Process Engineering Control & Manufacturing Issue 37 2019

Engineering Process

Control &

MANUFACTURING

PECM

Global Success Through Innovation Issue 37 2019 £3.95 www.pecm.co.uk

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Engineering Process

Sections Editors Choice Hannover Messe Show Preview ChemUK Show Preview Automotive Engineering Boilers & Maintenance Control & Automation Electrical & Electronics Facilities Management Fasteners & Fixings Fluid Handling Gears, Drives & Motors Health & Safety Hydraulics & Pneumatics Machining & Machinery Measurement & Monitoring News & Events Process Technologies Product News Software & Systems Training & Recruitment Valves & Flow Control

MANUFACTURING

Control &

Inside...

Inside Issue 37 8 52 56 60 67 72 84 100 102 107 112 120 130 133 148 162 167 173 178 184 192

BRITISH MANUFACTURING IN 2019: PREPARING FOR UNCERTAINTY Increasing digitalisation, the growing skills shortage and the uncertainty of Brexit — British manufacturing has a lot to contend with.

AUTOMATING THE WORLD’S FIRST FULL-SCALE LIQUID AIR ENERGY STORAGE FACILITY An environmentally neutral, gridscale energy storage system that utilises electrical energy to liquefy the air around us, store it, then expand it back through a generator to feed power into the grid - may sound a bit like tomorrow’s world.

UPSKILL ENGINEERS AND SUPPORT APPRENTICESHIPS, URGES NEW REPORT INTO ENGINEERING SKILLS A shake-up in UK engineering education is needed to address the current skills gap and shortage of engineers, a new report revealed today.

STARS CELEBRATED AT MANUFACTURING NATIONAL AWARD CEREMONY Leading manufacturers and talented apprentices from across the UK were recognised as national manufacturing champions at the EEF Future Manufacturing Awards held in London.

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Issue 37 PECM

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New benchmark in thermal flow measurement The The latest latest SA SA flow flow meter meter from from ifm ifm electronic electronic for for liquids liquids and and gases gases also also measures measures temperature. temperature.

Fast Fast response. response. Easily Easily readable readable LED LED display display can can be be set set to to change change between between red red and and green green and and the the whole whole unit unit can can be be rotated. rotated. Calibrated Calibrated for for water, water, oils oils and and air. air.

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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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EDITOR’S CHOICE

QUALITY CG PRODUCTS DOSCH DESIGN

YOUR INNOVATIVE PARTNER FOR A SUCCESSFUL 3D-EXPERIENCE

Since 1995 DOSCH DESIGN has been a fixture in quality CG products by staying on the cutting edge in 3D-design, animation, architectural visualizations, print publishing, motion design, etc. With its well-diversified product range DOSCH DESIGN supports CG artists in various fields in their daily work.

Especially in the field of Mechanical Engineering, tool making or the automotive industry, 3D-Design has become an indispensable element. Photography can afford incredible, but it also has its limits. This is not least known in mechanical engineering, where custom-made products and often also very large objects are commonplace.

In addition, machines are usually moved in assembly halls, which are not suitable as an environment for good photographs. That’s why many companies choose 3D-Design to perfectly showcase their products and services.

DOSCH DESIGN has developed a lot of helpful visualization tools that make life easier for designers and have become an integral part of many users’ creative arsenal. The company places great importance on depicting 3D models realistically - no matter whether

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PECM Issue 37

these relate to manufacturing, engineering, vehicles, buildings, industry, medicine, nature or garden, to name but just a few. However, DOSCH DESIGN don’t just leaves it at the mere creation of an individual object; instead, they pay great attention to the many little details around the product. For instance, car models include detailed depictions of brakes, wheels, bumpers, bodywork, doors, seats and the electronics. These details are

an important part of marketing for supply companies, developers and manufacturers who want to visualize processes for publications, animations, illustrations or instruction manuals.

DOSCH DESIGNs extensive product range with everything designers need to create the best looking visualizations is divided into the following categories:

DOSCH 3D offers completely textured 3D-models or 3D-scenes for all popular 3D-applications.

Users can select from over 100 products in different areas, like environments, nature, factory and production, product and industrial design, furniture, people or vehicles, to mention just a small selection. Professional users like automotive designers, architects or CG artists value the detailed and realistic 3D-models, which are great time and cost savers.

DOSCH TEXTURES Seamlessly tileable multi-layer textures for 3D-design, animation, CAD or print applications. Each product provides around 100 depictions which can be applied to 3D models in order to lend them an individual appearance. The textures can readily be used for 3D-visualization, animations, and for all kinds of computer graphics and web-design uses.

DOSCH HDRI Allow users to incorporate highly realistic, complex and stunning lighting in their 3D-scenes.

Perfect shadow casting and reflections create new dimensions of realism in any rendering.

All HDRI products allow CG users to bring 3D-objects to life by instilling their own style.

DOSCH VIZ-IMAGES contain perfect 2D-“cutouts” of people, cars, road elements, etc. Loading DVIs into Photoshop is a breeze, and direct use in 3D-scenes is possible through included planar 3D model. DOSCH DESIGN’s VizImages are compatible with most 2D- and 3D-applications, and the Alpha-Channel provided for each image makes them blend in neatly with just about any background scene.

DOSCH AUDIO support your motion design professionally with quality royalty-free music & sound

effects. These loopable audio effects are optimized for the use in advertising, TV-documentaries or trailers, business presentations and as dynamic background music to all types of video-clips, Including full-fledged TV & movie scenes.

FEATURES & BENEFITS DOSCH DESIGN Products • are regularly useable “license-free”, which means no further cost or fees are due when used commercially • are compatible with all popular 3D programs • are tremendous time-savers and productivity boosters • are available at an attractive price, and user benefit further through quantity discounts, as well as through money savings by purchasing special pre-set or custom collections • are supported by the company through free tutorials and samples, which can be downloaded easily at www. doschdesign.com/samples.zip Especially for Process Engineering Control & Manufacturing readers we provide an exclusive 10% discount on all products.

Please add the code pecm2019 at your order form to receive your discount!

Dosch Design Kommunikationsagentur GmbH Kirchgasse 1 97828 Marktheidenfeld Germany Tel: 0049 9391 50 70 90 0 info@doschdesign.com www.doschdesign.com Issue 37 PECM

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EDITOR’S CHOICE

THE RIGHT CONNECTION DIXON

A FULL HYGIENIC OFFER FROM DIXON Dixon offers the right connection for your hygienic process; from stainless steel hygienic fittings and adapters to food/ beverage standard hose assemblies and actuated valves to the food, dairy, beverage, brewery, cosmetic, chemical and pharmaceutical industries.

Over the last 30 years Dixon has significantly extended its range of Valves, Fittings and Couplings for the Hygienic markets through product development and acquisition.

Of particular note is Dixon’s range of high quality process valves which include ball, butterfly, diaphragm, seat, sample, and mix-proof valves which can be actuated to customer specifications and fitted with a range of stocked accessories that includes limit switches, solenoids and positioners.

The Dixon Breakaway Check Valve is an innovative solution that is designed to eliminate product loss too. It incorporates the Breakaway Coupling and a Hygienic Check Valve. It acts as a single unit that has a diverted breaking point which will break at a determined break-load. Then the check valve will close protecting the loading bay pipe system and avoiding product spillage.

The new compact sight glass launched in 2018 is used widely in food, dairy and beverage hygienic processes to view

products and fluids. This design is perfect for hoses and high traffic areas due to its Lexan™ glass and a stainless steel body construction. Ideal for arduous applications, heavy manual handling, high traffic and high activity areas to provide site added protection and asset security.

The sight glass is available as one of the many hygienic hose fittings

complementary to Dixon’s extensive hygienic hose range which 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.

Here in the UK, Dixon offers, specialised support and bespoke engineered solutions from concept, to design, through to installation. Dixon’s onsite manufacturing and engineering department means that new designs, animations and 3D modelling can rapidly be produced to support customer’s requirements. This has included pump carts, bespoke valve configurations and innovative display sight glasses used on beer pumps to infuse product.

Contact Dixon with your requirements today and find the right connection.

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

W: www.dixoneurope.co.uk E: sales@dixoneurope.co.uk

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PECM Issue 37

Your Right Connection For Hygienic Process Systems Dixon’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

EDITOR’S CHOICE

CABLE INNOVATION HEATSENSE CABLES

HIGH TEMPERATURE CABLE MANUFACTURING TECHNOLOGY REACHES A NEW LEVEL ABOUT HEATSENSE Established in 1984 by two engineers from Fothergill & Harvey in Lancashire, Heatsense has steadily built its reputation and is today regarded by many as the UK’s leading specialist manufacturer and supplier of thermocouple cables and extension wires. Many original customers continue to do business with Heatsense and a number of its original employees still work for the company.

CAPABILITIES Heatsense’s manufacturing capabilities cover a broad range of specialist high-performance thermocouple and signal cables that operate in extreme environments. The company is regarded as a technology leader in fluoropolymer extrusion.

The company manufactures thermocouple cables and extensions wires, equipment wires, coaxial cables, multicore cables, micro cables and fine wires.

Insulation materials include PFA, FEP, PTFE, ETFE, PEEK, EFGLAS, PE, PU, PVC, Taped & Sintered PTFE, Mica, Silicone, Polyimide & Aramid Yarns. Braiding materials include glass & ceramic fibres, other specialist yarns and various metals.

These cables are resistant to flame, oils, chemicals and operate in ultra-high vacuum, cryogenic, radiation and nuclear environments. The company offers a range of approvals that meet all internationallyrecognised specifications.

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PECM Issue 37

Markets include automotive, aerospace, nuclear, medical, general industry and oil & gas.

Highly customer focused, Heatsense offers a bespoke advanced technical design and manufacturing service, rapid response times, short lead times, low MOQ’s and competitive pricing.

Current management acquired the business in 2014, relocated it to Greater Manchester and made significant investment in plant and equipment, broadening the company’s manufacturing capabilities. Throughout 2018, the company saw significant growth; acquiring new equipment and significantly expanding its workforce.

Heatsense has achieved both ISO9001:2015 and ISO14001:2015 Accreditations since 2014 and is currently working closely with the NAMRC (Nuclear Advanced Manufacturing Research Centre) on the F4N (Fit for Nuclear) Approval Scheme.

The company is also working towards AS9100:2016 and aims to be accredited in 2019.

Call: (+44) 01706 767070 www.heatsensecables.co.uk

The UK’s leading specialist high-performance cable manufacturer We’re a technology leader in high-temperature fluoropolymer extrusion and material used in the manufacture of specialist high-performance cables that operate in extreme environments

INSULATION EXPERTS PFA, FEP, PTFE, ETFE, PEEK, EFGLAS, PE, PU, PVC, Silicone, Taped & Sintered PTFE, Polyimide, Aramid Yarns, Mica, Glass & Ceramic Fibre

MARKET SPECIALISTS

Automotive

Aerospace

Nuclear

Medical

Industrial

Research

PARTNERSHIP BUILDERS Advanced technical design & bespoke manufacturing service • Rapid response times • Short lead times • Based in the UK

• Service international partners • Competitive pricing • Low MOQ’s

*Registered *Registered owner owner of of the the world-renowned world-renowned INTEMP INTEMP trademark trademark

Find us online: heatsensecables.co.uk or call: (+44) 01706 767070

EDITOR’S CHOICE

UNIQUE VERSATILITY LOBO SYSTEMS

APPLICATION - JET ENGINE MAINTENANCE

THE PROBLEM:

Aviation jet engine maintenance requires engineers to stand at many heights and positions to provide MRO. Many steel and aluminium structures have fixed height and widths and cannot be made wider or narrower without major rework.

They have to be custom made for each project and are cumbersome and difficult to transport. Typically, they become redundant when the project comes to an end or if work at a different height is needed and can take up valuable hangar space.

THE SOLUTION:

LOBO Systems’ safe and secure platform product. The unique and patented clamp allows the system to be assembled without the use of tools into any size or shape.

Therefore, a solution can be provided to all jet engine types.

Aviation MRO engineers can reconfigure the system, adapting it from one project to another with ease, without the need for any tools from flat pack or from a LOBO Towerstore.

By fitting a wheel kit, the system can be transported throughout the hangar. The system can be assembled, disassembled and reassembled quickly, is easy to flat pack and is transportable.

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THE BENEFITS:

The unique versatility of the LOBO System brings cost and waste reduction and enhanced efficiency & performance, together with a safer working environment.

Its transportability means it can be used anywhere in the world and erected by anyone. This means aviation mechanics can erect the system to their exact requirements whenever and wherever needed, thus saving on labour costs. The LOBO System creates a safe

working environment, which increases productivity, reduces cost and maximises the return on investment.

Please contact us on one of the below methods: UK & Europe and Rest of World: + 44 (0)1332 365666.

North America: 1-800-640-5492.

Email: sales@lobosystems.com

Seeing is believing An aluminium tower can only do this:

But one LOBO System can….

…can do this:

….or this

….and much much more……

No Tools | Quick Assembly | Safe | Any Shape or Size | Flat Packs www.lobosystems.com

Conformities EU: BS EN1004:2004 BS 1139 parts 3 & 4, USA: OSHA Compliant, ANSI A10.8, 29 CFR Part 1920 (General Industry) Canada: CSA Z797-09 and 269.2 (M87 and -16) Australia: AS/NZS 1576.1:2010 and AS/NZS 1576.3:2015 Tower

EDITOR’S CHOICE

PREPARING FOR UNCERTAINTY COPA DATA

BRITISH MANUFACTURING IN 2019 Increasing digitalisation, the growing skills shortage and the uncertainty of Brexit — British manufacturing has a lot to contend with. Despite this, the United Kingdom is predicted to break back into the top five manufacturing nations by 2021. Here, Martyn Williams, managing director at COPA-DATA UK, examines how manufacturers can withstand this growing uncertainty and prepare for the future.

Contrary to widespread sentiment, British manufacturing is thriving. According to statistics by the EEF, the sector employs 2.6 million people, accounts for 44 per cent of exports and provides 13 per cent of all business investment. However, that’s not to say the industry is completely home and dry. Amidst upcoming political turbulence, manufacturers need to prepare.

INVEST IN TECHNOLOGY Manufacturers should plan for the worstcase Brexit scenario, but this could create challenges regarding current business models. We’ve all heard about the importance of adopting new technologies, but this could become more difficult without the ease of open supply chains. That said, manufacturers cannot stagnate.

Investments in new technology should only be made once manufacturers have identified the top pains in their facilities.

Frankly, these problems will exist regardless of whether Brexit occurs or not. For example, a manufacturer may find excess energy consumption is its biggest outlie, meaning implementing technology to reduce this wastage would be the best use of investment.

Industrial software with predictive maintenance, for instance, can provide original equipment manufacturers (OEMs) with opportunities to monetize their service revenues. Let’s say a manufacturer of automated conveyors has implemented this software onto its machines. Using predictive analytics to monitor the typical lifecycle of a conveyor, the OEM can predict when the equipment is likely to require maintenance and take action to prolong its lifespan.

That said, identifying the best solution isn’t always simple. There has been a tirade of new technology on the market, much of which is veiled in technological jargon, sometimes making it difficult to comprehend. Rather than choosing the newest technology on the market, manufacturers must do their research, examine case studies and ensure they choose a reputable supplier before making investments.

Using this data-backed knowledge, the manufacturer can offer a servitised version of the product, thus generating more income. As well as growing revenue streams, adopting service models allows manufacturers to foster business with existing customers. Greater customer retention could become invaluable, depending on the volatile political circumstances occurring outside of the factory walls.

ADOPT NEW SERVICE MODELS Deploying technology is an ideal way to manage pain points in manufacturing.

However, technology can also boost profits by enabling new service models. This is particularly pertinent for investments in software platforms that can be integrated with the cloud.

INVEST IN SKILLS Inside the factory, Brexit’s potential change to free movement will have an impact on recruitment and skills. That said, the bigger challenge remains the same— the sector simply doesn’t entice enough young talent. There’s a requirement for a massive expansion of schemes and initiatives to

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encourage people to join the industry, but that’s a challenge for the Government.

During the upcoming period of uncertainty, manufacturers should take responsibility to invest and upskill their existing staff. This is particularly important as organisations invest in digital technologies to automate processes.

Staff want to be certain that their skills remain valued, even in an increasingly automated environment. Inherently, employees want to be proud of what they do and pursue work which is meaningful. Lack of investment in this area will result in lost staff. During the ambiguity of Brexit, this risk isn’t worth the drain on time, resources and finances that recruiting new staff, and subsequently training them, will require.

Britain’s manufacturing outlook may not be as gloomy as some reports may suggest.

However, the sector should be preparing itself for a turbulent twelve-months ahead. Looking forward to 2019, manufacturers should continue pursuing their digitalisation goals, but must put a clear focus on investing in the right technology, creating business models for growth and importantly, maintaining and upskilling their valuable workforces. www.copadata.com

Safe Isolation saves lives Stay safe, prove dead and lock off with Martindale VIPDLOK kits

The simple solution to safe maintenance • Essential for compliance with Electricity at Work Regulations for safe working

• New VI-15000 Voltage Indicator, CATIV 1000V for all installations categories

• Includes industry leading voltage indicator, proving unit, locking off devices and tags

• Safe because it’s simple, no batteries, no ranges, no switches

Now available NEW VIPDLOKPRO Get the right locking off device every time with Martindale PRO Kits

Available from your wholesaler and online www.martindale-electric.co.uk Call: 01923 441717 email: sales@martindale-electric.co.uk

EDITOR’S CHOICE

STAINLESS STEEL SPECIALISTS AXIUM PROCESS LTD

316L STAINLESS STEEL FILTERS THAT ARE ROBUST, RELIABLE, SIMPLE AND EASY TO MAINTAIN Axium Process manufactures a comprehensive range of 316L stainless steel filters which can be fabricated to customer requirements, are of a robust construction and are easy and simple to maintain.

• • • • • • • •

Filtration range from 5 micron up to 8000 micron as standard 90° and In-line options Stainless steel Wedge Wire, Sintered Mesh and Perforated filter elements Standard and Compact options End connections to suit customer requirements Flow direction out-to-in or in-to-out Easy maintenance – no tools required for cleaning or access Suitable for backflushing, CIP (clean-inplace) and SIP (steam-in-place)

FILTER CHOICE: Selecting the right filter for an application can often be confusing but Axium’s engineers work closely with their customers helping them select the appropriate filter taking into account the type of media, particulate holding capacity, product viscosity, temperature, filtration level, flow rate, pressure requirements and seal material.

CUSTOM FILTERS: Filters can be customised to suit specific site or process requirements for applications ranging from pump and instrument protection to critical applications where filter failure or collapse is not an option.

FILTER CERTIFICATION: Axium Process’ stainless steel filters are manufactured in accordance with ASME-BPE principles and have material traceability to BS EN 10204 (3.1). Because the company operates across a wide range of industries including pharmaceutical and biotech where traceability is paramount, it can provide a full traceability dossier which can include: • • • • • • • •

Material Certification Ferroxyl Test Weld Procedures Pressure Test Weld Map and Logs Passivation Internal and External Surface Roughness TSE Certification

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PECM Issue 37

COMPREHENSIVE STAINLESS STEEL FILTER RANGE: Fine-Screen Sintered Mesh Filter Range (5 micron up to 200 micron) Designed for fine particulate applications such as those associated with water, pharmaceutical, food, beverage and chemical industries.

Pure-Screen Wedge Wire Filter Range (25 micron up to 6000 micron) Designed for applications where the highest quality has been specified, where filter failure or collapse is not an option or where product smoothness and consistency is essential such as creams, emulsions, yoghurts, soft cheese and paints.

AXIUM PROCESS LTD ONE COMPANY ONE SOURCE Specialising in bespoke, hygienic engineering design and customised stainless steel fabrication, Axium Process provides technical expertise and engineering solutions that offer the best possible value for money • • •

Hygienic pipework, skids, frames and system fabrication High specification pressure vessels & CIP skids Jacketed, duplex, triplex, multiplex filter systems Component customisation Process components, tube and pipe fittings

EconPLUS Perforated Filter Range (2000 micron up to 8000 micron)

• •

Ideal for pump and instrument protection providing essential security for a wide variety of process applications

axiumprocess.com

CUSTOMISED FILTER OPTIONS INCLUDE: Jacketed, Stand-alone complete with framework, duplex, triplex, multiplex options.

NEW EconPLUS Perforated Stainless Steel Filter Range – designed with simplicity yet security in mind A low-cost solution for process systems, pumps and equipment protection, providing essential security for a wide variety of process applications • • • • • • • •

Ideal for pump and instrument protection Robust and versatile security for many applications Cost effective, high quality, dependable design Precision machined components Mechanical clearance seal, no ‘O’ ring to replace or fail 4” body ensures maximum screen surface area No loose parts, manufactured as a two piece construction No tools required for element extraction

axiumprocess.com • +44 (0) 1792 883 882 • info@axiumprocess.com Issue 37 PECM 19

EDITOR’S CHOICE

Pryor Marking UK designed and manufactured Dot Peen, Scribe and Laser Marking Systems: • Serial Number Marking • Data Matrix Codes • Direct Part Marking • Component Traceability • Label Engraving • VIN Plate Marking • CE Marking As a key partner to the world’s best known automotive, aerospace and manufacturing brands, Pryor has the expertise and local support to help companies of all sizes integrate permanent part identification technologies.

100% UK designed and manufactured www.pryormarking.com

New bellows seal valve range for medium pressure The versatile bellows sealed globe valve range, FABA, has the new addition of the FABA Supra MD – now offering the process industry a stop valve with bellows seal suitable for medium pressures from PN 63 to 160.

Durable and failsafe, the reinforced bellows seal allows for up to 10,000 cycles. This model is reliably tight, even at higher pressures, proven by its leakage rate “A” tested in accordance with DIN EN. Available in cast steel, forged steel and heat resistant steal with nominal diameters of DN 10 to 100 and pressures from PN 63 to 160, the FABA Supra MD is offered with flange or butt weld end connection types.

For more information contact ARI-Armaturen UK Ltd E: enquiries@uk.ari-armaturen.com T: 01684 275 752 W: www.ari-armaturen.com

BABCOCK WANSON LAUNCHES ENERGY EFFICIENT OPTIMO 2 BURNERS WITH EXCEPTIONALLY LOW EMISSIONS Following a substantial research project with the aim of reducing exhaust gas emissions and improving the energy efficiency of burners, Babcock Wanson is pleased to announce the first of its new burners borne of this project: Optimo 2.

Optimo 2 is designed as a fully configurable stand alone burner for medium size firetube Steam Boilers ranging from 2 to 4t/h output.

Optimo 2 burners are available from 1500 to 3500kW output for new Steam Boilers and also as a retrofit solution to upgrade existing boilers to meet enhanced emission requirements.

