck fastener range to meet customers’ needs. The new Penta-Lok fastener and encapsulated Hucktainer® are ideally suited to this market. Star recognised a gap in the market for a mechanical blind fastener that can be quickly installed in the multiple variations of new composite panels. The Penta-Lok is a 6.4mm diameter plated steel, peel fastener which is ideally suited for use within thin materials or delicate composites.

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The Hucktainer® panel fastener has been designed specifically for joining light weight composite panels, plastic and fiberglass reinforced plywood to a wide range of materials. With this in mind Star Fasteners have brought to the market a coloured encapsulated head Hucktainer. Its increased head diameter spreads the load and helps eliminate panel crushing. Hucktainer can be encapsulated in any colour; with low order quantities and quick turnaround it is proving to be very popular. As Arconics’s largest UK Huck distributor, Star has gained a reputation as a solutions provider. Working with a broad spectrum of companies, both trade and end users. Technical knowledge, coupled with

an enthusiasm for solving customers’ challenges are what makes Star’s mix of services invaluable. The in-house powder coating service means any stock item can be coloured to meet customers’ requirements and despatched at short notice. Star also stocks associated new tools and related consumables, offering hire, repairs and servicing. It’s a unique mix that offers infinite solutions! For any more information please email sales@starfasteners.co.uk or visit www.starfasteners.co.uk

Software & Systems

Minesoft Founded in 1996 to develop databases and software solutions for the Information industry, Minesoft specializes in tools and services for retrieving, storing and distributing patent & technology information throughout the enterprise. Minesoft’s flagship product PatBase enables users, including corporations in fields such as the automotive and pharmaceutical industries, to protect their designs by checking novelty against existing patents and to solve technical dilemmas by studying patent texts, patent drawings and non-patent literature. Our Users can access and understand the most up-todate scientific research, new ideas and competitor information contained in patent documents with a range of search and display functionalities, including text and diagrams, semantic searching, translations and fullyincorporated PatBase Analytics. www.minesoft.com

Portable Rigging Kit Moves Materials and Equipment Up to 34,000 lbs

New ERP system set to revolutionise working practices for manufacturing companies

AeroGo Inc., offers a portable rigging kit to move machinery, material, and equipment up to 34,000 lbs. The compact and portable kit accommodates load configurations up to 40’ long and 34,000 lbs., and stores easily in an included waterproof wheeled case. Load placement is safely performed over nearly all flat surfaces with the use of compressed air and lightweight overlays. Satisfied customers have commented that ‘Rigging and setup are streamlined’ and ‘The system greatly reduces safety exposure.’ The kit includes four load modules and accompanying air hoses along with a flat supply hose.

A new ERP system has been launched, created specifically for manufacturing SMEs to provide them with absolute certainty over their ability to meet project delivery deadlines. KYLIE is an ERP (Enterprise Resource Planning) solution designed by manufacturers for manufacturers to enable companies to eliminate all their redundant processes and systems, increasing efficiency, reducing costs and providing them with an essential competitive edge.

For more information, call (206) 575-3344 or email info@aerogo.com. Equipment can be viewed online at www.aerogo.com/products/portable-rigging-kit/.

Unlike other ERP solutions, KYLIE can interface seamlessly with other software applications like SAGE. This means existing processes, such as payroll or purchase ordering, can easily be integrated. As a result, KYLIE can be installed with minimum disruption. For more information on KYLIE ERP or to arrange a demo, go to www.kylie-erp.co.uk, or email info@kylie-erp.co.uk or call 0845 2724100.