For more information, please contact Babcock Wanson on 020 8953 7111 or info@babcock-wanson.co.uk or go to www.babcock-wanson.co.uk

Leaders in bespoke calibration & test systems 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

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PECM Issue 37

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As As aa customer customer of of Knight Knight Optical, Optical, you you will will benefit benefit from from exceptional exceptional commitment commitment to to quality quality in in all all respects. respects.

Your Your individual individual specifications specifications are are vitally vitally important important to to us, us, which which is is precisely precisely why why pre-despatch pre-despatch testing testing is is rigorous rigorous to to the the highest highest degree. degree. Our Our onsite onsite quality quality assurance assurance and and metrology metrology departments departments take take personal personal responsibility responsibility for for ensuring ensuring each each and and every every component component that that leaves leaves our our premises premises does does so so in in strict strict accordance accordance with with customer customer requirements. requirements.

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EDITOR’S CHOICE

FOREFRONT OF INNOVATION IDEM SAFETY SWITCHES

SKORPION TRAPPED KEY INTERLOCKING WITH KEY EXCHANGE Established in the United Kingdom in 2003 IDEM Safety Switches are the UK’s largest machine safety switch manufacturer.

Continually at the forefront of innovation within this market and in providing the “Next Generation” of machine safety IDEM developed and introduced the SKORPION Trapped Key Interlocking with Key Exchange system in 2016.

Designed and manufactured in the United Kingdom, SKORPION has been developed to provide extremely robust mechanical coded key safeguarding and interlocking for hazardous machinery. All components of the system are available in Stainless Steel 316 or mirror polished die cast metal options.

The system works on the principle of releasing coded mechanical keys in a predetermined sequence to ensure machine power is isolated before any access can be gained to hazardous or dangerous machinery.

After the machine control has been isolated (first key turned in the system) the key from the isolator can then be used to release other trapped keys to enable access to the guarded areas.

After release of the first key (power isolation) safeguarding can be achieved without the need for electrical wiring, this makes the system ideal for use in harsh environments.

OPERATING PRINCIPLE

A trapped-key guarding system relies upon the transfer of keys between a power isolation switch (or control switch) and a locking mechanism fixed on a guard.

The essential feature of the system is that a removable key is trapped either in the guard lock, or in the power isolation switch.

The interlock on the guard is arranged so that the key is trapped and can be released only when the guard has been closed and locked.

This allows transfer of the key from the guard to the power isolation switch.

Closing the switch traps the key, so that it cannot be removed while the isolator switch is in the ON position.

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PECM Issue 37

If there is more than one interlock then a keyexchange block is necessary, to which all keys have to be transferred and locked in before the access key, which is of a different coding, can be released for transfer to the other guard interlocks.

Where there is more than one access guard, the key exchange block will accommodate an equivalent number of access keys.

Where a number of operations have to be carried out in a pre-determined sequence, then the transferable key is locked in and exchanged for a different one at each stage.

Please see the example for a visual explanation.

The SKORPION system offers the end user a wide range of system components and an infinite number of key codes to create their own bespoke system.

• Until the isolator key is returned to its original position within the lock, there is no way to enable the machinery to be restarted.

Recent product introductions have expanded the system and now include the MX Key Exchange, more isolation options including solenoid control isolation switches and solenoid release interlocks with options for rear release escape.

IDEM Safety Switches are based in the North West of England and our machine safety switches which receive international recognition are shipped globally from the UK and from our USA base which services the North American market.

SKORPION can provide the end user with the solution to many interlocking applications where typical solutions are not available or create a configuration headache.

With huge investment in R&D and innovation we utilise the latest technologies to bring new switches to the safety market.

SKORPION is part of an extensive range of machine safety switches and IDEM’s Stainless Steel 316 switches are IP69K rated and cope easily with high pressure, high temperature wash downs making them perfect for the

ADVANTAGES

• No reduction of integrity due to the distance between movable guard and control system.

• High mechanical integrity, robust fixings and holdings suitable for all types of guards.

• Eliminates the need for electrical wiring to each movable guard.

• Available in Stainless Steel 316 - making it suitable when the movable guard is placed in harsh or hostile environments.

• Suitable for CIP and SIP cleaning processes and can be high pressure hosed with detergents at high temperatures.

• Can be used where the movable guard requires to be removed completely.

• All keys are coded in the factory and it is virtually impossible to override the system.

• A trapped key system provides a quick yet safe and reliable access to machinery.

• Use of a trapped key system can also prevent shortcuts and enforce a logical set of procedures that need to be satisfied.

rigorous demands of the food, beverage and pharmaceutical industries.

We are proud to manufacture in the United Kingdom and ensuring the safety of your personnel is important to us, you can be secure in the knowledge that every single IDEM product is manufactured, tested and approved to the latest safety standards.

For more information on the full range of IDEM machine safety switches please visit www. idemsafety.com or feel free to contact us on +44 (0)1942 257070.

Issue 37 PECM

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EDITOR’S CHOICE

TOMORROW’S WORLD OPTIMAL

AUTOMATING THE WORLD’S FIRST FULLSCALE LIQUID AIR ENERGY STORAGE FACILITY An environmentally neutral, grid-scale energy storage system that utilises electrical energy to liquefy the air around us, store it, then expand it back through a generator to feed power into the grid - may sound a bit like tomorrow’s world. It is however, a very real prospect since the new 5MW Liquid Air Energy Storage (LAES) facility, designed

by Highview Power Storage will soon be operational thanks, in part to control and systems integration work from Optimal Industrial Automation.

After having built and tested a successful pilot plant (which has now been moved to University of Birmingham), Highview and project partner Viridor were awarded government funding by the Department of Energy and Climate Change (DECC) to build a pre-commercial scale 5MW Liquid Air Energy Storage technology demonstrator.

That LAES plant is now currently undergoing final commissioning in Bury Lancashire, where control panels built and supplied

by Optimal are dotted throughout the site ready to manage and synchronise each of the crucial stages of the process.

The LAES system comprises of three primary processes: a charging system, an energy store and a power recovery stage. In its commercial form, these can be scaled independently to optimise the system for different applications.

Mike Weeks, automation project engineer at Optimal describes the control architecture, ‘The entire system relies on a Siemens SIMATIC PCS 7 PLC for overall control; this manages I/O from other controllers, inverter drives, RTU units, meters and sensors.

Each of the large process items has its own unique set of control parameters, which we have connected over a Profibus network. We also connect to a GE PLC unit over Modbus communications that controls the waste gas turbo-expander, which is connected to the power generator set.

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‘From a supervisory control point of view the entire system is transparent and information is updated in near real-time whether engineers and operators are viewing the system on-site or remotely from head office in London. For many automation system integration projects, providing secure networking for control and visualisation, trending and analysis has become as important as the actual control over the electro-mechanical equipment onsite and this project is no different.

Stuart Nelmes Head of Engineering at Highview and leading the project comments, ‘The beauty of this system is that each component part of the process is built using tried and tested technology, which we know works and has established performance parameters. The design envelope and the application of some of it has been developed a little to meet our particular requirements, but it’s the way all the different processes interact which truly delivers the viability of the process.’

The funding has supported the design, build and testing of this LAES technology demonstrator on the same site as Viridor’s Pilsworth landfill gas generation plant. ‘This has proved to be a smart move for several reasons’ continues Nelmes, ‘the location was good from a planning permission point of view, but it also has a technical benefit in that we can use low-grade waste heat from the GE Jenbacher generator engines to make our gas expansion stage more efficient.

‘Expanding the liquid air, (or Nitrogen as we are using for this full-scale demonstrator project) has a refrigerating effect, so our process is more efficient if we can counteract that by using waste heat energy from combustion.

This is why conventional power stations are a good potential site for the final stage commercial installations, which is the next step for us.’

Green credentials are off the scale compared to other large-scale energy storage methods; once constructed the commercial installations will be close to environmentally

neutral, output is simply air, or in this case inert Nitrogen, which makes up 78% of the air anyway. Commercial installations are likely to be used as temporary energy banks for larger power stations, which are both slow and expensive to turn down, or turn off.

The solution would also be very effective for storing energy from renewable sources such as wind turbines when there is a grid surplus and then fed back in to the grid when demand peaks. Fast, effective peak-lopping is an extremely desirable function from an energy grid management point of view and is one reason why government funding has been provided. It is also a reason for considerable global commercial interest in the project.

The project will operate for at least 1 year and is intended to demonstrate how LAES can provide a number of electricity grid balancing services, including Short Term Operating Reserve (STOR), Triad avoidance (supporting the grid during the winter peaks) and testing for the US regulation market. Construction on the project began in February 2015 and it is expected to be operational during 2016.

Mike Weeks concludes, ‘The system is not massively complex, the main challenge we have is that it is a development project and by its nature some of the fine details of how best to realise various aspects of the control and monitoring architecture have been worked-out as the project has progressed. We have been able to remain flexible and help the design team and all the suppliers come together to achieve a harmonious working system that allows both proof of operational targets and room to fine-tune and learn from it.

SO HOW EXACTLY DOES AN LAES WORK? Air turns to liquid when refrigerated to -196°C, which is usually achieved by a cycle of compression, cooling and expansion, it can then be stored in conventionally insulated, ambient pressure vessels at very large scale.

Exposure to ambient temperatures causes rapid re-gasification and a 700-fold expansion in volume, which is used to drive a turbine and create electricity.

Highview’s technology draws from established processes from the turbomachinery, power generation and industrial gas sectors. The components of Highview’s processes can be readily adapted from large OEMs and have proven operating life times and performances.

WHY LIQUID AIR ENERGY STORAGE? • No geographical constraints • Close to environmentally neutral in operation • Competitive capital cost • Long lifetime 25+ years • Scalable to 200MW/1GWh • Components available from a global supply chain • Integration of industrial low-grade waste heat and waste cold • Uses no scarce or toxic materials Other partners include: GE, Heatric, BOC and Metalcraft. KiWi Power are engaged to commercialise the plant’s interaction with National Grid.

LAES technology can be scaled to deliver large-scale, long duration energy storage from around 5MW output and 15MWh of storage capacity to more than 200MW output and 1.2GWh of capacity.

It can be considered as being comparable to medium scale pumped hydro-electricity storage, but without the geographical restrictions of mountains and reservoirs.

When scaling up LAES technology, the system will be modular and benefit from scale and convenience, an advantage when locating it to different regions and applications.

Final word goes to Highview’s CEO Gareth Brett, “This is a breakthrough technology that enables a new and compelling solution for large scale, long duration energy storage.

There is nothing else available right now, that can be deployed at this scale and duration and at low cost. This project with Viridor will be an invaluable demonstration for the power sector to evaluate, implement, utilise and capitalise on this, a milestone in Liquid Air Energy Storage.” www.optimal-ltd.co.uk Issue 37 PECM

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EDITOR’S CHOICE

Our parent company Muller Coax was established 58 years ago and is now a recognised leader in valve design and innovation within the valve industry.

controlling water at 200 bar for fast shut off and giving feedback position sensing.

SOLUTION:The Muller Coax 5 VMKH50 valves meets all the criteria with leak tight shut off, and full open and close cycle of 200 milliseconds with reliable position sensors fitted.

We are synonymous for quality, experience and reliability in valve technology, this has been the case since the beginning of our dynamic development and it will continue to stay that way.

The reliable proven high valve solution met all the clients exacting criteria.

Valve pictured was built for a specific application for one of our many blue chip clients, below is a case study and solution provided to match the requirement.

For details of how we can assist with your requirements contact co-ax valves uk: john.osborn@coaxvalves.co.uk or visit www.co-ax.com.

APPLICATION: Customer required high pressure 2� BSP valve for

Muller Coax Original valve manufacture for 58 years for arduous & varied applications we have a valve to suit High pressure valves ATEX Valves Direct Acting/Externally Controlled Threaded/Flanged Contaminated Medias Fast Actuation Position Indication Switches Available Compact Size All Valves SIL 2 Rated SIL 3 available on request

Contact us Tel: 01908 067583 Email: john.osborn@coaxvalves.co.uk Web: www.co-ax.com

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PECM Issue 37

EDITOR’S CHOICE

Introducing Hydrotechnik UK’s HTUK Watchlog Hydrotechnik are proud to announce their new Wireless Data Monitoring and Acquisition system, designed for continuous measurement and monitoring of critical machinery, processes and systems. Rapid deployment, long transmission distances and stability of signals make this system easy to install and specify when wired options present problems.

The HTUK Watchlog wireless send and receive system is designed for continuous monitoring and logging of multiple pressure and temperature sensors over distances of 800m and/or 1.6Km. For more information please contact: Richard Price, Managing Director: richard. price@hydrotechnik.co.uk Chris Banks, Commercial Director: chris. banks@hydrotechnik.co.uk Matthew Davies, Marketing Assistant: matthew@hydrotechnik.co.uk

PSRE

Otter Controls Group

Process Plant operations are becoming more sophisticated making them more challenging to include the appropriate engineering of the necessary piping systems and equipment with a wide array of different technological, mechanical, and safety requirements to comply with. PRSE created a range of solutions in the PASS Software Suite to address the specific needs of Process Plant Design.

Otter Controls Group with a turnover of circa £70M and over 1,000 staff, manufactures and designs electro-mechanical controls and devices in eight locations world-wide including UK, Eastern Europe, China and India.

The PASS/INDUSTRY Process Complete module provides a comprehensive solution for Process Plant design and analysis with powerful and easy to use software tools of analysis, simulation, code compliant sizing that include embedded intelligence and integration with popular CAD tools.

Contact: Leonid Korelstein VP Research & Development PSRE korelstein@turboprovod.ru

We have extensive in-house design teams to develop customer specific products from High Voltage switches to DC cut-outs for automotive applications. Particular expertise is in waterproof and dishwasher proof connectors for both bespoke and generic applications.

High levels of automation and extensive lab facilities are present throughout the group.

We are world leaders in thick-film heating elements on stainless steel and ceramic.

Operating to TS 16949 and VDA 6.3 we have food grade appliance manufacturing capability and supply defence, railway, consumer and OEM manufacturers. sales@ottercontrols.com T 01298 762314

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EDITOR’S CHOICE

INDUSTRY-LEADING CENTRE MTC

MTC APPRENTICES BENEFIT FROM WORLD-CLASS TRAINING

The Advanced Manufacturing Training Centre, on the Manufacturing Technology Centre campus at Ansty Park in Coventry, is trebling the number of apprentices it trains. The industry-leading centre, sponsored by Lloyds Bank, is to provide training for 300 high quality apprentices a year by 2020.

AMTC apprentices are highly-regarded in industry and are exactly what the manufacturing sector is looking for to fill the high-tech jobs of the future.

AMTC apprenticeship courses have the advantage of not being company-specific or sector-specific, so the result is a fullyrounded apprentice capable of filling the most demanding of manufacturing and engineering positions. The apprentices are fully tutored in work behaviours and engineering basics, but are also exposed to the latest manufacturing technology.

The MTC’s future-focused world leading apprenticeship development programmes allow employers to maximise their Apprenticeship Levy spend, giving

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PECM Issue 37

Apprentices at the AMTC in Coventry.

been a challenge for the engineering and manufacturing sectors for many years.

As a measure of the respect that the AMTC’s training programmes have earned in the industry, the centre has been chosen to replicate its success as the training provider for a new centre in Oxfordshire to provide the skills needed by industry in that region, particularly in the field of atomic science.

The centre near Abingdon will equip 350 apprentices a year with badly needed technical skills for the local economy. a genuine return on investment and business impact, while ensuring they become increasingly globally competitive.

Lloyds Bank recently announced that it is investing a further £5 million to fund its sponsorship of the AMTC. The funding doubles the bank’s original commitment, bringing total funding to £10 million over 10 years. Lloyds sees the commitment as a sound investment in the future of the UK manufacturing sector and a major step in tackling the skills shortages which have

As AMTC managing director Paul Rowlett put it, “An AMTC-trained apprentice is a very special asset. They are trained to do a job and they can seed the pipeline to be the research engineers and skilled technicians of the future, filling vital roles.”

For more information on MTC Apprenticeships, contact Colin Bancroft, Employer Placement Leader, colin.bancroft@the-mtc.org, 02476 701 554.

ENGINEERING APPRENTICESHIPS

OPEN EVENING TUESDAY 26TH MARCH I 5PM – 7.30PM Start your career at the forefront of Great British Engineering The MTC connects young, talented apprentices with high calibre manufacturing and engineering employers who are looking to employ the best talent in the industry.

Take a tour of our amazing facilities and watch our apprentices in action.

Register online at the-amtc.co.uk/apprenticeships/open-evenings or call +44 (0)2476 701801

EDITOR’S CHOICE

EDUCATION SHAKE-UP NEEDED ICHEME

UPSKILL ENGINEERS AND SUPPORT APPRENTICESHIPS, URGES NEW REPORT INTO ENGINEERING SKILLS A shake-up in UK engineering education is needed to address the current skills gap and shortage of engineers, a new report revealed today. Engineering Skills for the Future - the 2013 Perkins review revisited calls for more support for higher education institutions and apprenticeships, and the upskilling of engineers to manage increasing digitalisation in their industry.

Work placements were highlighted as an advantage to employment prospects in IChemE’s 2017 report Social mobility and the chemical engineering profession in the UK. Support for the professional development of young chemical engineers and the provision of industrial work placements are actively encouraged in the requirements to become an IChemE Corporate Partner.

The report marks five years on from Engineering skills: Perkins review; when chemical engineer Professor John Perkins, a Fellow of the Institution of Chemical Engineers (IChemE), was commissioned by the Government to undertake the first review of engineering education from primary to professional level.

The uncertainty around Britain’s impending exit from the EU has also been highlighted in the report as a potential issue. Almost 560,000 EU Nationals are employed in UK engineering sectors, jobs that look uncertain with no clear immigration policy post-Brexit. The issue is particularly problematic when considering the UK current shortfall of around 37,000 – 59,000, in engineering roles requiring Level 3+ skills.

His latest instalment revisits the original challenges and recommendations set out in 2013; in order to provide a roadmap for government and the engineering community to action, now and into the future.

There has been increased support for apprenticeships and the introduction of Technician Level (T Levels) in the last five years. Today’s report recommends that the recently introduced apprenticeship levy should give more spending control to organisations; and subject content in T Levels should provide a broad technical education across disciplines, to enable students to have a broad range of routes into an engineering career, or higher education.

IChemE is supportive of this work. It has partnered with the University of Chester to offer the first chemical engineering degree apprenticeship in the UK and is currently working to ensure the degree is IChemE accredited.

According to the report, the UK’s track record of work placements is poor, and organisations have found it challenging to support the 45-day industrial placement required as part of T Levels. With 90% of the engineering businesses having fewer than 10 people, there are concerns the infrastructure is not robust enough to support and nurture professional development through work placements.

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Since the original Perkins Review, scant progress has been made in addressing the UK’s chronic engineering skills gap too. The report calls on government and the engineering community to upskill engineers and technicians to prepare for a wave of disruptive digital technologies into industry. It is hoped that Brexit presents an opportunity here, providing a stimulus for employers to think more strategically about unlocking the skills potential of their workforce.

Professional Engineering Institutions are cited as having a pivotal role in the upskilling of engineers, by providing a ‘hub’ between industry and individuals to ensure both needs are met. Professional registration was also specified as conferring mobility to engineers, as they highlight key competencies and skills.

IChemE contributed to the Higher Education section of the report, which acknowledges there has been an upward trend in the number of undergraduate engineering students since the last review. Female representation remains stubbornly low at an overall 15% across all engineering disciplines. However, latest figures from the UK’s Universities and Colleges Admissions Service (UCAS) reveals that chemical engineer bucks the trend, with 27% of undergraduates being

female.

In Scotland and Wales post-16 academic pathways are becoming broader and more inclusive. However, the report recommends an urgent review of post16 education in England, to encourage more students from a broader range of backgrounds into further and higher engineering education. The current system was criticised for narrowing education choices, potentially closing the door to technical and creative careers.

The report also recommends that the engineering community, including Professional Engineering Institutions, sign up to a Code of Practice to reduce fragmentation and improve the coordination of STEM outreach in schools. Currently over 600 organisations operate in the ‘UK STEM education’ space; however only 28% of 11-14 year olds have participated in STEM careers activities in the last year.

Libby Steele, Head of Education Affairs at IChemE, said: “We’re delighted to have contributed to the report and welcome the recommendations. We are supporting chemical engineers in several areas of professional development and will continue to work collaboratively with others to support this.

“There is so much diversity to a career in engineering, highlighted by the This is Engineering campaign. As a professional qualifying body and a learned society, we encourage students to consider all routes to a career in chemical and process engineering.”

The publication of the report coincides with the launch of a new set of adverts from This Is Engineering, a campaign to raise awareness of the breadth of careers in engineering. The campaign is led by the Royal Academy of Engineering and was developed in response to a recommendation in the original Perkins Review.

www.icheme.org

EDITOR’S CHOICE

EARLY WARNING SYSTEM BENDER

ELIMINATE DATA CENTRE POWER SHUTDOWNS AND ENSURE MAXIMUM AVAILABILITY Continuous power monitoring systems from Bender UK are designed to monitor and provide early warning of developing earth faults, removing the possibility of unnecessary power interruption and unplanned shutdown.

Tier 3 and 4 data centres are designed with redundant power from source to socket, to cater for any eventuality resulting from a single failure. But power outages in data centres can still occur. Redundant designs are deemed to be concurrently maintainable but switching off systems even for periodic inspection and testing carries with it the restart risk.

Bender residual current monitors (RCM) are used to monitor earthed systems (TT and TN systems) for fault currents or residual currents. They continually monitor insulation levels, providing early warning of earth faults and notifying the end user before the shutdown threshold is reached.

Continuous monitoring also enables data centres to fulfil the requirements for regulatory checks without shutting down the power. This enables the data centres to provide continuous, reliable service to customers and removes the risks that accompany even the most meticulously planned restart.

Downtime in colocation data centres is especially difficult, as a large number of customers’ data is located in one data hall.

Bender UK’s residual current monitoring solution reduces the headache involved with having to agree and organise a single maintenance shutdown period that pleases all your customers.

other tests during periodic inspection and testing can be carried out either with power on or with minimum disruption at circuit level.

Bender UK continuous residual current monitoring enables the data centre operator to meet these regulatory requirements without power shutdown.

BS7671:2018 651.2 states: “…Where a circuit is permanently monitored by a residual current monitor (RCM) or insulation monitoring device (IMD) it is not necessary to measure the insulation resistance if the functioning of the RCM or IMD is correct…”

Why monitor residual current in a data centre environment?