Issue 30 PECM

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Driving Innovation Forward Driving innovation is central to the ethos of Minesoft, a patent solutions provider for the intellectual property industry. With over 80% of the technological and scientific information available in patents inaccessible anywhere else, ignoring patents as an information source at best delays innovation and at worst, prevents it. “What we do offers a benefit to society because studying the existing patent literature helps scientists and engineers develop their best ideas,” says Ann Chapman, Minesoft Co-Founder. “Technologies of all kinds are continually driven forward. New ideas and innovative solutions to technical problems are published in patent documents every single week around the world, adding to the existing ‘State of the Art’”. Minesoft’s flagship product PatBase enables users, including corporations such as Audi and Siemens, to protect their designs by checking novelty against existing patents and to solve technical dilemmas by studying patent texts, patent drawings and non-patent literature. Our Users can access and understand the most up-to-date scientific research, new ideas and competitor information contained in patent documents with a range of search and display functionalities, including text and diagrams, semantic searching, translations and fully-incorporated PatBase Analytics. PatBase Express offers a streamlined and easy-to-use interface encouraging a wide range of Users to engage with patent information and identify opportunities for invention or licensing. Research and Development Business Units benefit from in-depth analysis of technological development in their field of expertise and identification of opportunities ripe for new product development and patenting activity. All this can be discovered and visualised using PatBase Analytics. Minesoft’s commitment to develop innovative products for the patent information market ensures organisations are empowered to explore new technologies and exploit patent literature. This commitment has resulted in Queen’s Awards for Enterprise and new product development, such as Minesoft’s version of IET INSPEC (published by the Institute of Engineering & Technology in the UK). Access over 15 million articles of peer-reviewed Engineering & Technology research literature abstracted and indexed by experts; Minesoft INSPEC ensures easy navigation with time-saving search features. Minesoft recently launched Chemical Explorer, a new text-mined resource for chemical patent searching. With over 10 million chemical names and entities disclosed in English, French, German, Chinese, Japanese and Korean. Extract patent documents quickly by drawing chemical structures or searching the text. Over the past three decades, patent filings have tripled! Sifting through a mountain of science and technology data is daunting, hence, Minesoft is proving to be an essential resource for innovative companies and universities to help harness the power of patents.

Liberate your patent research

Patent documents are the first source of intelligence about technological advancement in all fields of engineering and innovation. We have optimised PatBase Express so you can use it on your favourite mobile devices. Next time inspiration strikes weâ&#x20AC;&#x2122;ll be there for you

www.discoverpatents.net

Switches & Sensors

Process Technologies

Her Helps

DISCOVER THE KIS ADVANTAGE

The KIS Double Cantilever Advantage The unique KIS beam design allows moving or sliding of the load point with negligible effect on the output.

A fast resp Heraeus N Bromwich thermoplas The system robot cycle

High Accuracy Process Weighing For processes where liquids, powders or granules are mixed and measured.

Thermal Expansion

Vibration

Twisting Forces

blhnobel.uk@vpgsensors.com • blhnobel.com

Tel: 0208 339 7370 Fax: 0208 339 7371

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

Email: sales@blackfast.com

Dura conta manufactur was installe adhesive c aﬃxed in a of the mold coating to “tackiness” operation. problem. U little space operations

Web: www.blackfast.com

Save energy & save money! The KIS Double Cantilever Advantages Advantage 1: We start with the best gages and the best gage configuration. KIS Beam technology incorporates SR-4® foil strain gages connected as a full Wheatstone bridge that is temperature compensated and calibrated to deliver accuracy and reliability. All KIS beams are factory-calibrated for quick, easy installation and setup with no need for on-site calibration. Advantage 2: The KIS Beam’s cylindrical design enables KIS beams to be rotated within the module hardware to coincide with the exact direction of applied weight. The electro-polished stainless steel provides a nearly frictionless surface for the module yoke to slide on during periods of thermal expansion and contraction. BLH NOBEL—Your Partner All The Way As your partner from start to finish, we provide the right system for your specific needs, along with extensive technical documentation to support safe and efficient product designs, to ensure smooth installations and reliable, long-running service.

BLH Nobel www.blhnobel.com

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PECM Issue 30

Force applied directly to the

Air Dryer Technology is an independent specialist company sleeve (cutaway) over the gage providing service and after sales support on all types and makes of pocket area compressed air/gas dryer, ﬁltration and condensate management systems. The main activity is providing technical support and comprehensive packages for on-site servicing of compressed air/gas treatment equipment and desiccant air drying plant.

Air Dryer Technology also provides consultancy and equipment upgrades to increase efficiency and reduce energy costs. Retrofitting a dryer control system provides significant benefits by operating to actual site conditions, rather than original design specification. It will also confidence in equipment operation and performance.

Installing a dewpoint control system to a compressed air desiccant dryer considerably reduce operating costs, and provide eﬃcient dewpoint contr Movable beneﬁload ts include; point

• Controls Compressed Air Save Money • Monitor Dewpoint Reduce risk • Extends Service Time Maximise desiccant life • Extend Cycle Time Reduce switching valve • Constant Dryer Knowledge Increase confidence • Retrofit Design No equipment modifica • Record Performance Data Predict dryer failure Airedale House, CanalService/Technical Road | Bradford, WestSupport Yorks BD2 1AG • Installation Peace of mind Phone Number: +44 1274-782 229 | Fax Number: +44 1274782230

Tel: 0161Email: 788 blhnobel.uk@vpgsensors.com 7900 www.airdryertechnology.com

PECM Issue 21

Switches & Sensors

Switches

raeus Infra-Red Heating System in The Manufacture of Auto Glass

The Connected Factory Connect your devices and ignite productivity

Enter the connected world without leveling your factory.

From plug-and-play Ethernet switches to HMIs and visual management systems with built-in protocol conversion, our industrial automation and networking solutions will enable you to connect, monitor and control virtually anything, anywhere at any time. Visit www.redlion.net/connect and discover how to ignite productivity across your existing manufacturing environments.

ponse medium wave (FRMW) infra-red heating system from Noblelight is helping Dura Automotive Systems of Castle to ensure the reliable and precise adhesion of molded stic sealings to custom-designed, automotive glass windows. m is located in a robotic cell and integrates exactly with the e.

acted Bauromat (UK) Ltd a recognised leader in robot ring cells. Consequently, a cell featuring two Kuka robots ed to carry out the delicate operation of applying a prime coating to the quarter glass to allow a molded seal to be a subsequent operation. However to ensure ideal adhesion ded seal to the prime coating it was necessary to heat the a speciďŹ ed temperature to achieve the required cure and â&#x20AC;? before the glass is precisely over-molded in a further Infra-red was considered to provide the best solution to this 00800 54667 Toll Free takes I europe@redlion.net I www.redlion.net Unlike a warm air oven, an 733 infra-red system up very ÂŠ 2015 Red Lion Controls Inc. All Rights Reserved. e, can be precisely controlled to synchronise with the robot and is very energy-eďŹ&#x192;cient

www.heraeus-infraredsolutions.co.uk

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Red Lion Unveils Next Wave of Compact NT24k Gigabit Ethernet Industrial Switches Red Lion Controls, the global experts in communication, monitoring and control for industrial automation and networking, announced the addition of 18 new compact models to its N-TronÂŽ series NT24kâ&#x201E;˘ managed Gigabit Ethernet industrial switch platform. The new NT24k 10-to-14 port DINrail 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.

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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 temperature feedback control assures stable intensity without any fan cooling.

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The controller can be equipped with up to four individually controlled LED heads. required 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.

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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˛.

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Info.pewuk@eu.panasonic.com www.panasonic-electric-works.co.uk Issue 30 PECM

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IMBERA CRYSTALLIZES GROWTH IN CONJUNCTION WITH OPTIMAS ooling giant Imbera has reaped the benefits of a knowledgeable global fastener supply partner, by involving Optimas to strengthen and manage its complex component supply chain. During a period of over 2 years, Optimas has been able to streamline supply for Imbera's main production facility in Queretaro, Mexico, delivering tangible cost savings to the premium cooler manufacturer to aid company expansion.