Due to the nature of the loads installed in data centres, use of residual current devices (RCDs) is not recommended because of their nuisance tripping problems. By using Bender technology to monitor the RCD, any deteriorations are detected very early on before the shutdown threshold – ensuring reliability and allowing for smooth running of your data hall.

It is particularly important to examine the detail of power system performance; to detect and evaluate fault currents, equalising currents and insulation faults in a finely granulated way. Insulation faults, stray currents, overloaded N conductors due to harmonics or asymmetrical loads, interruptions of PE and N conductor and also EMC influences can interfere with the entire current supply system and have an impact on the operation.

Meet the requirements for periodic inspection and testing (PIT) without shutdown

The impact can range from triggering several protective devices, and unexplainable malfunctions of protection or IT systems to fire damage or even injury to personnel.

Power shutdown during periodic inspection and testing is intrusive and provides only a snapshot of the status of a power system. All

The advantages of Bender RCM technology have been proven through its use in large data centres in Europe, delivering safer

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PECM Issue 37

and more reliable systems and greater availability by providing advanced warning on developing insulation faults. Another benefit is the ability to pinpoint the location of an earth fault.

Continuous residual current monitoring using Bender RCM technology enables effective monitoring of power infrastructure, as well as cabling it also monitors the status of connected equipment including servers.

Bender technology also enables the operators and users to tailor the system to meet their individual requirements – supplying a bespoke solution. The RCM threshold response value and the time delay can be adjusted to precisely match the requirements of each individual location, which means that known sources of errors and transient faults can be masked. If a residual current exceeds a defined threshold value, the RCM system sends a warning to the building control system, identifying problems and issues before they become critical.

Residual current monitoring instantly alerts the control centre if a problem begins to develop, equipping the operators to take action before the problem becomes critical.

Data from the RCM system can feed into a normal PC or laptop on site, or to your data centre infrastructure management software.

Data can also be monitored remotely using the internet to securely log in and check the status and performance of one or multiple sites.

To find out more about how Bender UK can safeguard data centre availability and identify issues before they become critical visit stand D953 at Data Centre World or go to www.bender-uk.com/ solutions/data-centres

Residual Current Monitoring for maximum data centre availability

 Continuous monitoring of earthed (TT & TN) systems  Fast & early warning of developing earth faults  End user notification before reaching shutdown threshold  Reduce the chance of unplanned downtime and shutdown  Periodic inspection & testing without shut off  Enables predictive, planned maintenance

DATA CENTRE TECHNOLOGY

BENDER UK

Visit us at Stand D953

Low Mill Business Park, Ulverston, Cumbria, LA12 9EE Tel: 44(0) 1229 480123 email: industrialsales@bender-uk.com www.bender-uk.com

EDITOR’S CHOICE

SciQuip Ltd

RRC New Courses for 2019

Knight Optical

SciQuip Ltd supplies a wide range of testing and production equipment to industrial, manufacturing and R&D customers throughout the UK. The range includes Drying Ovens, Furnaces, Test & Climatic Chambers, Ultrasonic’s, Circulation Chillers, Balances, Shakers/Stirrers/Mixers, Sterilization & Depyrogenation Chambers, Freeze Dryers and Centrifugation equipment.

For 2019 RRC are introducing two new NEBOSH Courses to its Dubai classroom schedule along with expanding the courses offered in its UK centres.

Sapphire (Al203) has exceptional structural integrity and ability to operate up to 2030 degrees Celsius. Its high mechanical strength and thermal, chemical and scratch resista\nce makes it an incredibly desirable material for use in harsh conditions.

The company is carbon neutral and leads the sector in terms of environmental awareness, recycling and sustainability. As a UKAS accredited ISO 9001:2015 & ISO 14001:2015 company customers are assured of the very highest quality and levels of service. SciQuip is an approved public sector framework supplier.

Launched in London in mid 2018, RRC’s NEBOSH HSE Certificate in H&S Leadership Excellence course has proven exceptionally popular and for 2019 we have scheduled further courses in Birmingham, Glasgow, Manchester & Newcastle. We are also introducing the course to our Dubai centre with the first course in February, and a further 4 dates scheduled throughout the year.

Following the growing interest in environmental training in the Middle East region we are also introducing the NEBOSH International Environmental Diploma to our Dubai centre with the first course starting in the Autumn of 2019. This is a three week course and has been structured to incorporate the NEBOSH Environmental Certificate to allow students to gain two qualifications.

www.sciquip.co.uk

www.rrc.co.uk

SciQuip provides its customers with full before and after-sales support with fully trained product/application specialists together with factory trained service engineers using original manufacturer parts.

Sapphire windows have the capability of serving vital purposes in mission-critical applications, especially when used alongside sapphire lenses, prisms and blanks. They can be made thinner than other crystals due to the structural integrity of the materials.

Choose from random cut sapphire for any application other than UV, or C-cut or Z-cut for UV applications, all available from stock.

Fluorescence free sapphire windows are available as a custom made item only.

For bespoke requirements, our technical experts are able to manufacture to your specification. www.knightoptical.com

GAS METER TEST RIG SOLUTIONS FOR EVERYONE When a client approached Chell Instruments with a specific challenge, our engineering team got straight to work. Using our industryleading expertise and experience, the ideal solution was developed to satisfy their gas meter calibration requirements.

Now, a version of the Gas Meter Test Rig (GMTR) we created is available from Chell for everyone wishing to test and calibrate domestic gas meters, including manufacturers and calibration houses.

The GMTR is a multi-channel benchtop system that allows testing of the functionality, accuracy, stability and leak integrity of up to four domestic gas meters simultaneously.

It is compatible with older ‘diaphragm’ type positive displacement meters, as well as the newer ‘smart’ ultrasonic meters.

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As you’d expect, the device contains high accuracy flow, pressure and temperature instrumentation and can generate any flow set-point up to 12,000 litres per hour while maintaining a safely low outlet pressure to prevent damage to the gas meters under test. For valid error comparisons, the combined mass flow, pressure and temperature measurements can be used to calculate the true volumetric flow rate at each flowrate.

The system consists of a custom enclosure and a triple-range flow manifold with pneumatically operated isolation valves.

Pipework and custom gas meter outlet blocks allow volumetric flow conversion for up to 4 gas meters in series.

The system has a mass flow error of 0.4%Rdg +0.2%FS and also contains 4 pressure transducers and 4 PRT temperature probes, all connected to custom fixtures in the interconnecting pipework. The on-board display modules provide mass flow control and display, pressure and temperature measurement display and valve control.

Remote monitoring and control is also possible via the built-in webserver or with the user’s own software.

The GMTR is supplied with all parameters calibrated with ISO17025 certification in our UKAS accredited calibration laboratory and is the latest flexible addition to our range of gas meter test systems, adaptable to each customer’s needs. www.chell.co.uk

EDITOR’S CHOICE

RECOGNISING FUTURE TALENT EEF

STARS CELEBRATED AT MANUFACTURING NATIONAL AWARD CEREMONY

Leading manufacturers and talented apprentices from across the UK were recognised as national manufacturing champions at the EEF Future Manufacturing Awards held in London.

The biggest winner on the night was Paxman, winning the Manufacturer of the Year award – a title awarded to the most outstanding company amongst all the category winners.

The firm, a Huddersfield-based manufacturer of scalp cooling systems, used to reduce chemotherapy-induced hair loss received recognition in the Innovation Award. Judges were impressed with different business models that Paxman employed for different international markets, according to local contexts and highly regulated environment.

The judging panel said “This innovation displayed huge impact in terms of social and health benefits. It was multi-dimensional from finance, product development and service delivery.”

Judges were also won over by Tobias Cowan, aged 21, an engineering apprentice at HepcoMotion, a Tiverton based manufacturer of linear motion systems and automation components. The accolade came after he had battled his way through regional heats to make it through to the national finals. Tobias’ passion, hard work and attention to detail,

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along with his ambitions for a teaching role within the sector were the deciding factors for the judging panel.

Joining Tobias on the podium was Heather Johnson, a business procurement apprentice at BAE Systems, who was crowned Business Apprentice of the Year. She was named the winner after impressing judges with her bold approach as she looked to integrate real-life experience and skills into the work place.

Winners were selected by a panel of judges drawn from business leaders, industry experts and academics and was up against tough competition from a range of dynamic businesses, small and large, from across the UK. Richard Paxman, Managing Director at Paxman, says: “To be recognised as a leading manufacturer across the UK is fantastic.

I’m thrilled with both the innovation and manufacturer of the year awards as everyone within the business has contributed. To be able to provide our product across the globe really pleases me as I know what we do makes a huge difference to people in particularly tough times. We’re all delighted to have won.”

Tobias Cowan, apprentice at HepcoMotion, says: “This is a massive honour – I can’t believe I’ve won. It’s such a wonderful way

to crown what has been a fantastic year of my apprenticeship. Being an apprentice has given me the best start to my career, I’ve developed so much and winning this tops it all off. I’m absolutely thrilled to win”.

Heather Johnson, Business Procurement Apprentice at BAE Systems, says: “I am absolutely thrilled to have won this award and to have been crowned national winner.

It’s an amazing feeling to be recognised for doing something I genuinely enjoy and is setting me up for my future.”

Other award winners announced on the night were: Engineering Apprentice: Tobias Cowan, HepcoMotion Business Apprentice: Heather Johnson, BAE Systems Leadership: Peter Tack, Lander Automotive Ltd Developing Future Talent: AESSEAL Health and Safety: Advanced Insulation Sustainability: Eurocell plc Business Growth and Strategy: Paxman Innovation: Surface Measurement Systems Ltd

For more information about the awards visit: www.eef.org.uk/awards

EDITOR’S CHOICE

EXCIMER TECHNOLOGY IST METZ

LOOKING FOR ABRASION-RESISTANT MATT SURFACES? IST Metz, winner of accolades for its UV technology, uses the excimer process for bright matt results across a range of industrial applications.

IST Metz is a global specialist in UV curing and coating systems which now offers excimer technology to produce matt surfaces with high scratch and abrasion resistance. This technology is widely used for the cleaning and modification of surfaces in the manufacture of displays and touch panels, bleaches in the textile and cellulose industry, disinfection of air and water, and the matting of plastic parts.

After over 40 years in UV, IST Metz is a very well-established player. It started out in, and continues to serve, the printing industry but subsequently diversified into much wider industrial applications, recognising the benefits it can bring to many sectors with its coatings expertise. Currently it is generating great interest in its excimer technology.

IST entered the excimer (a shorthand for excited dimer) field 20 years ago, seeing the appeal of a matt surface finish. Its purpose is to create a roughened surface so that, when light strikes it, it is not reflected in a definite direction. That means the surface will look bright and the same from any direction, in other words matt.

IST uses very short-wave radiation and high energy to penetrate a very thin layer of a varnish coating. Xenon excimer lamps are used as the short-wave source. The surface dries very quickly causing shrinkage and

a wave effect on the surface which is then preserved by applying long wave radiation using a medium-pressure lamp. It is a system that gives high processing speeds and can be used on large surfaces.

IST customer Klebchemie has seen the benefits of excimer technology for wood flooring applications. Rainer Kampwerth, sales manager for industrial coatings at Klebchemie, says: “We are currently seeing a slight stagnation in high-standard, high gloss coatings. On the other hand, a rapid rise in ultra-matt surfaces is becoming apparent, Thanks to excimer technology, we are the market leader in this sector and were the first to push ahead with industrial installations for engineered wood boards. We now have a dozen such installations worldwide.”

He believes that chemical matting materials will continue to have their place but that physical matting, excimir technology, has added levels of matting that been thought of as extremely difficult or impossible until now.

“The gloss levels are now highly scratchresistant and have anti-fingerprint and anti-grease properties thanks to excimer technology. In short, the surfaces are more matt as well as more resistant to scratches and grease,” says Mr Kampwerth.

Last year IST Metz was awarded the title “Global Market Leader 2018” in the Mechanical and Systems Engineering sector

and in the category for Drying Systems based on Ultraviolet, Infrared and Warm Air. The Global Market Index 2018 listed 461 companies and those chosen for awards were selected based on a ranking by the University of St Gallen. This award IST sees as recognition of its innovation and practical commercial solutions.

IST Metz, which is based in Nürtingen near Stuttgart, was founded by Gerhard Metz in 1977 and today employs about 500 staff and has 15 subsidiaries around the world. Its UK subsidiary, IST (UK), is based in a 400m² facility in Skipton which includes training and presentation areas, systems and spares storage as well as being the main base for the sales and service team. Joint managing director Simon Mitchell is responsible for industrial applications of UV technology and can be contacted on 07771-614487. www.ist-uv.com/en/ Issue 37 PECM

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EDITOR’S CHOICE

3D PRINTING 3DPRINTUK-low volume calculator

3DPRINTUK

AN ALTERNATIVE TO INJECTION MOULDING How many times have you needed to produce just a few hundred small parts?

What are your options? CNC? Vacuum casting? Rapid injection moulding? If you haven’t done so before, it’s time you added 3D printing to that list.

Typically, injection moulding can be quite expensive due to the necessary tooling costs, resulting in both SME and global corporations opting for cheaper alternatives that are still high quality and durable.

3DPRINTUK are specialists in low volume production using state of the art SLS 3D printing systems, with the aim of bridging the void between prototype and injection moulding.

SLS 3D printing is ideal for smaller parts and allows 3DPRINTUK to produce parts for as little as 20p each. With no tooling cost this mean there is no financial barrier to entry other than the unit cost. This technique also offers additional design freedoms and scope for complexity. Parts can be as complex as you want. Unlike with moulding, milling or cutting, there is near complete design freedom. As long as everything is above approximately 1mm thick, it will print. One huge benefit to this is where complexity previously required a product to be made up from two or more parts that were each moulded, finished and assembled; you can now make that in one part, saving on multiple tooling and unit costs.

Playerdata - custom cases Is your part viable? Additive manufacturing is not suited to every application and establishing if it is a viable option requires you to look at several factors.

1. How big is your part? Pricing is based on size. The larger the part, the less viable it is, but small components such as jigs, fixtures

Suss my bike - production part and fittings can be extremely viable.

2. How complex is the design? Complexity is no issue for 3D printers; however, it is for injection moulding. This means that the more complex the part, the higher the tooling cost, and therefore the greater the viability of additive manufacturing.

3. How many do you want? If you’re looking for tens of thousands, then injection mould is a better option. If you need a few hundred, or low thousands, and the parts are small, then you’re in the right place.

If you already have a moulding quote, 3DPRINTUK has a handy comparison tool on their website. Simply input the tooling cost and the moulded unit cost, along with the XYZ dimensions of the part, and it will produce a graphical cost comparison.

Essentially, the smaller and more complex the part is, the greater the viability of additive manufacturing.

bloc blinds - custom parts

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3DPRINTUK.co.uk

we make plastic parts in low volume 1-10,000 UNITS no tooling cost what do you need?

Try our NEW online injection mould comparison calculator!

SLS 3D printing service. Low volume production and one off prints.

Fixtures & fittings, PCB enclosures, machine parts, jigs & clamps, end of arm tooling. Upload your part now for an instant quote!

www.3dprint-uk.co.uk/upload-and-quote

Compare Compare your your injection injection moulding moulding quote quote to to additive additive manufacture manufacture and and see see how how much much we we can can save save you you on on part part production production costs costs using using SLS SLS 3D 3D printing. printing.

hello@3dprint-uk.co.uk

3DPRINTUK 3DPRINTUK chosen chosen to to represent represent uk uk manufacture manufacture 2018 2018

T. 0208 692 5208

EDITOR’S CHOICE

GF Piping Systems

Measurement Accurate measurement is the basis for reliable process control

 Flow Sensors and instruments for mechanical, magnetic, sonic or visual measurement of flow.

 pH/ORP Sensors and instruments for measurement of pH/ORP also for aggressive media and removal without process shutdown.

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 Chlorine

 Level

Chlorine analysing systems designed to accurately measure free chlorine, in applications with varying pH levels.

Sensors and instruments for measurement of level using ultrasonic and hydrostatic pressure.

PECM Issue 37

www.gfps.com/uk @gfps_uk

EDITOR’S CHOICE

THERMASET Thermaset has been manufacturing high quality powder coating for over 30 years.

With an experienced technical sales team, we are able to provide our customers with a quality product, excellent technical knowledge and superb customer service.

Here at Thermaset we can provide you with a range of colours, finishes and powder coating types to ensure that we have the best solution for your requirements.

Our experienced development team have refined a full complement of primers to assist with multi-coat systems. This new range called the Thermaprime Series, will offer a diverse range of characteristics for individual requirements whilst improving life expectancy of the multi-coat systems.

The Thermaprime Series is made up of four distinctive products which have individual attributes to ensure the top-coat appears its finest and lasts as long as possible.

If you are experiencing any issues, or are looking to solve a specific problem whether that be colour, finish, application or just to discuss longer life coating systems, challenge us to find you a solutionThermaset ltd T: 01827 55777 E: enquires@thermaset.co.uk W: www.thermaset.co.uk

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EDITOR’S CHOICE

STANDING THE HEAT MATMATCH

MATERIALS SELECTION FOR FACING NUCLEAR FUSION PLASMA

As of today, there is still no net electricity contribution from nuclear fusion in our power grids. Here, materials scientist Benjamin Spilker, on behalf of materials search engine Matmatch, explores the world of nuclear fusion and the material characteristics that make research possible.

Plasma physicists were surprised by the behaviour of the plasma more than once in the decades of fusion plasma research. A highly prominent and important discovery has been made with the high-confinement mode (H-mode), in which the plasma suddenly changes its characteristics to a steep pressure gradient at the edge and an overall better confinement.

Even though we have come quite far, our understanding of the underlying mechanisms of the H-mode transition is still incomplete. Thorough modelling efforts are ongoing to reliably predict the operational scenarios and conditions in future fusion devices.

Despite all of the measures that can be taken to control the fusion plasma, the surplus energy and the product of the fusion reactions in the form of helium particles and other impurities need to be removed from the plasma in order to allow for a continuous operation and the generation of electricity.

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So-called plasma-facing materials are deployed to protect the vacuum vessel from the hot plasma particles and to efficiently remove the incident power fluxes. Nuclear fusion is sought after as a clean and sustainable energy source. Because of this, all in-vessel components are carefully selected in order to avoid the generation of any longterm radioactive waste that would require geological disposal.

The anticipated deuterium-tritium (DT) fusion reaction generates a continuous flux of highly energetic neutrons. These neutrons carry the potential to knock atoms from their lattice positions, causing material defects, but also to transmute atoms (transform the atom into a different chemical element) if a neutron is captured.

This neutron irradiation environment requires that the materials, which are in place to shield the rest of the machine from these neutrons, do not degrade to the point where they could overheat and fail under operational conditions.

Another important aspect for the environmental impact of fusion is neutron induced activation. When stable atomic nuclei capture a neutron, they can enter an excited state and become radioactive. These newly formed radioactive isotopes decay

with a certain half-life time, which should remain within specified limits.

Unfortunately, a major drawback of carbon has been discovered in the course of said research. Even when subjected to only small doses of neutron irradiation of 0.2 dpa (displacements per atom), which could be accumulated in a couple of days in a running fusion reactor, the thermal conductivity of carbon decreases to less than 20% of its original value. As a consequence, the material quickly overheats because the incident heat flux cannot be transferred to the cooling channels efficiently enough.

From these considerations and many others, it has been concluded that all-metal plasmafacing materials, such as beryllium, are the best way to go forwards.

For design engineers working on these projects, Matmatch’s materials comparison platform provides the ideal means of researching and sourcing materials suitable for handling nuclear fusion. By choosing the right materials, engineers and scientists can make a brighter future for fusion power.

www.matmatch.com

EDITOR’S CHOICE GAS-TIGHT BLOWERS FOR ADDITIVE MANUFACTURING METHODS In selective laser melting (SLM) a stable inert gas atmosphere must be ensured within the built chamber of the machine. A specified temperature range is also essential. Only under these conditions can high quality components be produced. It is further necessary to remove metal splash and smoke developing during the melting process.

At formnext (hall 3.0, stand H 69) Gebr. Becker GmbH will be presenting two blower types developed precisely for these and similar applications. The key dif-ference to other series is the gas-tight design which permits the precise control of the gas flow as well as the removal of contamination from the process.

In combi-nation with also gastight heat exchangers from the programme of Gebr. Becker they also create the conditions for an exact temperature control of the additive manufacturing process.

For plants with a small built chamber the gas-tight and speedcontrolled VASF side channel blowers of size 1.50 are ideal (figure 1). They are of a highly com-pact construction and can be easily integrated in the plants, enabling the flow management of the inert gas in the closed circuit and low energy operation as required.

• Vibration Sensors (IEPE + 4-20mA) • Test & Measurement Sensors • Hazardous Area Vibration Sensors • Seismic Sensors • Hydrophones • Vector Sensors • Proximity Probes • Vibration Switches

For larger plants in additive manufacturing and the correspondingly higher volume flows of inert gas the gas-tight side channel blower VARIAIR SV 300 is used. Here too, the speed-controlled energy-efficient drive enables the delivery rate to be adapted to the actual requirements.

Both blowers are designed for 24/7 industrial operation and proven worldwide in numerous demanding applications. Due to their gas-tight design they are suitable for the requirements of additive manufacturing in highgrade atmospheres. www.becker-international.com

Figure 1

RMIG is the world's largest manufacturer and supplier of perforated metal and its related products.

We know our customers’ requirements for price and quality and meet their demands with uncompromising service.

Not only do we offer standard and bespoke perforated metal sheets, we are able to offer you a range of secondary operations as detailed below.

Complete solutions With a continued investment in the latest equipment and a network of professional partners we are able to produce prime quality products and solutions – from a simple perforated sheet to the fully formed and coated custom made part.

Certifications Including FM, CSA, ATEX and IECEx Offer Compliance to Customers Worldwide • Cable Assemblies • Enclosures • Vibration Transmitters • Supportive Instrumentation

New Inclinometer range!

Visit our website for more information

WORLD-CLASS SENSORS FOR INDUSTRY +44 (0)1767 651058

www.kdpes.co.uk

Levelling For some applications a high degree of flatness is required, we have processes in place to ensure our perforated coils and sheets meet with your most demanding requirements.

Rolling and forming We can roll, bend and form perforated sheets to match your design.

Aesthetic finishes and protective coating We can offer powder coating and hot dip galvanizing solutions to meet your specifications.

For more information please contact us www.rmig.com email: info.uk@rmig.com Tel: 01925 839610

Cutting We can cut and shape perforated sheet to meet the needs of your final application.

Issue 37 PECM

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EDITOR’S CHOICE

ECOFLOW VENTURI STEAM TRAP EBE ENGINEERING

EBE ENGINEERING BRINGT VERBESSERTE VENTURIDÜSEN-KONDENSATABLEITER AUF DEN MARKT

EBE Engineering, ein führender Entwickler und Lieferant von VenturidüsenKondensatableitern, hat ECOFLOW auf den Markt gebracht, einen marktführenden Kondensatableiter, der die Flansche aus einem Guss in das Gehäuse integriert. Die Versionen EFK-F und EFG-F sind beide aus einem Stück gegossen und bestehen aus Edelstahl 1.4308, was den Ableitern konstante Festigkeit, Haltbarkeit und Maßhaltigkeit verleiht.

Der Body des neuen Ableiters besteht aus einem modularen Design, um niedrige und hohe Durchflüsse in einem Gehäuse zu vereinen. Dank eines einzigartigen und innovativen Venturikonzepts erweitert das neue Design die Leistung des Ableiters über variable Kondensatmengen hinweg.

Das Schweißen entfällt komplett, was zu einem absolut homogenen Design führt, und das den Ableiter stabiler und sicherer macht. Darüber hinaus vereinfacht es die Zertifizierung, wodurch die Produktion beschleunigt und eine gleichbleibend hohe Qualität gewährleistet wird. Der optimierte Herstellungsprozess ermöglicht es EBE Engineering, die Vorteile von Skaleneffekten an seine Kunden weiterzugeben. „Wir sind jetzt in der Lage, viele Einheiten sehr einfach zu montieren und zu liefern.”, sagt Nigel Egginton, Geschäftsführer von EBE

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Engineering. „Die verbesserte Skalierbarkeit des neuen Designs gibt uns weitaus mehr Spielraum, unseren Kunden Mengenrabatte einzuräumen.”.

Vor der Eintwicklung des ECOFLOW hat EBE Engineering jeden Aspekt des Venturiabscheiderdesigns neu bewertet.

Anschließend entwickelte und verfeinerte sie in Zusammenarbeit mit einer innovativen Gießerei die Gießgeometrie mit Hilfe von 3D-Modellierung und Gießsimulationssoftware. Anschließend wurde ein 3D-Druckprototyp erstellt, bevor vollständige Edelstahlproduktionsmuster in Betrieb genommen wurden. „Wir haben eine komplexe Fertigung für unsere Gussteile umgesetzt, was zu einem wirklich einzigartigen Ergebnis geführt hat, das unseren Kunden außergewöhnliche Leistungen bietet und EBE einen kommerziellen Wettbewerbsvorteil verschafft!”, so Nigel Egginton abschließend.

Die neuen ECOFLOW-Flanschverbindungen wurden speziell für die Anforderungen des europäischen Marktes entwickelt und hergestellt, so dass EBE Engineering seine führende Position behaupten kann.

Inzwischen hat EBE in Deutschland eine eingetragene Gesellschaft mit Sitz in Essen/ NRW gegründet, die sich speziell um deutsche sowie EU-Unternehmen kümmert, indem sie

ihnen eine reibungslose Auftragsbearbeitung und schnelle Lieferung bietet.

Da der ECOFLOW VenturidüsenKondensatbleiter keine beweglichen Teile beinhaltet, die ausfallen oder verschleißen könnten, bietet er eine Lebensdauer, die der der Rohrleitungen der Anlage entspricht und wesentlich länger ist als bei mechanischen Ableitern. Es bietet auch ein Höchstmaß an Zuverlässigkeit, da keine Ersatzteile oder Überwachungsgeräte benötigt werden.

Für größere, nominale Rohrgrößen ist der ECOFLOW kleiner als viele mechanische Ableiter, benötigt weniger Platz und da die Ableiter leichter sind, stellen sie eine ideale Lösung bei Gewichtsbeschränkungen dar.

Die ECOFLOW Venturi-Kondensatableiter arbeiten mittels des Dichteunterschiedes zwischen Dampf und Kondensat. Dampf ist gut 1000 mal weniger dicht als Kondensat, so dass am Eingang der Düsenöffnung des Ableiters der Dampf mit niedriger Dichte buchstäblich aus dem Kondensat gedrückt wird. Das Kondensat mit hoher Dichte und langsamer Bewegung wird dann vorzugsweise durch die Öffnung abgeleitet und fängt den Dampf mit niedriger Dichte hinter sich auf. www.ebe-eng.com

Delivering permanent solutions for all steam trapping requirements The ECOFLOW Venturi orifice steam trap, from EBE Engineering, is the most advanced Venturi orifice steam trap on the market today. The fully flanged cast housing was designed, developed and refined using 3D modelling and casting simulation software.

Producing a Venturi orifice steam trap to meet the rigorous requirements of todays steam plant users.

Developed Developed on on aa modular modular concept, concept, the the ECOFLOW ECOFLOW Venturi Venturi orifice orifice steam steam trap trap encompass encompass aa wide wide range range of of capacities, capacities, from from minimal minimal condensate condensate flow flow requirements requirements on on line line drainage drainage and and trace trace heating heating systems, systems, through through to to the the high high flow flow volumes volumes and and variable variable loads loads of of process process heating heating applications. applications.

● ● ● ● ● ●

Benefit Benefit from: from: Improved Improved production production efficiency efficiency without without downtime downtime due due to to failed failed steam steam traps traps Elimination Elimination of of expensive expensive steam steam leaks leaks Reduction Reduction in in maintenance maintenance with with aa full full ten ten year year performance performance guarantee guarantee on on all all Venturi Venturi orifice orifice steam steam traps traps

Increasingly the first choice for blue chip and forward thinking businesses.

Contact us to see how we can help you

Venturi Orifice Steam trap range EBE Engineering Ltd, 9 Charles Street, Newbury, Berkshire RG14 6QP • Tel: +44 (0)1635 282696 EBE Engineering UG, Kaninenberghöhe 50, 45136 Essen • Tel: 0201 171 80 806 pecmfeb2019@ebe-eng.com • www.ebe-eng.com

EDITOR’S CHOICE

CORROSION RESISTANCE RITTAL

ENHANCED FOR EXTREME APPLICATIONS The new Rittal VX25 large enclosure system delivers significantly enhanced value to electrical engineering companies thanks to its technical features, ease of assembly and high levels of safety. Now, new versions of the VX25 are available in stainless steel and NEMA 4X to enhance corrosion protection and to ensure the equipment within it is shielded from dust, as well as from splashes and jets of water.

The new Rittal VX25 large enclosure system is now available in stainless steel to deliver the highest level of corrosion resistance. The frame structure, doors, panels and the gland plate, as well as all the external parts such as 180° hinges and comfort handle variants, are all made of stainless steel.

While the sheet steel and stainless-steel enclosure types have IP 55 and NEMA 12 protection categories as default, the optional NEMA 4X version with its corresponding IP 66 category protection offers greater protection.

This means that the electrical and electronic equipment in the VX25 is protected from dust, water splashes and jets, even in the most demanding of environments.

In order to achieve the high NEMA 4X protection category, the enclosure underwent, among other things, a water jet test. This procedure (“hose-down” test) involved examining any gaps with seals for leaks using a jet of water with a flow rate of over 240 litres per minute for a test period of 40 min/30 s (6 mm/s per seal length). The tests confirmed that no water would penetrate the enclosure, under comparable conditions.

In addition, the tests included a check of the dust protection, corrosion resistance, and protection against damage caused by external ice formation.

The two VX25 enclosure variants have an

almost identical design, which means that the interior engineering of the stainlesssteel enclosures can also be applied, unchanged, to the NEMA 4X enclosures, saving electrical engineering companies both time and money.

Any requirement for energy-efficient cooling of VX25 stainless steel enclosures can be provided through the new Blue e+ cooling units, which are also available in stainless steel.

Further information at www.rittal. co.uk and www.friedhelm-loh-group. com or on twitter @rittal_ltd.

QUICK DATA FLOW. EASY WORKFLOW. ENCLOSURES ENCLOSURES

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PECM Issue 37

POWER POWER DISTRIBUTION DISTRIBUTION

CLIMATE CLIMATE CONTROL CONTROL

OUTSTANDING COOLING FROM ABOVE Rittal has developed a roof-mounted version of its award-winning and highly energy efficient Blue e+ cooling units; these are designed for enclosures of 800 x 600mm (W x D) upwards and deliver a cooling output of 1.3 kW. The new roof-mounted units also feature within the new VX25 large enclosure system as an integrated solution.

Roof-mounted climate control units are the top choice in control and switchgear applications where there is a lack of space on the front and side panels. This could be due to physical location of the enclosures and minimal gangway clearance, but could also be due to an abudance of interlocks, switches or other controls preventing adequate space for a wall mounted cooling unit.

Air routing within the enclosure is also optimised; the cold air is blown down the front of the enclosure and drawn back up the mounting plate, thereby effectively dissipating the heat from topmounted components such as frequency inverters.

The new roof-mounted cooling units of the Blue e+ series, like the existing wall-mounted units, work with a combination of heat pipe and conventional compressor technology.

Energy consumption is very low because neither a compressor nor a pump is required when the cooling units are operating on the heat pipe; only the fans that circulate the air by the heat exchangers need an electricity supply. This cooling method works particularly well if there is a large temperature difference between the inside of the enclosure and the surroundings.

AVERAGE ENERGY SAVINGS OF 75 PER CENT The additional compressor within the cooling units only kicks in when a larger cooling output is required. All the active components operate with speed-controlled drives so the cooling output always matches what is required, ensuring less energy is consumed.

Overall, depending on the ambient conditions and the application, the cooling units of the Blue e+ series use on average 75 percent less energy than conventional compressor cooling units do. Lower temperature deviations within the enclosure means that the service life of the components installed is extended.

In addition, the new units have a multi-voltage supply making them easy to operate at all common mains voltages and frequencies. This is a huge benefit, especially for engineers who sell their machines worldwide.

INTUITIVE AND COMFORTABLE OPERATION Blue e+ roof-mounted systems are easy and intuitive to operate, using a touch display for basic settings and to read status messages. The touch display can also be integrated into the door of the enclosure if required.

Another option is the IoT interface, which makes it simple to integrate the cooling unit in an Industry 4.0 (IoT) environment.

COMPLETELY READY-ASSEMBLED The Blue e+ cooling unit is a feature in the new Rittal integrated solution which consists of an enclosure with built-in climate control.

The cooling unit is installed in the upper section of the VX25 enclosure as a plug & play. The touch display is built into the enclosure door and the unit can be easily removed for maintenance.

For more information visit www.rittal.co.uk or on twitter @rittal_ltd. To arrange a FREE cooling review, go online, call our customer service team on 01709 704000, or email cooling@rittal.co.uk.

VX25. SYSTEM PERFECTION. There There are are always always two two versions versions of of this this enclosure enclosure -- real real and and digital. digital. The The maximum maximum data data quality quality of of the the VX25 VX25 ensures ensures greater greater flexibility flexibility for for configuration, configuration, manufacturing manufacturing and and assembly. assembly. And And with with the the “digital “digital twin”, twin”, the the person person who who knows knows your your company company best best –– you you yourself yourself –– can can plan, plan, order, order, process process and and do do much much more more besides. besides.

IT IT INFRASTRUCTURE INFRASTRUCTURE

SOFTWARE SOFTWARE & & SERVICES SERVICES

www.rittal.co.uk www.rittal.co.uk

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EDITOR’S CHOICE

FULL MANUFACTURING SERVICE DUDLEY INDUSTRIES

FROM PRODUCT DESIGN TO MANUFACTURE...

Dudley Industries is a company synonymous with high quality sheet metal engineering and partnering with businesses across differing industrial sectors - ranging from construction fit-out to instrumentation manufacture.

An engineering led company which practices 5S and lean manufacturing techniques, Dudley Industries provides a full manufacturing service encompassing design, development, refinement and manufacture of customers’ standard products and bespoke requirements. Dudley’s aim is to continually improve and exceed customer expectations in terms of performance and cost. This is managed through company practices and procedures that are externally audited and accredited with the requirements of ISO 9001:2015, in addition to applying a ‘right first time’ DFM and DFA philosophy.

At the heart of the business is a highly experienced team of designers and manufacturing engineers led by the design manager, Richard Hooke, who has 32 years of experience in the industry. There is a high degree of crossover between design and manufacturing functions and this multidisciplinary approach enables the team to take products quickly from concept to full production.

Significant investment has been made in laser cutting and robot finishing equipment.

This combines with Dudley’s laser, punch and etching machines which are directly linked to the CAD system, along with CNC controlled folding machines and a variety of presses and rolling machines. This computer controlled design and manufacturing process ensures maximum accuracy and flexibility.

It also gives Dudley Industries the ability to vary production from small batches to full scale runs. Commenting on the kind of work the company carries out, Hooke said: “We predominantly work in sheet metals of various materials from 0.5mm to 4mm thickness. We have jobs on the go where the customer has designed the product and we are producing to their drawings.

However, in that scenario we work with the customer to understand what they want and refine the design to improve the product and costs. We also provide a full service from initial concept sketches to full design drawings and manufacture.”

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Dudley Industries is currently working with major businesses providing bespoke housings for equipment ranging from high end scientific instrumentation for laboratories to printers used in industrial settings. In the past the company has also manufactured vending machines, CCTV camera housings, security boxes, medical waste boxes, pest control products, to name but a few.

For more information visit Dudley Industries www.dudleyindustries.com

Dudley Industries Ltd Total solution provider for metal engineering.

We've been honing our metal engineering skills for over 76 years.

Our team of skilled design and manufacturing engineers can take your idea from design, prototype through to large scale production runs.

3 Quality as standard - ISO 9001:2015 Dedicated in house design studio On site tool room to create proďŹ les to your exact needs Flat bed laser cutting Power presses up to 400 ton Press Brakes to 2m width Punch press up to 6mm MIG & TIG Welding plus plasma welding robot for complex processes ABB Robotic linishing cell for complex product designs Dedicated team for assembly, branding and ďŹ nishing

CONTACT US TODAY TO DISCUSS HOW WE CAN SUPPORT YOUR PROJECT

Sales: +44 (0) 1253 738311 E-mail: sales@dudleyindustries.com www.dudleyindustries.com

EDITOR’S CHOICE

Hanover debut for BOGE’s Anniversary Edition S-4 screw compressor At the Hanover Fair this year, BOGE Compressors will be unveiling two new screw compressors, including a special 111th Anniversary Edition of its S-4 machine. In a celebration of 111 years of engineering innovation and high-quality manufacturing.

This year marks BOGE Compressors’ 111th anniversary, the company plans to celebrate this in style by unveiling a special Anniversary Edition of its popular S-Series screw compressors at the Hanover Fair (April 1-5, 2019). Now in its fourth generation of development, the S-4 takes energy saving, sound pressure dBA and ease of maintenance to an entirely new level. The S 111-4, a new ‘limited edition’ compressor, packs some novel technologies, all of which will be revealed to visitors to the stand at this year’s show.

Visitors are warmly invited to meet the BOGE team at the Hanover Trade Fair in Hall 26, Stand B56. www.uk.boge.com/en

Immune to liquid, debris, smoke & dust

Breathe easy: New ESAB PAPR provides heavy-duty protection

The LBKSystem detects the presence of humans & can give a pre-alarm in order to avoid the sudden stopping of machinery.

For heavy-duty protection from welding fume and particulates when welding, gouging and grinding, ESAB Welding & Cutting Products introduced the new ESAB PAPR (Powered Air Purifying Respirator) system at EuroBLECH 2018.

It is a lower cost alternative to traditional laser based floor scanners and it won’t be triggered by visible objects like smoke, dust, wood shavings, machine waste or water splashes. LBK-S01 heads can also be mounted behind mesh guarding or hidden behind an acrylic facia.

The maximum depth of monitored area is 4m but with six sensors can cover an area 15m wide thanks to its beam width of 110 degrees. The LBKSystem consists of a single LBK-C22 control unit & from one to six LBK-S01 sensing heads.

Configuration, e.g. depth of warning & danger areas, sensitivity & restart functions are quickly & easily set using the free application software.

Contact Sensor Centre at info@sensorcentre.com or call 01844 201607 www.sensorcentre.com

WANNER ANNOUNCES NEW HYDRA-CELL HEAVY DUTY, HIGH PRESSURE, MULTIDIAPHRAGM SEAL-LESS PUMP Wanner has launched the Hydra-Cell® T200 Series Medium Pressure, multi-diaphragm pump range, which in terms of flow rate and pressure are the highest performing pumps in the Hydra-Cell range and the biggest pumps ever produced by the Company. They feature a seal-less design that eliminates leaks, hazards and the expense associated with seals and packing; lowering the cost of ownership and giving a longer service life than competitive pumping technologies.

There are two models, currently, in the T200 Series, rated at 207 bar (3000 psi) and 241 bar (3500 psi) with maximum flows of 387 l/ min (102.2 US gpm) and 349 l/min (92.4 US gpm) respectively. The new pumps are ideal for oil and gas production, mining operations, boiler feed and high-pressure cleaning, along with chemical and petrochemical process and transfer applications.

Hydra-Cell pumps have no dynamic seals, cups or packing to leak, wear or replace, eliminating seal maintenance costs while hazardous

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materials and VOCs (volatile organic compounds) are fully contained.

The seal-less design, combined with robust check valves, also enable the pump to handle abrasive particles up to 800 microns in size and with less wear than gear, screw or plunger pumps.

The Hydra-Cell T200 can operate with a closed or blocked suction line and can run dry indefinitely without damage, eliminating downtime and repair costs.

With energy costs becoming an ever-increasing element in overall operational cost the T200’s low energy consumption, in relation to performance, will contribute significantly to its claim of having the lowest cost of ownership. www.hydra-cell.eu

The ESAB PAPR features a P3 filter and pre-filter to remove particulates and the latest control technology, allowing the operator to adjust air flow between 170 and 220 L/min to suit the environment and application. As an extra measure of safety, it incorporates both visual and audible alarms to the alert the operator in the event of a blocked filter or low battery.

Compatible helmets include the SENTINEL™ A50 for Air, G30 Air, G40 Air and G50 Air and Warrior™ Tech. From time-honoured processes in welding and cutting to revolutionary technologies in mechanised cutting and automation, ESAB’s filler metals, equipment, and accessories bring solutions to customers around the globe.

For more information, visit esab.com.

MULTILINE E MULTI-MEDIA CONNECTOR The MULTILINE E is a modular, multiple and multi-media connector that makes it possible to combine many different types of operating media such as compressed air, gases, fluids, electrical and electronic signals in one interface. It is designed for convenient use in control cabinets, tools, and machine components. The unique feature of the MULTILINE E is that electrical connections and media can be connected simultaneously in one drip-free connection.

MAXIMUM MODULARITY IN THE INDUSTRIAL ENVIRONMENT • One interface for compressed air, gases, fluids, electrical and electronic signals • Maximum modularity due to freely configurable connections • Different media can be connected and disconnected simultaneously

• Locking lever reduces the manual force needed for assembly • Shorter machine set-up times MODULAR KIT SYSTEM WITH MORE THAN 1000 VARIANTS For connection of a wide variety of M12 connection lines (5-pin, 6-pin, and 8-pin, B-coded and D-coded) and a variant of the M12 power plug for power electronics up to 630 volts.

• Integrated coding patterns in the housings prevents incorrect connections • Easy, tool-free mounting and dismounting

www.eisele.eu

HANNOVER MESSE

HOME OF INDUSTRIAL PIONEERS 1 – 5 April 2019 Hannover ▪ Germany hannovermesse.com #HM19

Get new technology first 11

HANNOVER MESSE SHOW PREVIEW

HANNOVER MESSE 2019 HANNOVER MESSE

WELCOME TO THE AGE OF INDUSTRIAL INTELLIGENCE Hannover. Industrie 4.0. Artificial intelligence.

Additive manufacturing. Cobots. Such terms are common today in industry. With the lead theme “Integrated Industry – Industrial Intelligence”, HANNOVER MESSE 2019 – the world’s leading tradeshow for industrial technology – delivers insights into how man and machine will work together during the next stage of digital transformation.

From 1 to 5 April 2019 in Hannover, Germany, exhibitors demonstrate that digitalization is the future of manufacturing – but in the form of assistance, not competition. Thanks to technologies such as automation, strengthboosting exoskeletons and augmented reality, factory workers are more productive than ever.

“Globalization and digitalization are driving industrial transformation,” said Marco Siebert, Director International Relations, Deutsche Messe AG. “HANNOVER MESSE is the venue where the global business, manufacturing and political communities gather to discuss these two crucial topics as well other current issues and challenges facing industry.

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For example, how do we ensure that algorithms enable machines to process and react to data logically but not act nefariously?”

The 2019 program features six main exhibit sectors: Integrated Automation, Motion and Drives (automation, power transmission, motion control and fluid technology), Integrated Energy (conventional and renewable energy systems), Digital Factory (software and IT for production), Industrial Supply (subcontractors and lightweight design), ComVac (compressed air and vacuum technology), and Research & Technology (applied research and technology transfer). Key topics run from machine learning, robotics, digitalization and IT security to sector coupling in the energy industry, supply chain management, lightweight design and e-mobility.

More than 6,500 exhibiting companies from 70 countries and 225,000 visitors from 80 countries will participate in 2019. Two thirds of exhibitors and one third of visitors come from outside of Germany. Approximately 95 percent of visitors are trade professionals. In 2018, roughly 8 percent of visitors (16,100) and 23 percent of exhibitors (1,160) came from Asia.

GLOBAL PLATFORM FOR STARTUPS, LEARNING AND NETWORKING

Digital transformation is a driving force in today’s industrial marketplace. HANNOVER MESSE hosts more than 90 conferences and

that cover this and many other major trends and topics in industry.

For example, the forum Industrie 4.0 Meets the Industrial Internet draws upwards of 8,000 attendees. Global Business & Markets, HANNOVER MESSE’s foreign trade platform, hosts 220 exhibitors and attracts more than 5,000 participants. Young Tech Enterprises, the startup hub at HANNOVER MESSE, consists of an exhibition, a forum, pitches, matchmaking events, and workshops.

A new highlight for 2019 is the Industrial Pioneers Summit on 2 April, which brings together thought leaders and innovators from all fields to discuss strategies and scenarios for the future of industry, business and society.

PARTNER COUNTRY SWEDEN

Sweden is Partner Country of HANNOVER MESSE 2019, a designation that further strengthens the bilateral partnership that Sweden and Germany signed in early 2017.

Sweden’s four focal points for the show are electro mobility, e-health, test facilities for innovation, and the digitalization of SMEs. Sweden’s main exhibit is in Hall 27. Visitors will find additional Swedish technology pavilions throughout the show.

The supporting program includes the Swedish-German Business Summit as well as various forums and networking events about innovation and business opportunities in Sweden.