For over 70 years, Imbera has been manufacturing high quality cooling units, with the business typically introducing 10 new products to market every year. A major player in the industry, Imbera exports its coolers to 45 countries worldwide. However, a complex supply chain that involved multiple vendors was complicating operations, so the business took the decision to involve fastener and supply chain experts, Optimas. With a proven history in delivering component supply solutions to a number of other

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HVAC manufacturers in the region, Optimas could demonstrate to Imbera its capacity to deliver, which allowed the new partnership to blossom. Ricardo Rodriguez, Regional Director at Optimas OE Solutions Mexico, explains: "Our dedicated service for Imbera has delivered value through total cost and efficiency savings to their operations. Our combination of increasing efficiency, reducing stock inventory, consolidating suppliers and standardizing components provides a strong framework which can adapt easily to Imbera's future growth. A relationship based on mutual trust, expertise in industry and success has been embodied by our increased involvement in further divisions of the business - a relationship that with this framework, is only set to grow."

Consolidating and strengthening supply

Originally, Imbera was ordering parts directly from a complex network of vendors, which made it difficult to

accurately track costs and efficiency across the entire supply chain. As a result, Optimas was required to consolidate the supply chain to provide Imbera with one singular point of contact regarding component supply. To gauge the requirements of Imbera, Optimas conducted joint fastener implementation meetings to understand the existing framework and areas that could be streamlined. To limit the number of individual vendors supplying to Imbera, Optimas first set about grouping as many components as possible within a reduced number of manufacturers. By this method, parts were consolidated within certain suppliers, allowing an increased efficiency of product selection, but also reduced the total cost of acquisition when ordering multiple fastener variations. The approach increased uniformity within the supply chain for Imbera, which allowed the business to more accurately measure the overall performance of its logistics framework, improving the strength of sourcing.

Tel: 52-81-2282-1400 Web: www.optimas.com Ricardo.Rodriguez@optimas.com

Reducing inventory to improve capacity

Another major concern for Imbera was centered on the additional storage space that was being allocated to hold fastener supplies from vendor deliveries. Before the involvement of Optimas, Imbera was holding between eight to twelve weeks of stock on-site at any one time. This reduced capacity at the facility, presenting a constriction on business real estate for potential expansion. However, with control over the supply chain, Optimas introduced a policy of three deliveries a week, which enabled Imbera to reduce fastener stock down to one to two weeks. This was undoubtedly aided by the proximity of an Optimas center to the Queretaro facility, which meant a reliable stream of parts and expertise was present in the locality. An integrated Vendor Managed Inventory (VMI) coupled with a Just-In-Time Replenishment system ensured Optimas could take total responsibility, fully managing components from order to point of use. Optimas strives to supply a blend of global standards delivered at local level, which couples the desirable attributes of local responsiveness with worldwide quality. Local to local service, conducted in local language and currency, ensured a

smooth supply relationship. To minimize the potential impact of implementation, Optimas carried out a full component risk assessment in conjunction with Imbera. The primary focus was to ensure the risks of downtime due to part shortages were effectively reduced - a key proviso for an OEM manufacturer.

Coolly shaping fastener policy Having achieved a uniform supply methodology, Optimas and Imbera could work in tandem to shape fastener policy. Imbera's ownership of its design and engineering facilities made it a particularly adaptable customer, as the business could amend its approach as it saw fit to accommodate changes in fastener policy. With such an open forum, Optimas and Imbera quickly found common ground to push component methodology further. Teams from Imbera and Optimas began actively standardizing component choice to boost efficiency and cost effectiveness. Instead of specifying new or expensive solutions to overcome engineering challenges, Optimas could lend expertise regarding alternative components which achieved the performance levels required at a more competitive cost point.

Actively applying this methodology also ensured that the supply chain remained consolidated, despite being required to service multiple existing and new products. The approach delivered the quality of component needed, with minimal disturbance to the logistics framework, at a reduced outlay.

Supporting growth With this shared success, Optimas now supplies over 10 million pieces annually to Imbera, with local inventory increasing and sustaining responsiveness to keep operations moving. Last year, an additional 15 items were contracted to Optimas, with Imbera now involving Optimas in additional divisions of its business to provide cost and efficiency savings across operations. With Imbera forecasting 30% growth during 2017, the strengthened supply framework and defined fastener policy developed with Optimas is a key component of sustaining this expansion effectively. Implementing uniformity and measurability has delivered the scalability that Imbera requires for the future.