HANNOVER MESSE 2019 Real-Time Innovations (RTI) will feature Connext 6, the latest version of Connext DDS, the connectivity platform for real-time applications, at Hannover Messe 2019. It is specifically designed for the demanding requirements of the Industrial Internet of Things (IIoT). RTI will also discuss how to use DDS, TSN and OPC UA for advanced manufacturing applications.

Connext DDS is specifically designed to address the performance, scale and resilience requirements of IIoT applications.

The connectivity platform enables the communication between smart devices and subsystems, monitors and controls physical-world processes and provides the non-stop availability and security essential for mission-critical systems. Moreover, it provides a rich set of connectivity capabilities optimized for IIoT systems and supports all of the fundamental communication patterns used in the IIoT. For example, Energy systems require high reliability, performance, security and scale across the critical infrastructure. RTI Connext DDS provides a solid foundation for advanced and intelligent energy systems of tomorrow. Industrial-strength data sharing can improve power generation and

distribution, and enable the efficient use of renewable energy resources at large scale.

Connext DDS complies with the Data Distribution Service (DDS) standard and allows sharing data across multiple networks. It is designed to implement a

layered databus pattern while also fostering interoperability and an open architecture.

Security plugins, interoperable security (including forward interoperability with future Connext DDS versions) as well as plug-and-play with systems that incorporate components from multiple suppliers are available. It also provides the capability to efficiently retrieve historical system data when needed, without flooding the network bandwidth. Additionally, the software offers seamless device mobility to ensure there isn’t a loss in connectivity when devices roam across networks. www.rti.com Issue 37 PECM

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CHEMUK SHOW PREVIEW

BUSINESS NETWORKING CHEMUK

UK CHEMICAL INDUSTRIES TO CONVERGE IN HARROGATE FOR NEW EXPO, CHEMUK 2019 Industry professionals from all sides of the UK’s chemicals sector are set to descend on the Yorkshire Event Centre, Harrogate, Yorkshire on 1st & 2nd May 2019, for the brand new, free to attend CHEMUK 2019 UK supply chain expo & speaker programme.

The CHEMUK 2019 event will bring together the UK’s chemical processing & chemical product formulation industries, providing an intensive 2-day supply chain sourcing, business networking, intelligence gathering, best-practice & strategy development experience.

Designed to introduce new relationships and strengthen existing ones throughout the intersecting layers of the UK’s ‘chemical sector’, the event allows the ‘industry’ to consider the big challenges and opportunities.

2-Day Chemicals Industry Supply Chain Expo CHEMUK 2019 will provide visitor groups with a diverse and impressive showcase of 170+ specialist exhibitors showcasing latest plant, equipment, materials and services supporting the chemicals industries, driving operational performance, efficiency, futureproofing, safety, compliance and more..

Show organiser, Ian Stone, comments: “The chemical industry is profoundly affected currently by a host of major industrial and market changes and CHEMUK aims to provide connectivity with solutions providers, thought leaders, industry bodies to help navigate through essential next steps, as well as provide vital ‘intelligence takeaways’ to facilitate next steps in vital planning and investment programmes.

SECTORS IN FOCUS

Feature ‘sector-specific’ sessions will address the needs of key end-user/formulation industries and corresponding challenges for the chemicals industries - including sectors such as Cosmetics, Personal Care Products, I&I Cleaning Products, Adhesives & Sealants and others...

HARROGATE VENUE

Hosted at the recently completed Yorkshire Event Centre in Harrogate (Leeds City Region), CHEMUK 2019 is located to be equidistant between the crucially important

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North West, Humber & Teesside chemical cluster regions. In addition, providing easy access for the important Yorkshire-based chemical & bio industries plus good central UK positioning. With FREE ENTRY into all exhibits, features & presentations, plus on-site FREE PARKING, as well as easy access by rail and air, the venue provides an easy experience for all visitor groups

WHO SHOULD VISIT?

CHEMUK 2019 reaches out to all key chemicals/chemical product & chemical using industries, targeting Chemical Process Engineers, Operational, HS&E, Control & Instrumentation, Test & Inspection, Manufacturing, Formulation, Logistics, Procurement & Supply Chain, R&D & Scientific professionals plus Chemical industry business teams.

Stone continues: “CHEMUK provides the perfect tailored environment for those industry professionals throughout both the chemicals processing and chemical-based product formulation industries, to meet a host of both established as well as new supply chain groups.”

Organisers are anticipating attendee groups from across the broad industrial chemicals processing & distribution sectors, from petrochemicals & base chemicals, to fine & speciality, intermediates & additives, polymers, inorganics, dyes, pigments, green chemicals, process chemicals and more, Stone comments “whether sourcing supply chain materials partners, or essential plant, equipment , apparatus or specialist industrysupport services, CHEMUK 2019 is designed to create a ‘one stop shop’ environment

for chemicals sector sourcing & partner development.

Equally, the event provides chemical-based formulated product industries, from the cosmetics & personal care industries to paints & coatings, household & industrial cleaning, pharmaceuticals, water treatment, plastics and others, with crucial access to supply chain raw materials, chemical product processing plant & technologies, support services.

Industrial Logistics & Contract Manufacturing For attendee groups looking for industrial logistics, contract manufacturing & packaging solutions, the event will host a cross section of leading providers supported with tailored best-practice and intelligence.

B2B Meetings Pre-registered visitors to CHEMUK 2019 will be able to pre-arrange meetings with other visitor groups as well as exhibiting companies in advance using the event’s online B2B networking tool.

Dates for the Diary CHEMUK 2019 takes place on Wed 1st & Thur 2nd May, 2019 Venue: Yorkshire Event Centre, Harrogate, Yorkshire Opening Times: Day 1: 9.00am – 5.00pm Day 2: 9.00am – 4.00pm FREE PARKING for all visitors Register NOW for your FREE entry badge at www.chemicalukexpo.com

1ST & 2ND May 2019 Yorkshire Event Centre, Harrogate, Yorks

REGISTER NOW FOR FREE ENTRY!

The brand new UK Chemical Industry Supply Chain Expo & Open Conference 2 Packed Days 170+ Leading Exhibitors Latest Plant & Equipment Process Flow & Control Focus Supply Chain Networking 2-Day FREE Conference Intelligence & Best Practice Skills & Careers Programme

FREE ENTRY & PARKING!

Supporting Partners include:

www.chemicalukexpo.com

Shapa

1ST & 2ND MAY 2019 REGISTER FREE AT WWW.CHEMICALUKEXPO.COM

CHEMUK SHOW PREVIEW

we

WHEN THE GOING GETS TOUGH…

Litre Meter now distribute the Lake Monitors range of VA meters for a variety of applications including bidirectional flow, high temperature and high pressure.

bar are in stainless steel.

There are versions for pneumatics, hydraulic test analysis and phosphate ester measurement, too. Call today.

The Basic unit is rated to 116°C and 240 bar in brass. High temperature versions 315°C www.litremeter.com Landscaperated Water to Industry 2019 CHEMUK final 2.pdf 1 15/02/2019 13:59:50 and high pressure versions to 410

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Visit www.omex.com

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SEEPEX TO SHOWCASE NEW HYGIENIC PUMP AT CHEMUK 2019 At CHEMUK 2019 stand M5 (1-2 May, Harrogate), progressive cavity pump supplier SEEPEX UK will showcase its new hygienic pump range. The BCFH range is the first to be certified by the European Hygienic Engineering and Design Group (EHEDG) under its new testing regime. Certification guarantees residue-free cleaning at a lower temperature, with lower chemical concentration and a shorter cleaning time than other cleaning-in-place (CIP) solutions.

As well as giving end-users peace of mind that their closed equipment is microbiologically clean, equipment designed to this standard typically requires 76% less cleaning time compared to other CIP solutions, saving on water, detergent and energy. Not only does the BCFH range adhere to these strict safety and hygiene requirements, it does so without compromising product quality.

Thanks to their low shear action, SEEPEX’s PC pumps do not affect a product’s physical quality – even sensitive, viscous or aggressive media.

Visitors to the SEEPEX stand can also learn about the company’s Smart Dosing Pump (SDP). With an integrated control system delivering low pulsation flow and metering accuracy of ±1%, the SDP can be easily integrated into continuous or batch dosing systems. In addition, dry running and overpressure sensors feed back to the drive to protect the pump from damage, helping to increase service intervals and the lifespan of the product. The SDP provides all the benefits of a traditional PC dosing pump with enhanced control options, future proofing your dosing system and resulting in less chemical usage.

“SEEPEX progressive cavity pumps and control systems are used in the chemical and pharmaceutical industries wherever low to highly viscous, aggressive or abrasive media must be conveyed accurately with low shear and minimum pulsation,” explains Peter McGarian, Managing Director of SEEPEX UK. “We look forward to welcoming visitors to stand M5 at CHEMUK 2019 and helping to solve their pumping challenges.”

CHEMUK 2019, the new UK Chemical Industries Supply Chain Expo & Open Conference, takes place 1-2 May at the Yorkshire Event Centre, Harrogate. www.seepex.com

MORE THAN CLEAN EHEDG PUMP The EHEDG certified BCFH range of progressive cavity pumps handles thin to highly viscous products, including those containing soft solids with a low shear action and minimal pulsation which enables accurate flow control. BCFH pumps fulfill the stringent demands of cleanliness in the food, beverage, chemical, pharmaceutical and cosmetic industries.  EHEDG Type EL Class 1 and 3-A Sanitary Standards certified

 Equipment requires less cleaning time compared to other CIP solutions

 Enhanced internal design ensures residue free cleaning with CIP/SIP

 Easy maintenance due to detachable rotor connection and split suction casing SEEPEX UK Ltd. | sales.uk@seepex.com | www.seepex.com

Issue 37 PECM

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AUTOMOTIVE ENGINEERING

ULTIMATE EXPRESSION ASTON MARTIN

ASTON MARTIN VALKYRIE V12 TURNS THE HYPERCAR ENGINE UP TO 11,100

• New naturally-aspirated 6.5-litre 65° V12 produces 1000bhp • Maximum RPM – 11,100 • Developed in conjunction with Cosworth using proven F1 knowledge, materials and methods • Engine is fully-stressed element of the chassis, yet weighs just 206kg • Hits all programme targets for emissions compliance and durability

With development of its new V12 progressing apace the time is right to reveal some closely guarded secrets of the Aston Martin Valkyrie’s extraordinary powerplant. Developed in conjunction with longtime technical partner Cosworth, the new V12 had to satisfy a simple, yet extraordinary brief: to create the ultimate expression of the internal combustion engine.

The programme called for a normally aspirated engine from the very beginning, for while turbocharging has absolutely come of age and offers significant and widespread

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benefits - especially in a road application the greatest driver’s car of the modern era demands an internal combustion engine that sits at the absolute pinnacle for performance, excitement and emotion. This means the uncompromising purity of natural aspiration.

The resulting engine is an absolute masterpiece. Displacing 6.5-litres the 65° V12 sets exceptional new standards for maximum rpm and specific output with a certified peak power output of 1000bhp (or 153.8 bhp-perlitre) at a mind-blowing 10,500rpm, before continuing on to a maximum rpm figure of 11,100: figures that are unprecedented for a naturally-aspirated, emissions-compliant road car application. Peak torque is 740Nm at 7,000rpm. With these peak outputs purely delivered by the ICE (Internal Combustion Engine), Aston Martin Valkyrie’s performance figures will be further boosted by a battery hybrid system, details of which will be revealed later in the development programme.

Cosworth’s F1 expertise is also evidenced in the Aston Martin Valkyrie engine’s weight, which also set new standards. Given the engine is a fully stressed element of the car (remove the engine and there is nothing joining the front wheels to the back!) and the level of technology in the combustion system, keeping weight down was a huge challenge. Especially as the programme actively avoided use of extreme materiel alloys which are so new that material properties over time are unproven.

Aside from the major castings - block, cylinder heads, sump and structural cam covers - the majority of the engine’s internal components are machined from solid material. These include Titanium conrods and F1TM-spec pistons. Not only does this allow the use of material with ideal properties, but the ultra-fine machining process means greater consistency and components optimised for minimum mass and maximum strength. The result is an engine that weighs just 206kg.

By way of comparison, Cosworth’s 3.0 litre V10 F1TM engines (the last before weight limits were imposed by the FIA) weighed 97Kg. If scaled-up to 6.5 litres this pure race engine would weigh 210kg.

One of the best examples of the painstaking optimisation involved is the billet machined crankshaft. Starting life as a solid steel bar 170mm diameter and 775mm long, it is first roughed out, then heat treated, finish machined, heat treated again, gear ground, final ground and superfinished. Upon completion 80% of the original bar has been machined away and some six months have passed, but the end product is a crankshaft that’s an astonishing 50 per cent lighter than that used in the Aston Martin One-77’s V12 - itself a Cosworth-developed evolution of Aston Martin’s series production V12 and, for a time, the world’s most powerful naturally aspirated road car engine.

Bruce Wood, Cosworth Managing Director, said of the project: “Being asked to create a naturally aspirated V12 engine fit for what

will surely be one of the most iconic cars of all time is an immense source of pride for Cosworth. Decades in F1TM taught us to expect a pretty demanding specification from someone with Adrian Newey’s unsurpassed track record, but when we started talking about specifics of power, weight, emissions compliance and durability combined with ever harder and sometimes conflicting targets, we knew this would be a challenge like no other. It’s been a fantastic partnership between Aston Martin, Red Bull and Cosworth with each party bringing a distinct clarity of vision that has proved essential in delivering an internal combustion engine way beyond anything previously seen in a road car application.”

Dr. Andy Palmer, Aston Martin Lagonda President and Group Chief Executive Officer, said of the Aston Martin Valkyrie’s V12 engine: “To anyone with a drop of petrol in their blood, a high-revving naturally aspirated V12 is the absolute pinnacle.

Nothing sounds better or encapsulates the emotion and excitement of the internal

combustion engine more completely.

Despite the apparently insurmountable challenges it presented, there was never any question that the Aston Martin Valkyrie would make do with anything less. From the outset the team at Cosworth were unflinching in their commitment to achieving benchmarks which pushed the boundaries of the possible. The result is a quite extraordinary engine. One which I doubt will ever be surpassed.”

Evoking the spine-tingling, ultra-highrevving F1TM engines of the 1990s, but benefitting from two decades of progress in design, material and manufacturing expertise, the Aston Martin Valkyrie’s 1000bhp V12 is a masterpiece, from one of the world’s most illustrious engine builders: an internal combustion engine without peer for a hypercar without precedent.

www.astonmartin.com/en-gb Issue 37 PECM

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AUTOMOTIVE ENGINEERING

PRODUCT DATA INTELLIGENCE ACTIFY

LEVERAGE ALL YOUR CAD DATA WITH ACTIFY

Discrete manufacturers of all sizes share a data problem: How to maximize value from all the information that is available about products and services?

Information is recognized as a business asset that creates real value. The magnitude of information is continuing to increase driven by the proliferation of data from the internet of things (IoT).

To expand data’s value, we must share product information across the enterprise in meaningful ways that unlock insight and support collaboration, efficiencies, and cost reduction. The more that data is used, the more value is extracted from it and the higher the benefits are for companies, such as being faster, better, and cheaper at producing products. However, there are many barriers when it comes to sharing data because companies have created siloed data sources that are difficult to find and access.

Ask yourself what functionality is really needed to be successful? Over the years manufacturing companies have spent a fortune on expensive CAD, PDM, PLM and ERP systems without ever gaining the promised results. An investment into

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productivity tools which aren’t effectively implemented or used to maximize business impact, will erode profit margins.

Today’s business problems are not about creating more data or buying additional expensive and complex technology, but rather accessing the existing business data and gaining insight. Just imagine if you could release the business value that is trapped in these applications and other key data sources like spreadsheets.

Disruptive technologies like Actify Product Data Intelligence can help release your enterprise data and increase results without the typical costs! Actify facilitates data visibility and data usability. Managers enjoy having the maximum amount of information available to contextualize the business, make informed decision and improve business outcomes.

The benefits of Product Data Intelligence are illustrated in the diagram as a demonstration of value. Contact Actify for more information and for a personalized demonstration of value for your organization.

Actify provides a set of business solutions designed to support the creation, management, dissemination and collaborative use of product data (i.e. product definition information including BOM structures, CAD files, specifications, requirements, manufacturing instructions, etc.).

Actify delivers powerful and affordable Product Data Intelligence solutions to the aerospace, automotive, industrial automation, and discrete manufacturing industries. Actify’s solutions enable designers and knowledge workers alike to participate in product design and development activities, thereby lowering collaboration costs and improving manufacturing performance.

Actify is passionate about leveraging available enterprise data to make manufacturing companies smarter by harnessing the product data trapped in all their data sources.

Contact Actify for more information.

Visit: www.actify.com Email: sales@actify.com

AUTOMOTIVE ENGINEERING

INTELLIGENT SYSTEM JAGUAR LAND ROVER

JAGUAR LAND ROVER LIGHTS UP THE ROAD AHEAD FOR SELF-DRIVING VEHICLES OF THE FUTURE Jaguar Land Rover has developed a system that projects the direction of travel onto the road ahead of self-driving vehicles, to tell other road users what it is going to do next.

The intelligent technology beams a series of projections onto the road to show the future intentions of the vehicle - for example stopping and turning left or right - as part of research into how people can develop their trust in autonomous technology. In the future the projections could even be used to share obstacle detection and journey updates with pedestrians.

These projections, tested on autonomous pods developed by Aurrigo, feature a series of lines or bars with adjustable spacing. The gaps shorten as the pod is preparing to brake before fully compressing at a stop. As the pod moves off and accelerates, the spacing between the lines extends. Upon approaching a turn, the bars fan out left or right to indicate the direction of travel.

Trials were set up by a team of advanced engineers, working in Jaguar Land Rover’s Future Mobility division, supported by cognitive psychologists, after studies showed 41 percent of drivers and pedestrians are worried about sharing the road with autonomous vehicles*.

The innovative system was tested on a fabricated street scene at a Coventry facility with engineers recording trust levels reported by pedestrians both with and without projections.

The trust trial programme - which also included fitting of ‘virtual eyes’ to the intelligent pods in 2018 to see if making eye contact improved trust in the technology** - was conducted as part of Jaguar Land

Rover’s government-supported UK Autodrive project.

Pete Bennett, Future Mobility Research Manager at Jaguar Land Rover, said: “The trials are about understanding how much information a self-driving vehicle should share with a pedestrian to gain their trust.

Just like any new technology, humans have to learn to trust it, and when it comes to autonomous vehicles, pedestrians must have confidence they can cross the road safely. This pioneering research is forming the basis of ongoing development into how self-driving cars will interact with people in the future.”

Safety remains the priority as Jaguar Land Rover invests in self-driving technology, becoming automotive leaders in autonomous, connected, electric and shared mobility. The trial is aligned with the brand’s long-term strategic goals: to make cars safer, free up people’s valuable time and improve mobility for everyone.

This commitment extends to Jaguar Land Rover’s current models with a suite of Advanced Driver Assistance Systems including Adaptive Cruise Control, Blind Spot Assist and Intelligent Speed Limiter available across its range of vehicles, including the Jaguar F-PACE and Range Rover Velar.

www.aurrigo.com

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AUTOMOTIVE ENGINEERING

DOMED CAR & AUTO BADGES All our domed car badges are manufactured to Automotive specifications. The adhesive is suitable for use as wheel centre and bezels or directly to body work.

Bespoke Badge Manufacturers We supply a wide range of domed badges for all industries which can be customised to include your own design, logo and details. We offer a full print and dome service for manufacturers wishing to enhance their products.

We can print directly from your supplied vector artwork or hi-res PDFs. All our products are tailor made to your requirements and ideally suited for all control panel and product marketing, even in harsh environments. For a cost effective and professional way to brand and personalise your products for your market or application contact us by phone or email with your requirements.

The inks used are either solvent or latex based depending on application. The resin used for the domed badges is a stable twopart polyurethane.

The finished product will not go cloudy and UV stable so they will not fade in sunlight. The scratch resistant surface will ensure your logo will remain clear and visible for years to come.

We can produce in a number of different finishes such as Silver, Chrome, Gold, White, Brushed Aluminium, Etc... Whatever you require.

Small Production Runs Here at Dash Dynamics, unlike many of our competitors, we specialise in small production runs. So if you just need a set of wheel centres for your newly purchased or refurbished alloy wheels, then no problem.

Turnaround time is fast! In most cases, if you order before 1.00pm, the order will be produced the same day and after overnight curing it will be sent the following day via first class post or carrier depending on size. International orders are accepted too.

Size matters For larger trade bulk orders, rates improve. Feel free to pick up the phone and call us on 01995 606 158 or email us at info@dashdynamics.co.uk for costs against volume.

Small Production Runs Here at Dash Dynamics, unlike many of our competitors, we specialise in small production runs. So if you just need a series of machine panels for a new prototype or low production run, then simply send us your artwork and we’ll get on with it.

All at a realistic price.

Turnaround time is fast! In most cases, if you order before 11.00am, the order will be produced the same day and after overnight curing it will be sent the following day via first class post or carrier depending on size.

International orders are accepted too.

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Sales@Insequence.co.uk +44 (0) 1869-238 080 www.Insequence.com Issue 37 PECM

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AUTOMOTIVE ENGINEERING

THE FIRST 450 DAYS BMW

SIX QUESTIONS FOR ELMAR FRICKENSTEIN, SENIOR VICE PRESIDENT AUTOMATED DRIVING AND DRIVER ASSISTANCE, BMW AG

In September 2017, you and your team moved to the Autonomous Driving Campus in Unterschleissheim. What prompted the BMW Group’s decision to create this new site?

We are currently experiencing the largest paradigm shift in the history of the automotive industry. The industry is set to witness more change in the next decade than in the past 30 years. Today, we are already on the brink of highly automated driving.

There are many challenges to overcome as we progress towards highly and fully automated driving, the biggest of which is surely to handle the overall complexity of the task. To succeed, we must have the courage to change our way of thinking. And this is exactly what we have done. Having the Campus as a central site where all of the BMW Group’s autonomous driving resources are bundled forms a fundamental element of our all-embracing approach. Here, we

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work closely interconnected also with our technology and collaboration partners on the development of the necessary technical solutions. For example, software developers can immediately test out code they have just written – in the actual vehicle and in just a few steps. Everything is done on a common code base. The Campus with all its facilities was completed in record time; we moved in just one year after receiving the go-ahead.

After the first 450 days there, what changes do you feel working together at the Campus has brought about?

At the same time as moving to the Campus last year, we adopted an agile working method known as LeSS – Large Scale Scrum.