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Valves & Flow Control

Bee Valve Offers Hard-to-Find PVDF Cam Couplers/Adapters

Actuated Solutions offers widest range of APL Switchboxes on market

Bee Valve Inc. manufactures a complete line of hard-to-find PVDF cam couplers/ adapters. This material is partially applicable where ultra-high purity or UL94-VO listing is required. PVDF is chemical resistant halogens and strong acids, even at higher temperatures. PVDF couplers/adapters are the preferred choice for corrosive chemical, ozone and high radiation applications.

One of the UK’s leading valve automation providers, Actuated Solutions, is announcing it now offers the widest range of genuine APL switchboxes on the market, and has even more product developments in the pipeline. With six different APL switchboxes currently available - starting with the very competitive aluminium bodied APL2 and extending to the new high specification, ATEX approved APL7 Explosion Proof switchbox with integral solenoid valve - Actuated Solutions continues to offer the market a one-stop-shop for all valve automation projects; whatever the level of complexity.

Bee Valve couplers and adapters are available in sizes from 1⁄4 in. to 3 in. All couplers feature stainless steel handles and pins. EPDM gaskets are standard, Buna-N and Viton are also available. All Bee Valve couplers and adaptors are interchangeable with other military spec couplers and adaptors.

www.actuated-solutions.co.uk/

www.beevalve.com

Plast-O-Matic Plast-O-Matic provides a complete line of standard and custom designed thermoplastic valves and controls for difficult chemical and ultrapure applications. The ISO 9001 registered company offers an extensive line of manual, actuated, and automatic valves including actuated ball valves, energy-saving solenoid valves, and the highest performance pressure regulating and reducing valves in the industry. Superior True Blue valves are designed for Semiconductor Fabrication, Chemical Processing, Water & Wastewater Treatment, Mining, Metal Finishing, PC Board Fabrication, Commercial Laundry, Pulp & Paper, Battery Manufacturing, Petroleum & Alternative Energy, Laboratory, Medical, Food & Beverage industries – virtually any demanding application that requires corrosion resistant or ultrapure processing. Product certifications include CSA, NSF, CE Mark, UL, and EU RoHS.

WESTINGHOUSE Servicing & Repairs of Rotary Valves and Diverter Valves Free of charge assessment by a DMN engineer Genuine spare parts used to the original manufacturer’s specification Comprehensive 12 month warranty with continued support with all refurbished DMN valves Refurbishment service by the original manufacturer ATEX certification and validation services

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

www.dmn-shop.co.uk

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COMPONENTS FOR BULK SOLIDS HANDLING

www.plastomatic.com

Valves & Flow Control

ROTARY VALVES – AIR LEAKAGE AND PERFORMANCE All rotary valves leak air (or gas) even where there is no pressure differential as even the product entering the valve displaces air into the inlet area. This is significantly increased when operating under a pressure differential due to losses past the operational clearances and carry-over of pockets of high pressure decompressing into the inlet. The total of such losses are normally referred to as ‘leakage’ and given a single quantity value. There are many factors that affect the rate of leakage and the ratio of the elements that make up the total. All are affected by the system conditions prevailing at any given time. In practical terms most manufacturers only offer leakage charts based on tests measuring leakage past valves in a static, product-free condition. Because the presence of product has a mitigating effect on leakage, known as the ‘Blocking Factor’, the manufacturer’s published rates are seen as having adequate contingency for providing allowances

for sizing blowers, fans etc. Where leakage rates are considered critical then better analysis will be necessary, taking into all aspects of the duty conditions. What is important is that upward leakage can have a significant effect on the system performance either positively or negatively especially where the valve is operating in a flooded condition. The upward flow can reduce throughput by opposing product flow as well as aerating the product and reducing its bulk density. Allowance for this must be made when sizing the Rotary Valve. This is progressively less of a problem as valve sizes increase as the larger throat sizes make for better dispersion of leakage air. Valves should also be fitted direct to the outlet of any hopper so that leakage air can disperse easily. This is less of a

problem when the valve is not controlling the throughput but care needs to be taken if the conditions could result in flood feeding at any time. For more details on air leakage, contact Gericke RotaVal + 44 1249 651138 sales@rotaval.co.uk www.rotaval.co.uk

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DIXON –THE RIGHT CONNECTION FOR HYGIENIC HOSE, VALVES & FITTINGS ixon, leading supplier of hoses, fittings, valves and accessories offers an extensive range of hygienic process equipment for the food, dairy, beverage and brewery industries including FDA and 3A approved stainless steel fittings, unions, tube, pumps, hose assemblies and valves.