And we aligned the organisational structure to the new working environment. Working in feature teams with end-to-end responsibility, our employees at the Campus produce valid results in two-week sprints that they

can test out and experience in the actual vehicle. It’s incredible to see just how much this new way of working together motivates the developers. The remarkable spirit I can sense here on a daily basis is another thing that reminds me of Silicon Valley. That is why I personally see the Autonomous Driving Campus as symbolising the dawn of a new era in mobility. I’ve been at BMW for 30 years and have both witnessed and played an active part in many changes. But when I moved to my new workplace at the Campus on September 18th 2017, I was in no doubt that a new chapter in the BMW Group story was beginning here. The Campus is different, new, innovative and quite unique in the automotive industry. We need to embrace change in this way if we want to master the complexity of autonomous driving; the development of new technologies calls for new approaches.

What do you like most about the new working method?

The agile working method is based, among other things, on the principle of ongoing improvements for both products and methods. For example, the teams convene for a ‘sprint review’ at the end of each sprint. They present their results to all the employees in a kind of marketplace. This means that when they plan the next sprint afterwards, consideration can also be given to issues arising at short notice as a top priority. Then there is the ‘retrospective’, when the teams share observations from the last sprint and work together to identify measures for improvements in the next sprint. The beauty of it all is that these regular exchanges put the developers in a position where they can make decisions themselves, which is crucial not only for product advancement, but for this style of teamwork as well. Hierarchical delegation becomes a thing of the past as a result, while knowledge is scaled to maximum effect and made available to everyone. That’s how you develop for the future.

What are the next development steps towards autonomous driving at the BMW Group?

With the Campus, the switch to the LeSS working method and our organisational structure, we have created a solid basis for mastering the complexity of the task. This enables us to establish new key technologies such as artificial intelligence and simulation as the focus of development. We are also gradually expanding our fleet of vehicles.

Currently we have 80 vehicles operating in Europe, the USA and China. The aim with these measures is to validate our highly and fully automated driving technology and to carry out the transition from demonstrator development to production development.

How will customers benefit?

In 2021, we will be offering customers a perfected system in the BMW iNEXT that adds noticeable value to the vehicle experience.

Highly and fully automated driving will give our customers back one of the most precious commodities of all: time. The optional “Highway Pilot” will allow customers to drive on the motorway from Munich to Hamburg, for example, at speeds of up to 130 km/h (81 mph) and spend the time doing other things, such as reading a newspaper or just enjoying the landscape. We will also be operating pilot fleets with Level 4 technology based on the BMW iNEXT in selected regions. Our motto is always “safety first”. With the right technology, the right technology partners and an agile working model, automated driving will make our roads safer for everyone. Our Campus creates the basis for customer-centric development. Thanks to the unique spirit instilled by the Campus, we are changing the

face of personal mobility for our customers and giving them back valuable time.

Finally, if you had to describe the Campus with three hashtags, what would they be? #EmbracingChange #Transformation #GermanSiliconValley The BMW Group With its four brands BMW, MINI, RollsRoyce and BMW Motorrad, the BMW Group is the world’s leading premium manufacturer of automobiles and motorcycles and also provides premium financial and mobility services. The BMW Group production network comprises 30 production and assembly facilities in 14 countries; the company has a global sales network in more than 140 countries. www.bmwgroup.com Issue 37 PECM

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4-6 June 2019, NEC

The UK’s leading exhibition for the automotive aftermarket and vehicle production industry targeting trade visitors from the UK

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BOILERS & MAINTENANCE G P BURNERS LAUNCHES FACILE RANGE OF SELF-REGULATING BURNERS Swindon based combustion equipment manufacturer, G P Burners, has launched its FACILE range of fully automatic burners.

The company claims that the new, state-of the-art models are the first self-regulating burners for industrial and commercial combustion applications. The patented FACILE burners feature innovative and smart technology to deliver ease of operation, faster commissioning, optimum performance, energy efficiency and reduced emissions.

FACILE burners independently and automatically set up plant parameters such as temperature, pressure and boiler power, as well as reacting to ambient variables including altitude and climate.

The system recognises and adapts to all types of boilers and processes for optimum performance.

These characteristics simplify installation and dramatically reduce commissioning time, compared with conventional burners. For the rare occasions when operator intervention is

MANUFACTURERS & DISTRIBUTORS OF STEAM BOILERS & ANCILLARY EQUIPMENT

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The FACILE range includes six LO NOx models with emissions of less than 80 mg/kWh (Class 3) and a power output range from 100 to 810 kW Email: info@gpburners.co.uk Web: www.gpburners.co.uk

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COMBUSTION ENGINEERING

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09:04

CONNECTORS & FITTINGS

THERMOSET HARTING

REDUCE DOWNTIME AND PROCESS COSTS FOR THERMOSET PLASTICS INJECTION MOULDING The applications and uses for thermosetting plastics have grown substantially over recent years. The benefits of this type of plastic are largely due to its favourable plastic properties.

Thermoset plastic polymers cross-link together when being cured and so form an irreversible chemical bond. Along with thermoplastic, this is one of only two organic, polymer-based plastic materials.

THERMOSET: THE MATERIAL FOR EXTREME SITUATIONS Closed-meshed, cross-linked thermoset molecules require a completely different temperature profile to thermoplastics. The compound is injected from a cold cylinder module into a hot mould.

Further heating and melting of the compound in the mould causes a decrease in viscosity that is only reversed when crosslinking increases. The finished component is then irreversibly cross-linked, which makes it extremely hard.

The temperature reached within a thermoset injection mould tool is significantly higher than a thermoplastic version. As such, the electrical connectors that are surface mounted to the tools, and carry the temperature monitoring thermocouple contacts, will experience temperatures of 30 to 40 degrees C higher than the typical standard connector working temperature of 125-degree C. As a result, there is a tendency that these connectors will have a reduced operating life.

These potential connectivity component failures can occur during the plastic component assembly process, which means critical mould temperatures will cease to be controlled. Consequently, in some high volume production conditions, parts may come off the line which do not meet quality standards, resulting in increased and costly waste materials.

HARTING has recently launched a new high temperature version of its Han series multipole connectors that addresses these issues through its extended maximum working temperature capability. This significantly extends the operational lifetime of the thermoset plastic injection mould tools, reducing potential tooling maintenance and

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service periods, line downtime and ultimately, operating costs.

separately applied, detrimental protective coating finish.

HARTING has used its considerable technical expertise to develop special connectors which provide reliable solutions for these high-temperature environments.

The connector insert and contacts must withstand the high ambient conditions of the location and the additional heat generated inside the housing when under mated load.

HARTING has selected high-temperatureresistant copper alloy contacts that maintain constant electrical properties when heated.

In addition the high-temperature LCP plastic inserts ensure a longer service life.

For example, bulkhead connector seals must not melt or adhere to other integrated component parts over the full operating temperature range. Consequently, HARTING has opted for a non-stick coated hightemperature-resistant rubber version, which avoids bonding between the hood and housing even if they are left mated for several years.

Many of the hoods and housing coatings and lacquers available on the market are not suitable for long-term use at high temperatures as they can cause melting, which can lead to mated parts sticking together. Thanks to the application of a special surface treatment to the aluminium die-cast hoods and housings, HARTING has been able to dispense with any additional,

As a result of these features, HARTING’s Han® High Temp connectors can permanently withstand operating ambient conditions of +200°C, providing extended operating lifetimes and ensuring reduced line downtime, compared to competitor solutions. *Article reference source: https://www. osborneindustries.com/news/thermosettingplastic-uses-applications/

For further information visit www.harting.com/UK/en-gb

CONNECTORS & FITTINGS

NERO BOOSTS PRODUCT RANGE WITH STAINLESS STEEL PRESS FITTINGS Nero, the market-leading distributor of stainless pipeline products, has invested in a new range of press fittings, which can be used by installers for both domestic and commercial applications.

The stainless steel Press Fittings range includes elbows, couplings, bridges, adaptors, tees, valves and reducers, from 15mm up to 108mm. With no need for welding or soldering, the fittings can be assembled in situ, offering a safe, fast and cost-effective solution.

The products have a maximum operating pressure of 16bar and a temperature range of -35°c to +135°c, although higher temperatures can be achieved using optional FPM seals. All the fittings come with a blue press indicator which will break off once a full seal has been achieved.

Darryl Spencer-Hicks, Operations Director at Nero said: “This significant investment in our range adds to the 15 product groups we already offer, providing customers with enhanced choice across a broad range of applications.

“The Press Fitting products can be used for installing building services in all types

of properties, so are ideal for construction projects across sectors.

be delivered next day if stocked items are ordered before 4:30pm.

“We pride ourselves on our high levels of customer service, so have also invested in new storage to accommodate the range ensuring the highest levels of stock.”

The Press Fittings range is 316L / 1.4404, WRAS / DVGW approved and complemented by tubes in all sizes to fit.

The new products are available from Nero’s central warehouse in the Midlands and can

For further information or to place an order, visit www.nero.co.uk or call 0121 665 3900.

ENGINEERING CONNECTIONS

5 STAR CUSTOMER SERVICE

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CONTROL & AUTOMATION

NOW. NEXT. BEYOND BOSCH REXROTH

WHAT THE FACTORY OF THE FUTURE HAS IN STORE

Compare factories of 20 years ago to those of today and in most cases they won’t look too dissimilar. On the surface, you may be right, but dig a little deeper and their heart will have changed as they adjust to a more volatile global marketplace. Alongside increased cost pressures and heightened quality standards, consumers now expect customised products, fast delivery, greater flexibility and shorter lead times. As a result, efficient working practices are more important than ever – but how can factories of the future accommodate this?

Of course, the digital transformation – from the configuration of networked machines and systems through to the fully digitalised value stream – will be key. With some six billion objects now IoT-connected, we’re already seeing manufacturers taking significant steps towards a digital future.

But for some, taking the leap into the digital age isn’t straightforward, with the benefits of Industry 4.0 and the process of

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implementation not fully understood.

To understand where the benefits of digitalisation lie, Bosch Rexroth developed its own Factory of the Future, demonstrating every possibility and exploring how manufacturers can implement them stepby-step for maximum impact. Let’s explore some of the key benefits, and how close the future is.

DIGITISING YOUR VALUE STREAM In the Factory of the Future, all hardware modules and functions are represented digitally in real-time. Sophisticated software solutions collect, transfer and process data from manufacturing and logistics to analyse, simulate and improve all processes across the value stream. On the factory floor, real-time gathering and processing of data from sensors not only enables production quality checks at the point of manufacture, but also facilitates accurate machine and

system health checks through continuous monitoring.

Distributed intelligence manifests itself in all technologies and gives machine manufacturers new options. From cabinet free drives which reduce cabling; low energy, intelligent hydraulic power units; to assembly workstations which provide employees with work instructions that are adjusted to the individual’s level of training and knowledge. At the same time, for factories looking to evolve gradually, older machinery can realise many of the benefits cost-effectively using a pre-configured plug and play IoT gateway.

MAXIMISING YOUR FLEXIBILITY Setting the stage for increasing productivity in serial production, smart factories will make it possible to (re)configure production lines and facilities to fast changing requirements.

Taking connected hydraulic systems as an example - sensors can be added to horizontally and vertically networked machine architectures. Predefined functions within the software can be used to control the position, velocity, distance/force, different synchronous cylinders or path-dependent braking and improve performance by dynamically adjusting flow and pressure.

Managing these functions in real-time, via the software, allows users to operate more efficient when producing small batches and reduces the retooling work for new products.

Further improving flexibility, the increasing use of wireless technology has the potential to mobilise machines and plants. Instead of power cables, which effectively tie a machine to a specific place in the factory floor, machines will be powered by inductive charging from the floor of the hall, with the added benefit of 5G connectivity as a faster, more stable means of data transfer.

This functionality simplifies conversion to new processes, making factories highly flexible. Production configures itself independently in-line with the product to be manufactured. Communication between machines and systems is mainly wireless.

Production layouts are optimised and operating data is captured and analysed, producing real-time data which drives continuous improvement and virtually eliminates machine downtime.

STEPPING INTO THE FUTURE What we’ve learned in developing the Factory of the Future is that when you consider what can’t be changed, surprisingly little remains: the floor, the walls and a roof. The rest of the factory: the machines, automation topologies, equipment, communication paths, even the people and how they work together are subject to the changes demanded by modern manufacturing.

The notion that a process facility is too large or too old to move towards digitisation is a common one. Whether a facility chooses to take a granular approach to getting connected, or prefers the idea of a complete digital overhaul, it is important to remember that digital technologies are highly scalable – making them relevant to any business, of any size, at any stage of the process.

In fact, Industry 4.0 presents a host of opportunities for manufacturers to incrementally change how they do things.

Putting sensors on key pieces of machinery to provide real-time insights into equipment health and making use of the Internet of Things to collect data, streamline operations and improve efficiency are just some of the benefits.

To discover more about the evolution of smart factories, explore Bosch Rexroth’s Factory of the Future at: www.boschrexroth.co.uk/fotf Issue 37 PECM

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COBOTS ON TOUR! Have you ever considered how automation could benefit your operations but not been sure of where to start? If you’d like to learn more about the opportunities and challenges of automation, then join our industry experts at Universal Robots on the UK Cobot Automation Tour of 2019.

The Automation Tour kicked off on February 12th in Oxford, but don’t worry if you missed the first stop – we’ll be popping up all over the UK with the cobots all the way into the summer. We’re excited to announce the locations for the upcoming events which will be taking place in Manchester, Newcastle, Birmingham, Edinburgh and finally Southampton, where the tour will end on the 11th July.

By joining one of the stops of the Tour, you’ll get a chance to get all of your questions about robotics and automation answered by our leading industry experts.

The participants at our first stop in Oxford were not only introduced to our leading UR collaborative robots, their capabilities and applications, but also got the chance to program and operate the cobots themselves and experience their ease-of-use first hand.

We believe that automation really is for everybody. In order to demonstrate the wide variety of tasks that cobots can be programmed to carry out, a wide range of UR + partners, including Robotiq, SICK, and SKFRobotics, will also be exhibiting their

automation solutions. This will provide visitors with the perfect opportunity to see and engage with a wide range of industry experts in one place.

The next stop of the Tour will be in Manchester on 19th of March. Places are filling up quickly, so make sure to register your interest here to reserve your space.

To register for one of our other upcoming events or to find more information about the Universal Robots’ Cobot Automation Tour please visit: info.universal-robots.com/ne/uk/ urplusevents2019

WHERE QUALITY IS THE WATCHWORD

At ChinaSavvy, quality is paramount and we always meet – and very often exceed – our customers’ requirements and expectations.

ChinaSavvy has 15 years’ experience in sub-contract manufacturing and we have delivered world-class engineering services around the globe.

Whether you are a small business or a blue-chip global corporation and you want metal or plastic products designed and manufactured to the very highest standards, make ChinaSavvy your first call.

Talk to us about your casting requirements, metal fabrication, precision machining and production using plastics and carbon fibre – ChinaSavvy offers 19 different metal processes, including six different methods of

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casting such as sand casting, die casting and permanent mould gravity casting.

film extrusion, thermoforming, vacuum forming and rotational casting.

As well as casting, ChinaSavvy can source a variety of precision machining processes and we are acknowledged as an outstanding, world-class CNC machining company, offering superb milling and turning.

Above all, we have an unrivalled commitment to quality assurance, communications, logistics and customer service.

In precision metal fabrication we can produce extremely high-quality parts for very competitive costs, whether using laser cutting, plasma cutting, water jet cutting, punching, stamping or hard material cutting using electric discharge machines (EDMs).

When manufacturing in plastic (and producing prototypes in just a few days), we offer injection moulding, blow moulding, polyurethane moulding, profile extrusion,

There’s nobody in the world quite like ChinaSavvy so get in touch now and we’ll do the rest: www.chinasavvy.com ChinaSavvy HK Ltd Frome BA11 2PW United Kingdom Tel: +44(0)1373 830577 Email: uksales@chinasavvy.com

CONTROL & AUTOMATION

COBOT AUTOMATION TOUR 2019

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DASH DYNAMICS – YOUR ANSWER FOR BRANDING AND CONTROL PANELS Dash Dynamics understand the need for clear, easily understood graphics for Machinery and Branding.

Using the latest design, printing and doming techniques we work alongside your business to create Resin Domed badges for use on panels and equipment to enhance their appearance and give accurate information on their use. Product branding also requires a bespoke look, that’s where the use of quality Resin Domed sets your products above the normal.

Need low volume production runs, a fast turnaround time? That’s no problem. We are happy to work with single badges and we usually can manufacture and ship the following day. Need higher volume? Just get in touch and we will be happy to offer you a quotation.

Website: www.dashdynamics.co.uk Email: info@dashdynamics.co.uk Tel: 01995 606 158

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SOLVING A COMMON PROBLEM CP AUTOMATION

PRECISE ALIGNMENT FOR TISSUE CONVERTING

Industrial sales and repair specialist, CP Automation, has introduced the Re Spa web guiding (WG) series to its product portfolio. These intelligent retrofit parts are set to solve common problems for tissue, aluminium foil, paper and plastic film manufacturing and processing plants, by offering precise alignment of web winding and consistent printing and cutting processes.

Effective alignment from the unwinder to the rewinder is a must for any converting businesses wanting to increase productivity and product quality. Re Spa’s web guiding systems are an ideal retrofit option that can be added directly to the existing system’s unwinder, to guarantee a fast and accurate correction of material position.

The Re Spa WG705 web guiding product is

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designed for reels up to 600mm in width, while the WG2003 suited to reels larger than 600mm. Both are fitted with ultrasonic sensors that feedback the position of the material to the web guiding controller, which sends a correction signal to the roller to reposition the material accordingly.

A further source of frustration for converting is the alignment of the web prior to folding after the cutting process has taken place. At this point, the web is smaller, so there is less room for error. The material must therefore be perfectly aligned on the roller in order to create precisely central folds. The WG705 offers easy pre-folding alignment correction, guaranteeing a precise fold in the middle of the product.

“Re Spa has identified a clear need for this product in the converting industry,”

explained Tony Young, director of CP Automation. “Factories in all industries are becoming smarter, and tissue, film and foil processing and manufacture certainly won’t get left behind. Alignment issues don’t need to be a costly or recurring problem anymore, as these devices from Re Spa are now available for postunwinding and post-cutting precision.

“Businesses that have retrofitted these parts are already reducing their production waste, reducing time spent on setup and increasing print quality.”

For more information on CP Automation’s Re Spa product range, visit www.cpaltd.net and www.re-spa.com, or e-mail sales@cpaltd.net.

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CONTROL & AUTOMATION

INDUSTRIAL TRENDS FOR 2019 COPA DATA

PREDICTIONS FOR MANUFACTURING Industry 4.0, the Fourth Industrial Revolution or the Industrial Internet of Things (IIoT).

Regardless of the phrase used to describe digitalization in manufacturing, there’s no denying that a shift has already taken place.

But, is the age of industrial buzzwords coming to a grinding halt? Stefan Reuther, Chief Sales Officer at COPA-DATA, gives his three predictions for industrial automation in 2019 — no buzzwords included.

‘INDUSTRY 4.0’ IN PRACTICE Manufacturers have long felt the pressure to invest in new technologies. In the so-called age of Industry 4.0, this pressure has been heightened by an influx of products and initiatives, all claiming to help manufacturers digitize their operations. Unfortunately, some of these schemes are nothing more than a waste of money.

Don’t get me wrong, there is certainly value in investing in technology to enable digitalization in factories’ practices.

However, rushed approaches have led to some manufacturers making haphazard investments. For example, some have delegated digitalization to third parties and as a result, are not in charge of their own automation.

Before embarking on a digitalization scheme, manufacturers should first examine which

technology is practical to their facility. A good place to begin is to listen to the people on the factory floor. Understanding how technology can practically help workers can ensure that investments are pragmatic.

from production. To identify areas of improvement, manufacturers would need to collect production data and compare this with data from Enterprise Resource Planning (ERP).

Another thing to consider is simplicity, by reducing complexity of processes and gaining a clearer overview and full control.

Manufacturers should choose technology that is easy to understand, implement and scale up in the future. Looking forward to 2019, digitalization should be approached in a more practical manner — a steady, incremental transformation is better than a failed one.

Without a pre-determined strategy like this, manufacturers run the risk of simply collecting and storing hordes of data. There’s no value in data if it is left to gather dust.

Over the next twelve months, we hope to see data strategies become an integral part of manufacturing. That said, data strategies are only comprehensible when using the correct software.

LESS DATA HOARDING, MORE DATA USE Software is another area that has been constantly hallmarked as a method to speed up manufacturing digitalization. However, before investing in software for data collection, manufacturers should begin 2019 by implementing a coherent data strategy.

THE SOFTWARE EVOLUTION Recent years have seen a shift in the amount of investment manufacturers assign to software. Traditionally, hardware would have received the largest bulk of cash, but this is beginning to change — particularly as more advanced software platforms emerge.

Rather than simply collecting and storing data, manufacturers must identify the results that they want to achieve and decide how data can help them to meet these business objectives.

Software for manufacturing facilities is no longer limited to Manufacturing Execution Systems (MES) and Supervisory Control and Data Acquisition (SCADA). The realm of industrial software is experiencing a convergence of IT and operational technologies (OT), giving birth to new platforms which integrate a plethora of different areas — including enterprise data from the corporate level, through to field and process level automation.

Consider this as an example. Let’s say a manufacturer wants to improve return on investment (ROI) in the facility by reducing the amount of materials wasted

While this may sound more complicated than traditional systems, these platforms often boast better design, visualization, calculation logic and ergonomics than their predecessors. This makes the operation of systems safer, simpler and more transparent.

I might have promised no buzzwords, but software is the driver of what is so commonly referred to as Industry 4.0. As a result, it is no surprise that we are likely to see increased investment in integrated platforms like these over the next twelve months.

The age of conceptualizing the possibilities of manufacturing digitalization is over.

During the next twelve months, the products and initiatives hailed as ways to transform manufacturing facilities will finally be put to practical use.

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CONTROL & AUTOMATION

EMPOWERING WORKERS PRODUCTS4 AUTOMATION

NEXT AR APP HEADS UP OPERATORS IN HUMANMACHINE INTERACTION ON THE PLANT FLOOR Progea has developed an augmented reality (AR) app that incorporates Human Machine Interfaces (HMIs) onto Smart Glasses. By superimposing digital information onto physical objects, the AR HMIs empower factory workers to interact with machines and manufacturing processes virtually. The app, NExT AR, uses the SCADA/HMI platform Movicon.NExT, so it provides genuine feedback and control while seamlessly integrating with other management systems and software layers.

AR offers a unique opportunity to enrich our working environment, by providing an interactive platform that displays relevant virtual information and aligns real and digital objects with each other in real-time.

When AR is associated with head-updisplays (HUDs), its potential skyrockets, as it enables hands-free interaction with the surrounding mixed-reality environment.

An area where AR HUD has massive potential is the factory floor. By eliminating the physical separation between machines and their automation data, this technology can help factories to improve industrial processes and product quality whilst minimising errors, downtime and costs.