Dixon’s extensive hygienic hose range offering odourless and taste free properties suitable for liquid foodstuffs now includes Heat Traced, Hot Water Thermal and Duplex hose assemblies as part of the standard range along with a range of rubber, silicone, PVC and PTFE hose assemblies which can be custom made to exact requirements with accessories including wash down guns and steam lances.

The newest addition to the range is the impact resistant compact sight glass used widely in the food, dairy and beverage hygienic processes to view products and fluids. This design is perfect for hoses and high traffic areas. With an on-site valve actuation shop, 3D design, full technical and sales back-up and BSI approved manufacturing and engineering department, Dixon can design and produce individual bespoke valves, hose assemblies and fabricated configurations to quickly and efficiently solve customer problems. This has included pump carts, bespoke valve configurations and innovative display sight glasses used on beer pumps to infuse product.

As part of their portfolio Dixon now offer a hose management programme designed to help make your facilities as safe, efficient and productive as possible. Experienced Dixon hose personnel will perform a survey to register and assess hoses on site and make recommendations. Dixon Hose-Connect is a secure, user friendly web based app. It is a source to allow you to access your Hose Maintenance documentation, including Service History reports, Hose Asset Register via unique tag references and hose identifiers, as well as training videos for your site. Talk to Dixon today to find out more about Hose-Connect or finding ‘The Right Connection’

Dixon Group Europe Ltd T: +44 (0) 1772 323529

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E: sales@dixoneurope.co.uk

Your Right Connection For Hygienic Process Systems Dixonâ&#x20AC;&#x2122;s extensive hygienic and pharmaceutical range of products includes: fittings, tubing, hygienic unions, manual and automated valves, pumps, hose assemblies and a range of accessories.

Mixproof Valves

Sample Valves

Fittings & Tubing

Seat & Process Valves

Fabrications

Pumps

Dixon offers a full range of FDA approved hose and hose assemblies offering odourless and taste free properties suitable for the transfer of liquid foodstuffs.

Food Grade Rubber

Silicone

PTFE

Dixon Group Europe Limited Tel: +44 (0)1772 323529 Email: sales@dixoneurope.co.uk www.dixoneurope.co.uk

Valves & Flow Control

• 3D Scanning • Reverse Engineering • Inspection Specialists • 3D Printing • Large Volume Scanning

Flow Control Signal 4.0 Analogue transmitter for remote monitoring & control • Signal 4.0 Analogue transmitter makes flow indication possible via 4-20mA (or 0-10V) output signal • Flow Switches, monitors, indictors + Signal 4.0. Compatible with any float-type sensor within the range. • Retrofit possible on existing units or supplied combined on new units • Signal 4.0 is compact, reliable and its operation is independent of flow media

01895 200015 sales@tamo.co.uk www.tamo.co.uk 22 Sarum Complex, Salisbury Road, Uxbridge, Middlesex. UB8 2RZ

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BAROMETRIC

HYDRAULIC

PNEUMATIC

Pressure Measurement Standard and Custom Transducers

DIFFERENTIAL

CLEANIN-PLACE

DEPTH

At OMEGA, we can provide customised solutions or standard products for all of your pressure needs. To learn more visit omega.co.uk/pressure or email sales@omega.co.uk

Surge protection in thin slices The 3.5 mm solution for MCR applications TERMITRAB complete is the world’s narrowest surge protection for MCR technology. The new product range provides you with a complete system kit, featuring a status indicator and optional remote signaling. The narrowest protective devices are only 3.5 mm wide.

For additional information call +49 52 35 3-00 or visit phoenixcontact.com