For example, an operator in the field could perform maintenance activities faster, while watching instructions on how to perform each task correctly. Similarly, it would be possible to turn valves while monitoring the values of the flow downstream change in real-time, making carefully judged adjustments.

THE FUNCTIONALITIES OF A HIGH-QUALITY SCADA ON HUD The NExT AR app was created to allow plant operators to follow key performance indicators (KPIs), receive alerts and notifications as well as interact with critical plant processes in real-time from anywhere across the factory floor. More precisely, the app connects wearables to the factory’s SCADA (supervisory control and data acquisition) system, thus creating a selfcontained, hands-free and ergonomic HMI (human-machine interface). In this way, operators can access any dashboards, alerts, pages, screens, real-time and historical data stored within the SCADA system.

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NExT AR is compatible with Microsoft HoloLens and Android smart glasses, including Google Glass, and uses Movicon.

NExT industrial SCADA platform as its centralised data management system. The latter was also developed by Progea and is available in the UK through Products 4 Automation (P4A).

Remote access from NExT AR to SCADA is provided by the Movicon.NExT HTML5 Web Client. The two systems interact via Wi-Fi connections and OPC UA server-client communication channels. In this way, the HUD can display any data from Movicon.

NExT. More precisely, the functions of Movicon.

NExT accessible from NExT AR and the interactions between the two platforms are fully customisable, in order to satisfy different industrial needs. Bespoke solutions can

be either created by the users, via software development kits (SDK), or by Progea itself.

Furthermore, the modular and flexible workspace presented by Progea’s SCADA is designed to ensure ease of use and intuitive navigation via advanced visualisation capabilities and captivating graphics.

The platform uses Windows Presentation Foundation (WPF) resolution-independent and vector-based rendering engine. This next-generation technology offers 2D and 3D graphics. As a result, these features are also present in NExT AR, which can support 3D and holographic imaging visualisations as well as “’pinch and zoom’ functionalities that further optimise user interaction.

FACTORIES BECOME SMART UNDER THE EYE OF AR HUD In the past, plant operators and engineers

had to choose between staying at their own desk to monitor the equipment via the SCADA system or be on the factory floor to look at the machines themselves, where they were out of touch with other plant and control systems.

Thanks to NExT AR, this dilemma no longer exists, as the shop floor and higher enterprise levels can truly connect.

As mixed reality becomes more and more popular for industrial applications, users’ expectations will continue to grow. Progea is continuously pushing the boundaries of what is possible with AR HMI, by implementing new functionalities and expanding the compatibility of NExT AR to new wearables.

In this way, the company is deploying the Industrial Internet of Things and paving the way for Industry 4.0. www.products4automation.co.uk

Issue 37 PECM

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CONTROL & AUTOMATION

CLOUD BASED SOLUTION MITSUBISHI

INDUSTRIAL ROBOTS ACCESS AI VIA THE CLOUD Mitsubishi Electric has developed a cloudbased solution for pro-active maintenance based on the AI platform within IBM Watson, which enables the smart analysis of operational data to predict and highlight future maintenance requirements.

The theory is that sometimes service schedule requirements for robots are inadvertently missed which, despite the extended duty-cycles and the general reliability of modern robots, is not a healthy situation for continuous plant operation. By using an innovative predictive maintenance method however, users are engaged with their robots, receive operational and maintenance data and thereby keep them healthy via planned maintenance schedules, reducing operational costs, increasing asset productivity and improving process efficiency.

PUTTING PREDICTIVE MAINTENANCE ON THE DIGITAL AGENDA

Today many companies are still caught by surprise when machine failures occur.

They tend to fix problems during enforced downtime, or implement preventative maintenance based on set schedules or numbers of operational hours. However, using predictive maintenance techniques production problems can be highlighted long before they result in unplanned downtime or impact on yield. Maintenance personnel can take corrective action before failure or before degraded machine performance results in sub-standard products being manufactured.

The additional benefit of predictive maintenance is that by potentially avoiding some fixed-schedule maintenance tasks you don’t service equipment when it isn’t required, rather on-demand, therefore saving time and expenditure.

This latest solution from Mitsubishi Electric offering predictive maintenance for robots utilises the AI platform within IBM Watson to assess actual maintenance requirements and then suggest actions to take in an efficient and timely manner. The platform uses predictive maintenance models, digital simulation and extrapolation of trends to provide maintenance information based on actual usage and wear characteristics. This is particularly pertinent to robots, where users don’t always appreciate that periodic maintenance is a mandatory requirement.

There are a number of moving parts within SCARA and articulated arm robots, depending on the type and model they include servo motors, gears, ball-screws, belts, bearings and seals. Items will experience wear over time and require eventual replacement while others will need fresh lubrication and a service check on belt tensions etc. Considerations such as duty cycles, operating environment and loading can all play a part in dictating service requirements, so being able to visualise components with a live status and then receive considered advice tailored to that particular machine will match servicing closely to requirement.

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Voice commands for industrial robots The system also demonstrates how the speed and efficiency of any necessary maintenance activities taking place can be enhanced using voice commands. An augmented reality platform is used to create a visual overlay which provides live information in real-time interactive screen graphics. Siri for example can then be used to issue simple commands based on the knowledge gleaned from the screen.

Increased visibility of live status information is expected to provide opportunities for significant reductions in downtime.

Augmented reality provides additional support for maintenance Using this, system maintenance activities can also be optimised through the use of smart glasses, where the operator receives guidance on what tasks need to be performed. The glasses can show CAD drawings of the various robot parts, superimposed over the robot itself. The glasses can also show the maintenance manual and individual instructions.

This type of next generation human / machine interaction works well with the latest safety solutions that can do-away with the traditional interlocked cage in many instances, relying on smart proximity sensors and Mitsubishi Electric’s MELFA SafePlus feature to manage robot movement safely in the presence of humans. www.gb3a.mitsubishielectric.com

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CONTROL & AUTOMATION

SMART TECHNOLOGY SCHNEIDER ELECTRIC

THE IMPACT OF AI ON THE INDUSTRY

By Martin Walder, VP of Industry at Schneider Electric

Artificial Intelligence is one technology that will revolutionise the field. A recent report

by Accenture showed corporate profits are said to increase by an average of 38% by 2035, thanks to the advanced deployment of Artificial Intelligence into financial, IT, and manufacturing applications.

In the UK, we’re at the earliest stages of AI implementation. We lack in clarity as to its deployment across multiple use cases. However, many organisations are evaluating potential risk and reward scenarios, and the technology is becoming more widespread. Investing early, as with Digital Transformation pay dividends, but there are some crucial lessons to follow.

COLLABORATION BETWEEN HUMANS AND MACHINES

Smart technology is encroaching on every aspect of our lives. Turn on the news and you’re bound to come across a discussion of the benefits of the latest technology and examples of their use.

The manufacturing industry embodies this evolution. Advances to technology are having an increasingly significant impact on the production line. Today, there is a direct correlation between tech investment and efficiency. For manufacturers taking the plunge and modernising their plants and equipment, they can expect better quality products and less wastage. The result? Improved competitiveness and ultimately profitability.

Industry 4.0 and associated technology, such as IoT, AI and robotics, have become part of the manufacturing vernacular, without many understanding their potential. Digital transformation offers great unmatched potential for manufacturers. Not only does it greatly improve communication between devices, systems and personnel both inside and outside of the company, but it also cut energy consumption, increases efficiency, and increasingly delivers even short-term ROI.

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AI has the potential to exponentially increase the productivity of our industrial assets. It represents a new way for humans and machines to work together in industrial applications. However, in these scenarios, many variables need to be accounted for in order to achieve a successful and competitive outcome.

On the factory floor, AI technology enables us to learn and predict tendencies to solve complex problems. For example, managing a process with almost countless variables, such as control of temperatures, pressures and liquid flows, is very prone to error. In almost all factory settings, there are too many variables for any human brain to analyse successfully. By implementing AI, crucial operational decisions can be supported in real-time, greatly improving safety, security, efficiency and productivity.

The quality of the data that trains the AI algorithms needs to be combined with the human expertise, which is always needed for interpretation and guidance.

For example, in the Food & Bev industry, AI can improve quality inspection, providing humans with vision analysis and sound analysis which goes beyond the ability of a human alone.

AI AND INDUSTRY 4.0 AI is becoming an important part of Industry 4.0. It brings with it the great potential for innovation to dramatically

increase the productivity of industrial assets, better manage the evolution of the workforce, and greater energy efficiency.

Let’s take discrete and process manufacturing as an example. Here, asset maintenance is one of the industrial processes that is emerging as an early AI application. As a result, we’re seeing more manufacturers understand that predictive maintenance can be blended with the more traditional approach or preventative maintenance. The two, work hand-in-hand.

A great example of how AI is revolutionising Industry 4.0 and improving efficiencies on the factory floor is Variable Speed Drives (VSDs). VSDs are connected to motors on the factory floor. They attain data and insights into abnormal behaviours and thus flag these issues so that they can be repaired, or where necessary, replaced. The benefit here is that a piece of equipment on the factory floor is only replaced when absolutely necessary, saving the manufacturer money and reducing operational downtime.

Machine learning also comes into play here. It can be executed at the edge to help in the early identification of many potential faults including, power generation turbine blade damage or plant motor coupling approaching failure.

Going forward, it’s clear then that the Industry needs to consider the advantages of automation through the use of robotics, machine-learning and artificial intelligence.

Currently, there are only 71 robots in the UK per every 10,000 manufacturing employees, compared to over 300 in Germany.

If robots and humans can work together collaboratively, the benefits to manufacturers will be huge. No human can work 24 hours a day – but a robot can. The productivity gains are massive. Whilst the journey into Industry 4.0 is yet to begin for many, those looking to succeed need to consider investing in technologies such as AI and machine learning. Ultimately, this is the best way to increase efficiencies and enhance productivity.

www.schneider-electric.co.uk/en/

CONTROL & AUTOMATION

CHURCHILL CONTROLS

Mega_Bridge can communicate on a closed LAN or across networks and sites via Amazon Web Services, fully administered by Churchill Controls. This enables important security features using TLSv1.2 for authenticated and encrypted communications channels.

Mega_Bridge adds flexible and fully featured internet protocol (IP) connectivity to the well-established Mega_Link family of Telemetry & Control units used to pass two-way instrumentation, measurement and control data between sensors, equipment and industrial plant. n

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Contact us: 01344 750233 sales@churchill-controls.co.uk www.churchill-controls.co.uk

The Multi³ ™ is suitable for a multitude of applications, maximising productivity and accuracy.

A fully integrated ready to use ‘Plug and Play’ solution, cost effective and operator friendly.

Multi³ ™ Benefits • A ‘Plug and Play’ machining/trimming/additive solution • Cost effective and operator friendly • Multitude of applications • Customizable, adaptive and movable • Fully supported programming software and training

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CNC Robotics 3b Olympic Way Sefton Business Park Aintree Liverpool L30 1RD

0151 523 8009 info@cncrobotics.co.uk

www.CNCRobotics.co.uk Issue 37 PECM

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ELECTRICAL & ELECTRONICS

DISTRIBUTOR FOR ICOTEK GMBH FOREMOST ELECTRONICS

ICOTEK CABLE ENTRY AND EMC SYSTEMS NOW AVAILABLE FROM FOREMOST ELECTRONICS

Foremost Electronics, the Essex based specialist distributor of electromechanical components, has been appointed as a distributor for Icotek GmbH. Icotek have been developing innovative cable entry and EMC cable shielding systems for over 15 years, hold a number of patents and are designed-in to global OEMs and leading companies in a wide number of industries.

for cables without connectors, brush cable pass-thoughs, strain relief and cable management, EMC cable shield clamps and the CONFIX cable conduit system.

Icotek products now available from Foremost include ATEX and railway cable entry systems specified to EN 45545-3, cable entry frames and glands for cables with connectors fitted, cable entry plates

Alan Cook, Managing Director of Foremost, comments, “Wherever electric lines, pneumatic and hydraulic hoses or optical fibre have to be securely routed into a machine, a plant or a control cabinet the

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Applications for icotek products include machine tools, railway technology, wind turbines, solar technology, vehicle construction and packaging machines, automation and robotics.

icotek systems provide a reliable solution.

Icotek products provide tight sealing and provide superior strain relief.

For applications that have the possibility of extreme contamination by water, dust, vibration or extreme temperatures icotek offer reliable, cost effective solutions.�

To see the icotek products available from Foremost, please visit www.4most.co.uk call +44 (0)1371 811171 or email sales@4most.co.uk

4Most Electronics: Importer and specialist distributor of E-MECH products

CABINETS & ENCLOSURES UK Primary source and Channel partner for Nvent Schroff nVent Schroff electronic cabinets are designed to help you keep your systems running smoothly for the long term.

Including industrial controls, electrical components, data communications and electronics in virtually any environment.

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View the complete product range online: www.4most.co.uk For further details please call or email us on: T +44 (0) 1371 811171 E sales@4most.co.uk W www.4most.co.uk Part of the 4most Electronics Technology Group: evconnectors.com | enclosures4u.com | ipjoysticks.com

ELECTRICAL & ELECTRONICS

INTERNATIONAL SPECIALIST TR FASTENINGS

PROVIDING FULL SERVICE SUPPORT THROUGH INNOVATION AND TECHNICAL EXPERTISE TR Fastenings Ltd (TR), the international specialist in the design, engineering, manufacture and distribution of high quality industrial and Cat C fastenings is increasing its capacity to support customers across the globe with new product innovation and technical support.

INNOVATIVE PRODUCT DESIGN, ENGINEERING AND MANUFACTURE: THE EPW SCREW The EPW screw, which was designed, developed and patented by TR, is a selfextruding, high strength thread-form fastener which creates its own female thread in punched sheet metal, thereby dramatically reducing assembly times and costs. The screw works by being aligned to the pilot hole in the sheet metal, where it then forms the extruded collar, combining the forming of the thread and the creation of a strong extruded profile, before finally tightening and clamping into the metal.

The key benefits of the EPW screw include: • Removable and strong screw joint • High stripping torque • High break loose and prevailing torque • Excellent vibration resistance, meaning it can withstand pressured environments • Combined thread forming and creation of strong extruded profile • Very high radial compression on screw shank • Standard machine screws can be used in the thread created by the EPW

TR has 31 business locations within the UK, Asia, Europe and the USA including, eight high volume, high-quality and cost-effective manufacturing sites. As a full service provider to multinational OEMs and Tier 1 companies spanning several sectors including electronics and automotive, TR delivers comprehensive support to its customers across every requirement, from concept design through to technical engineering consultancy, manufacturing, supply management and global logistics.

SUPPORTING THE EMERGING EV CHARGING INDUSTRY In the electronics market, TR is working with a number of firms involved in the design,

manufacture and development of Electric Vehicles (EVs) with the main focus on the associated charging units.

Along with the extensive product ranges typically used in electric charging units, TR also has the necessary technical knowledge, sector expertise and experience to support these customers as this sector continues to emerge and develop.

TR is already actively supporting a number of key customers involved in the design or manufacture of EV chargers for both commercial and residential use.

TR’s qualified engineers and sales staff are on hand to advise designers, production and purchasing teams on a number of matters, from Design for Manufacture (DfM) to new fastener technology, sourcing insight and cost reduction.

www.trfastenings.com

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Global specialist in the engineering, manufacture and distribution of industrial fastenings and Cat C products Manufacturing 8 manufacturing facilities with an annual output of over 8 billion components.

Supplier A global network of AVL approved suppliers enabling an international source of supply.

Logistics Tailored services to meet customer requirements ensuring an effective Lean Supply Chain solution.

Design & Engineering As a Full Service Provider (FSP), we offer early design and technical involvement, VA/VE engineering, global sourcing and logistical solutions.

Quality Meeting the customers’ quality needs and specifications as their enhanced demands increase.

Distributor A network of valued distributors in the UK and Europe actively selling our proprietary products to end users.

Industry TR Fastenings supplies in excess of 60 billion components annually to 5,000 companies globally across a wide range of industries.

Now supplying total hardware solutions for Electric Vehicle Charging Units Contact us: +44 (0) 8454 811 800 sales@trfastenings.com www.trfastenings.com Issue 37 PECM

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Power Resistors alternatives to ARCOL/OHMITE by ATE + Metallux BEC Distribution has announced new availability of ATE and Metallux range of alternative Power Resistors for ARCOL/Ohmite resistors. ATE and Metallux are world-class manufacturers of power resistors, with own production and R&D facilities in Italy and Germany specialising in flat, round and wirewound over aluminium, ceramic, compact brake resistors, Steel Grid Brake and modules constructed of water-cooled break resistors.

Product applications include voltage dividers; de-charge resistors and start or charging resistors.

Other applications include frequency converters for motor control using built-in or stand-alone units. Green Energy applications include heating elements for high power solutions or where brake energy can be reused as heating energy.

For further information please visit www.bec.co.uk

Building Energy Efficiency for the Future Sandford Electrical Services has been providing BEMS and electrical control panel consultation, design, and manufacturing services since 1989. Everything is done under one roof so things tend to be streamlined, quick, and transparent.

We are also one of the few UK companies to be BS EN 61439 accredited meaning you are ALWAYS safe in our hands!

Sandford is a premium brand. But savvy constructors have worked out that investing in high quality BEMS and electrical control panels adds enduring value (and cache) to their build.

We’ve worked on some of the most iconic and complex building projects in the UK. We can do the same for you.

Contact us on 01628-668-808 www.sandfordelectrical.co.uk

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Trizo Ltd – Contract Electronics Manufacturer Investing in New Technology

UK based electromechanical assembly services from NSF Controls

Continuous investment in new technology is key to success. With this in mind, Trizo Ltd has commissioned an additional surface mount pick & place line; IINEO II+ and 3D Automated Optical Inspection technology. This investment is the result of successful growth in business since relocating to bigger production purposebuilt facilities in Bridgwater during December 2015.

Taking the pressure off a fluctuating order flow, manufacturing capacity or engineering resource challenges, NSF Controls provides a range of assembly services and solutions, currently producing over a million assemblies annually, exporting to over 30 countries across five continents.

This new production technology will enhance Trizo’s commitment to customers as well as the continuous improvement and total quality methodologies within the business, enhancing Trizo’s portfolio of incredible pieces of machinery. Continually investing in new technology for the business will safeguard continued growth. This is a true measure of Trizo’s continuous commitment to the highest quality standards. www.trizo.com

Newbury Electronics instrumental in helping Skalene scale the heights of electrical engineering Martin Horrod, founder, Skalene, a leader in EMC Design & CE certification, recalls; “We were attracted to Newbury’s online PCB Train service due to its simplicity and the cost benefits of PCB pooling. We’ve utilised their kitting and assembly service which, when combined with the free-issue Rs and Cs, delivers real value.

Feasibility studies of innovative technologies require a fast turnaround of prototype PCBs for test and evaluation. One project involved an automated microfluidic sample handling platform for DNA library preparation.

“Newbury were instrumental in allowing us to produce prototypes and tweak designs with rapid turnaround. The platform, based on a modular architecture, consisted of up to 10 PCB’s per system of peltier temperature controllers, precision pump and valve controllers and interface and communication PCBs”. www.newburyelectronics.co.uk

The company is BSI Quality Management System ISO 9001:2015 and BSI Environmental Management System ISO 14001:2015 certified ensuring consistently high quality manufacturing standards.

NSF Controls has the flexibility and the multi skilled operators able to deliver precisionproduced products with scalable capacity from single workstations to dedicated production line assembly for high volume orders.

Please contact our team on +44 (0)1535 661144, email info@nsfcontrols.co.uk or visit nsfcontrols.co.uk

EPack Power Controller Range for Optimal Adaptability Across Electrical Heating Applications The new Eurotherm™ by Schneider Electric™ EPack™ power controller range combines a high level of functionality and configurability with straightforward set up and operation.

Global certification to international standards and a robust design for high reliability in demanding environments allows it to be adapted to a wide spectrum of three phase applications and markets such as Heat Treatment for Aerospace and Automotive, Life Sciences, Semiconductor and Food & Beverage. www.eurotherm.co.uk/products/power-control/power-controllers/epack 01903 268500 info.eurotherm.uk@schneider-electric.com

ELECTRICAL & ELECTRONICS

THE NEW LED VARIOLINE STEGO

VARIOLINE ENCLOSURE LAMP: MORE LIGHT AND VARIABILITY

Stego introduces the new LED Varioline, the most effective LED enclosure lamp within the STEGO product range so far. Its powerful and homogeneous lighting ensure natural vision and confusion-free color reproduction which are key to user safety in enclosures. Versions with an optional integrated socket provide for additional application options.

The Varioline LED enclosure lamp from STEGO combines bright lighting with compact dimensions. Available in two versions with sizes from 400 to 700 mm, it provides more than 1,000 Lm / 1,700 Lm at a moderate power consumption of 11 W / 16 W. Even large enclosures & panels are thoroughly illuminated in their depth and height. Its translucent and thus glare-free rotatable light tube is equipped with bright mid-power LEDs. With a beam angle of 120° these enable homogeneous illumination within control

cabinets and enclosures. Specially selected LEDs provide for a long service life of 60,000 hours, which make the Varioline virtually maintenance-free. The Varioline emits triedand-tested 6,500 K coloured daylight, so users benefit from natural vision conditions and confusion-free colour rendition.

All of the Varioline’s variability comes into play, when in addition to excellent lighting extra electrical devices need to be operated.

For example, the Varioline LED 121/122 offers an integrated socket for the power connection of laptops or diagnostic devices.

Numerous European and international plug types, such as e.g. the US and Australia, are available.

The LED Varioline also features versatile switching options. On-off switch, motion detector or connection for an external door contact switch allow for adaption to the

requirements of each individual application.

Screw or magnet fixing are available as mounting options and offer flexible and vibration-proof installation. Daisy chaining makes it easy to configure more extensive lighting situations. Up to eight lamps can be connected serially.

STEGO - Perfect Thermal Management Since it was founded in 1980, STEGO has been developing, producing and selling an ever-growing range of products for the protection of electric and electronic components. www.stego.co.uk Issue 37 PECM

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SEAMLESS NO BREAK POWER POWER CONTINUITY

NO BREAK POWER INSTALLATION No Break Power System installation is True Power Continuity 24/7 The no-break system will continue to supply power, seamlessly and smoothly, total Power Continuity automatic NO Break power failure prevention, fully installed systems by Power Continuity Ltd. PowerContinuity installations provide emergency power without interruption.

We design and build bespoke automatic systems from 300kVA to 10 megawatts inclusive of all LV switchgear and on site testing.

Think of the lost production indecision makes? Still dreaming that power loss won’t happen to you?

Without a NO Break power failure prevention system, you can’t STOP production disruption and losses. Even a power spike or power drop will corrupt servers, loss of data, burn out inverters, damage robots, cause ovens to drop temperature or go into a shut down mode.

Then there’s the days and weeks that the maintenance & facilities teams take just ‘juggling all the balls in the air’, efforts that the finance directors don’t want to know about until it’s too late. Then it hurts, REALLY HURTS. Why wait for the pain, when Power Continuity can take the strain. Power Failure Prevention from Power Continuity Ltd Our famous, Power Continuity NO BREAK Power Failure Protection ‘kicks in’ automatically to seamlessly and smoothly provide emergency power without a ‘hiccup’ to your production.

With Power Continuity NO Break Power Protection installed :• Food Producers lose no production.

• Pharmaceuticals lose no production • Distributors have total UP TIME • Financial Insitutions operate with out any power loses.

You may say, “We’ve never had a total power outage in years”. Really?

Then you’ve definitely overlooked the following:-

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Power Dips - Yes these do happen regularly.

Even momentary power dips can and will crash any robotic production line ‘out of sequence’ or breach sterile production lines.

Re-setting takes time and money as well as the lost production. Power Continuity can stamp these out forever. Sorted!

Brown outs and Micro Power Spikes - Yes these happen too, especially during the winter months and during HOT summers.

These have the same impact as Power Dips.

Double Whammy. Get one or both at the same time. Let Power Continuity stop them, once and for all. Sorted!

Over voltage & Under Voltage Yes, these are just as bad as Power Dips & Brown Outs.

Even momentary Over Voltage will knock out machinery, invertors and corrupt data.

Power Continuity will eliminate these too.

True NO Break Power Protection is Power Continuity Ltd. We’ll design your Data Centre or Production Facility from the ground up.

We carry out a detailed power survey, to firstly, identify your power risks, then

secondly, offer automatic fully installed Power Continuity Systems to ensure power failure won’t happen again on your site, after our installation.

Power Continuity installed, emergency standby generators and UPS systems, together with our Air Conditioning and Fire Suppressions systems offer total protection . PowerContinuity is reliable, emergency power without interruption;24/7 Install 100% Automatic Power Protection Systems that offer 24/7 Power Continuity.

That’s why we are Power Continuity Ltd. Bespoke trademarked Power Continuity Generators & UPS systems that respond every time. Your power sorted!

We Design. We build. We Install.

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NO BREAK Power Continuity = 100% Production We are Power Continuity Call us on 0845 055 8455 We’re here to help 24/7

ELECTRICAL & ELECTRONICS

CONTROLLING OBSOLESCENCE J MARTANS

HOW TO MANAGE OBSOLESCENCE IN INDUSTRIAL CONTROL PANELS

Over the past 50 years, a growing number of industrial businesses have adopted computer-based automation systems.

However, many of these systems are now nearing their official end-of-life and becoming obsolete, leaving engineers with the challenge of managing obsolescence effectively. Here, Maria Torrisi, business development manager at industrial automation expert JMartans Automation, explains how industrial plant managers can manage obsolescence in control panels.

The control panel is the backbone of the modern industrial plant. Whether a business is at the forefront of the Fourth Industrial Revolution or focussed more on day-today production, automation is pivotal for modern industrial companies.

While these systems present plant managers with a wealth of benefits in the form of efficiency savings and improved effectiveness, their importance is beginning to pose a unique challenge for industrial businesses. Today, many plants still use the control panels installed several decades

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ago, which means they are now verging on obsolescence.

Although businesses can partner with specialists to supply obsolete industrial components, a growing number of plant managers are realising that modernising systems is more beneficial and less risky in the long-term. However, this is rarely an easy task, as the control system is often responsible for controlling an important process that can significantly harm productivity if stopped.

For example, it might be that a control system is responsible for managing a conveyor in a dairy production plant. Since dairy is a sensitive food item that must be handled carefully and promptly with full traceability, even a momentary pause in production can mean an entire line of product must be disposed of to ensure safety standards.

So, how do you manage obsolescence in a critical control system? From JMartans’ experience as a systems integrator in Malta, we’ve found that the best approach is

to complete an upgrade or replacement project in phases. By doing this, plants can minimise operational disruption.

This could mean replacing the front end of a control system first, such as by modernising a SCADA system and ensuring it works with the obsolete components and equipment, before upgrading those individual obsolete parts. A systems integrator taking this phased approach can then avoid causing costly, unwanted downtime and ensure systems remain operational.

The reason why many industrial businesses continue using legacy equipment purchased decades ago is often due to the risk of planned downtime affecting performance.

By working with an experienced automation systems integrator like JMartans, plant managers can get the best of both worlds: an effective, modern control panel without lost production.

www.jmartans.com/

AC-DC Battery Backed Power System 1U 19” Rack Mounting up to 300 Watts The PFD Series is a no break system to provide constant DC power without interruption in the event of an AC mains failure. Available in 150W and 300W versions and nominal DC outputs of 12V, 24V or 48V

Features • AC Input 180-264VAC 50/60Hz • Nominal 12V, 24V or 48V DC output versions • With external batteries can provide constant power without interruption • Can power your load and charge batteries simultaneously • Zero interruption in the event of AC power failure • Intelligent battery condition monitoring with low battery voltage shutdown • Full protection for over load, short circuit, over voltage and over temperature • Front panel LED display monitoring • Dry contacts, RS232, USB and optional SNMP output monitoring • Temperature controlled fan • *Higher power versions available built to order*

www.powersolve.co.uk

Tel: 44-(0)1635-521858 Email: sales@powersolve.co.uk

ELECTRICAL & ELECTRONICS

CONNECTIVITY SOLUTIONS FISCHER CONNECTORS

FISCHER CONNECTORS DEMONSTRATES ITS LONG-TERM VISION FOR CONNECTIVITY WITH BREAKTHROUGH TECHNOLOGICAL PARTNERSHIPS AND CROSS-MARKET CUSTOMER APPLICATIONS Fischer Connectors, the global provider of ultra-reliable and high-performance connectivity solutions, continues to push the boundaries of innovation in rugged miniaturization, high-speed data transmission, sealing, wearability and the Internet of Things (IoT). At the biennial tradeshow Electronica held last November in Munich, the company showcased how it is reimagining connectivity with its customers thanks to breakthrough and forward-looking technological partnerships Markets with Wearable Technologies Ltd. and SolarStratos, as well as crossmarket customer applications in the medical, security, industrial, unmanned vehicles, marine and miniature computing fields.

Oil and Gas

Construction

Mining

Jonathan Brossard, Fischer Connectors Group’s CEO, explained: “The electronics world is changing at an incredible speed, and the connectivity solutions that make electronic ecosystems work efficiently, reliably and safely are instrumental in driving the technological innovations that shape our world. Our long-term vision for connectivity is based on our sense

Fischer Connectors is an official partner of “SolarStratos, To the Edge of Space” of responsibility as a global provider of pioneering and ultra-reliable connectivity solutions that are easy to use and to integrate into our customers’ devices. We are showcasing examples of how Fischer Connectors turn ambitious ideas Utilities has helped Transport Warehousing into solutions that shape the future.”

were also able to talk to two of The Challenge Visitors Fischer Connectors’ technological partners who joined them on their booth, showcasing Reduce risks, increase safety, their pioneering work in: • The Industrial Internet of Things (IIoT) and and ensure compliance wearable solutions with Mark Bernstein, CEO

SMART WORKER PLATFORM

WTL’s connected smart worker platform uses the plug & use Fischer Freedom™ Series in smart garments for industrial workers

of Wearable Technologies Ltd (WTL) from the UK. WTL’s connected smart worker platform uses the plug & use Fischer FreedomTM Series in smart garments for industrial workers.

These garments have an array of sensors and devices that enable real-time monitoring and data analysis of multiple workers’ health, wellbeing, and exposure to potential hazards and dangers, such as noise, gas, vibration, proximity, plus biometrics sensors, as well as radios, GPS, etc. The data is collected centrally and sent to their dashboard which displays data from all specified workers simultaneously and in real-time. WTL will be running continuous, live demos of its IIoT smart worker ecosystem and dashboard on the booth.

• Electrical solar aviation with Raphaël Domjan, founder and pilot of SolarStratos.

Fischer Connectors is an official partner and proud provider of the mission-critical connectivity solutions for this Swiss project which aims to shape the future of solarpowered aviation by sending the first manned solar plane to the stratosphere.

In addition to an array of assembled and integrated solutions used in customer devices for a wide range of high-tech industries, visitors discovered some of the most innovative applications on the market today engineered to meet wearability and IoT as well as high-speed data transmission requirements – two of the hottest trends in the electronics industry.

Fischer Connectors’ product portfolio includes two of the company’s newest and most innovative solutions in these fields: the breakthrough plug & use Fischer FreedomTM Series launched last June, and the new configurations of the ultra-miniature signal & power Fischer MiniMaxTM Series compliant with the latest data protocols USB 3.0, Ethernet and HDMI

Incident capture Harness with LP360TM connectors for sensors & devices, unified comms

Alerts, reporting and compliance Real-time device validation, monitoring and reporting

Analytics and insights Incidents tracking, investigation and analysis, predictive analysis, personal safety coaching

In any Internet of Things (IoT) 37 application, it is always the ‘Data’ that matters more than the ‘Things’. This 94 PECM Issue is why the seamless integration of the Eleksen Smart Worker Platform with the Fischer FreedomTM Series connectors is vitally important to optimising the gathering of the data.

You can see Fischer Connectors solutions at the Hannover Messe. Hall 12, Stand B01.

fischerconnnectors.com

WITH BREAKTHROUGH TECHNOLOGICAL PARTNERSHIPS

GROUND-BREAKING LP360TM TECHNOLOGY RECEIVES TWO INNOVATION AWARDS Fischer Connectors’ efforts to reimagine connectivity in close partnership with their customers have borne fruit. The Fischer LP360™ connector – the first product in the new Fischer Freedom™ launched in June 2018 – has won two prestigious awards for technological innovation: the LEAP Award from Design World and the Innovators Award from Military & Aerospace Electronics.

LEAP AWARD

On December 11th, 2018, Design World announced that the Fischer LP360 ™ had won the 2018 Leadership in Engineering Achievement Program (LEAP) Award in the Connectivity category. Judges commented: “A breakthrough signal and power connector with easy mating and easy cleaning that maximizes usability, efficiency and performance. This product changes the way of fast connection without looking. I think that this will change the way connectors and connectivity is done. A simple and great solution … very clever and useful product.” The LEAP Awards program celebrates annually the most innovative and forward-thinking products serving the design engineering space. Its world-class judging panel is comprised of OEM design engineers from a wide variety of industries, along with other engineering experts representing the mechanical and electrical design fields.

“I think that this will change the way connectors and connectivity is done. A simple and great solution … very clever and useful product.” - LEAP Awards judges

MILITARY & AEROSPACE ELECTRONICS

On November 13th, 2018, Military & Aerospace Electronics and Intelligent Aerospace announced their 2018 Innovators Awards, giving the LP360™ rugged connector from Fischer Connectors the highest rating – Platinum – in the Interconnect Technology category. The annual Military & Aerospace Electronics Innovators Award program is a coveted and prestigious distinction for honorees around the world who have made a groundbreaking contribution to the military and aerospace industry and are recognized as leaders and innovators to the largest collection of military and aerospace professionals.

Make your life easier with some of the most innovative connectivity solutions on the market today engineered to meet wearability & IoT requirements as well as high data transmission rates: ■

Ultra-reliable, IP68 sealing

■

Miniature

■

Plug & Use

ffischerconnectors.com fi sche sc herc rcon onne nect ctor ors. s com m

Issue 37 PECM

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ELECTRICAL & ELECTRONICS

RMO-H-Final.pdf 1 22/06/2018 15:34:58

New patented technology!

In 2018 DV Power delivered the first handheld micro ohmmeter (< 1 kg), which generates up to 300A regulated DC current

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RMO500A Representing DV Power in the UK and Ireland

Drallim Industries Limited

Millwood House, Drury Lane | Ponswood Industrial Estate St. Leonards on Sea | East Sussex | UK | TN38 9BA Tel: +44(0)1424 205140 | Email: hvtest@drallim.com | Web: www.drallim.com (When enquiring please quote PECM )

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PECM Issue 37

ELECTRICAL & ELECTRONICS

AVOIDING SERIOUS ACCIDENTS MARTINDALE

SAFE ISOLATION ESSENTIAL FOR SAFE MAINTENANCE When it comes to working on electrical installations, whether itâ&#x20AC;&#x2122;s maintenance of equipment or installing new machinery, implementing safe isolation procedures is essential to achieve compliance with the Electricity at Work Regulations and stay safe. There are around 1,000 serious accidents per year at work due to contact with electricity and 10 times as many involving electricity, many of which could be avoided by following simple procedures and using the right equipment to the latest standards. Average fines for noncompliance have tripled over the last two years.

VIPLOKPRO150 Complete safe isolation kit for all installations

Guidance requires operators to work dead whenever possible and achieve this by following a clearly defined procedure which involves isolating the source of supply, locking off the supply and proving dead before any maintenance work is carried out.

Ensuring the right tools are available for the job might seem like common sense, but itâ&#x20AC;&#x2122;s still an issue among some maintenance teams, who may be potentially putting their lives and those of their colleagues at risk. For example, using a multimeter to prove a circuit is dead is not permissible as it could easily give a misleading reading if set to the wrong range or if the batteries need replacing. A dedicated voltage indicator with no ranges, switches or batteries is by far the most reliable method for proving dead. Having the right locking off device to hand for all types of common circuit breakers or fuse holders is a must.

Many contractors are now turning to complete safe isolation kits which include all the necessary equipment to safely lock off the circuit being worked on and prove dead. The latest kits now include matching voltage indicators and proving units and contain a complete range of locking off devices and hazard warning labels for all types of site and installation. The kits keep everything to hand and simplify any compliance issues with the latest test equipment standards.

To simplify the whole process, Martindale Electric has put together two new safe isolation kits fully compliant with the latest edition of GS38 in handy combination carry cases. The most comprehensive

Stay safe, lock off & prove dead

solution for safe isolation available, the new kits contain the industry standard VI Series voltage indicators, matching proving device and the new 13 piece LOKKITPRO. The new LOKKITPRO kit enables safe isolation procedures to be carried out on a wide range of distribution boards in all types of facilities. The kit includes the complete range of Martindale locking off devices for MCBs, red spot type fuse holders and more challenging installations requiring cable locks.

Martindale LOK6 Universal fuse carrier lock off

www.martindale-electric.co.uk

ELECTRICAL & ELECTRONICS

IDEAL CONNECTION JPR ELECTRONICS

SCHÜTZINGER QUICK RELEASE TERMINALS NOW AVAILABLE FROM JPR ELECTRONICS Specialist distributors JPR Electronics offers a wide range of quick-release terminals manufactured by market leading connector manufacturer Schützinger. Since the launch of their first quick-release terminal an entire product family has emerged and successfully established itself in the market. Quick-release terminals provide the ideal connection in any situation where a safe and rapid connection must be created quickly between a conductor or cable and another device.

Typical applications for quick release terminals include instrumentation, burn-in, test and repair bays or any test applications in which cables, conductors or electrical devices need to undergo functional testing.

Wires are connected to the terminals by pressing on the head of the terminal post and inserting them between the connection jaws where the strong internal compression spring guarantees good contact. Versions are available with 2 apertures as well as shockproof versions for applications operating

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PECM Issue 37

above protective low voltage levels. Quick release Kelvin four-wire terminals are also available allowing measurements to be made without errors caused by transition resistance of the measuring leads and any thermovoltages.

Schützinger quick release terminals are rated from 5A to 16A can accommodate panel thicknesses from 0.8 to 7mm and are available with options of termination safety shield and 4mm plug connection for converting existing terminals to quick release. Standard colours are blue, green, yellow, grey, brown, white, purple and greenyellow.

Paul Raynor, Director of JPR Electronics, comments, “Schützinger quick release terminals are particularly suitable for quick connection and testing of electronic products and electrical appliances as they come off the end of production lines. They can be used for both functional testing and burn-in if required.”

In addition to the wide range of standard quick release terminals JPR can supply customised Schützinger products. Custom options include reduction of the spring force for frequent use with low electrical load, increased spring force for higher electrical loads, additional colours and colour combinations for casing and button, customised connection types and alternative typeface or customer logo.

Other Schützinger products available from JPR include a wide range of 2mm and 4mm terminal posts, safety sockets and plugs including stackable variants, standard and safety crocodile clips, packaged 2mm and 4mm test lead sets and a comprehensive multimeter test lead and probe kit.

For more information call +44 (0)1582 47 00 00, email sales@jprelec.co.uk or visit www.jprelec.co.uk

ELECTRICAL & ELECTRONICS

SHOCK PROTECTION DOEPKE

BS7671 18TH EDITION REVISED RCD REQUIREMENTS If you are involved in the safety specification and or installation of electrical equipment, take note of changes that will come into force in BS7671 January 2019 (18th Edition).

There are a number of recommendations directly linked to improving the security and safety of electrical installations protected by RCDs.

Why is BS7671 relevant to most industrial sites?

The Electricity at Work Regulations and the HSE refer to BS7671 as a “Code of Practice” for electrical installation”. Circuits may rely on additional protection provide by RCDs, to reduce deaths from electrocution and or fire. Installations using Type AC RCDs may not provide the level of protection required, when supplying modern equipment containing switch mode power supplies and inverters. The 18th Edition Regs specify the Type of RCD required, based on the types of residual current generated by the equipment connected to the supply see 531.3.3 and Annex A53 Fig A53. This is a general requirement and applies to all installations. Particular requirements see Part 7.

531.3.3 Types of RCD The type of RCD installed must be capable of providing the required level of protection based on the residual currents that may be generated under possible fault conditions: “Different types of RCD exist, depending on their behaviour in the presence of DC components and frequencies. The appropriate RCD shall be selected from the following”, this clause goes on to list the various types of RCD namely A, F, B and their suitability for different types of residual current.

Type AC RCDs are only listed for general purpose applications such as electric kettles, emersion heaters, filament lamps. Many modern appliances contain semiconductors, and are not suitable for connection to Type AC RCDs e.g.

The internal topology of a Single phase VFD/ VSD will determine the residual current characteristics (Type A, F or B) and therefore the type of RCDs that can be installed safely upstream. 3 phase VFD/VSD must only be connected to Type B RCDs, irrespective of the application or location.

Two examples of possible fault currents in circuits containing semiconductor devices (PECS): see BS7671 Annex A53 Fig A53.1 Circuit with fault location

Normal load current IL

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Annex A53.1 gives details of typical faults currents associated with circuits containing semiconductors and the required RCD type (see example 1 and 2).

These recommendations along with other changes are directly linked to reducing the risks associated with electrical faults, namely fire and electrocution.

For additional information on RCDs refer to www.doepke.co.uk/ download/Techpub-16 Issue 37 PECM

99

FACILITIES MANAGEMENT

The NEW Mini Pocket Spirit Levels From Hultafors Tools

Don’t let Forklifts bring dirt and water into your warehouse

Cost effective industrial and commercial cooling

Now available in the UK with a modern design, clear-focus vials for levelling work in tight spaces. It’s always been Hultafors Tools’ vision to give professional tradesmen and women the best quality tools for optimal onsite performance. That’s why these NEW Mini Pocket spirit levels have now been added to its range of best in class levelling and marking equipment.

Why? Because this could cause a serious slip hazard in your warehouse and that is the last thing you need. There is an even higher risk if your forklifts are going in and out of your warehouse regularly. The wheels carry a lot of dirt and water from outside, especially if it’s raining. However, there is a solution to prevent slips and falls in your warehouse – Waterhog Forklift Mats.

Evaporative cooling is the perfect solution when cooling large commercial and industrial buildings, drawing 100% fresh air from outside.

The ergonomic design includes a crushproof vial with a +60% magnifying effect and luminescent effect for easy reading in light or dark conditions. Both new models look great and, added to all the other products in the Hultafors’ range, there’s something to suit every conceivable levelling requirement.

Waterhog Forklift Mats are the answer to your problem. Not only does it prevent slip hazards, but it also keeps the environment safe and clean. These mats are designed for forklift entrances, such as loading bays. To ensure safety and protection, the mats scrape and wipe away dirt and moisture from the wheels. This can also prevent the forklifts from skidding.

Getting more information on the Hultafors Tools range of Spirit Levels easy. You call the Helpline on 01484 854788 or check out www.hultafors.co.uk and download a digital catalogue.

To request a free sample, or to place an order, please call 0121 313 6748 or visit www.mats4u.co.uk today.

Easy to install and maintain, evaporative coolers are up to 80% cheaper to run than traditional air conditioners, using only water and electricity, with COPs>10. For this reason, they are particularly suitable for industrial plants, warehouses or semi-open areas, also available for spot cooling in order to cool particular spaces that are hot and uncomfortable to work in.

Seeley International is world leader in designing and manufacturing highly efficient evaporative cooling solutions. Come and choose the solution that best suits your needs!

Stand A315, Southern Manufacturing.

Email uksales@seeleyinternational.com or visit www.seeleyinternational.com

SEAMLESS

INDUSTRIAL FLOORING

Resurfacing of badly worn floors and new build installations Impact, abrasion and point load resistance Anti-static, anti-bacterial, slip resistant, chemical resistant & suitable for heavy traffic plus high bay category one and two Fast installation for minimum downtime Integrate corporate colour schemes, colour matching and corporate logos into the same hardwearing and durable flooring For a complete Nationwide service from FREE survey and recommendations, to preparation and installation with single source, uncomplicated warranties…

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RESPOL - innovative flooring solutions GUARANTEED!

CONTRACTORS HEALTH & SAFETY ASSESSMENT SCHEME

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www.industrialflooring.co.uk www.chas.co.uk

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PECM Issue 37

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Hilsonic Hilsonic is is aa specialist specialist in in the the supply supply of of ultrasonic ultrasonic cleaning cleaning equipment equipment for for the the powerpower7HO 7HO generation generation and and ZZZ KLOVRQLF FR XN ZZZ KLOVRQLF FR XN marine marine industries industries Issue Issue 16 16 PECM PECM

15

A FORCE TO BE RECKONED WITH STAR FASTENERS

NEW! HUCK RANGE FORCETM BATTERY INSTALLATION TOOL Available from Star Fasteners, the Huck® Range Force battery installation tool has been designed to combine industry-leading performance with superior reliability. This new advancement in battery-powered installation tooling is the only battery tool on the market with electronically adjustable pull force for installation of pintail-less BobTail lockbolts.

It can install the complete Huck range of structural and non-structural rivets (up to 1/4” / 6.4mm) as well as two-piece fasteners (up to 1/4” BobTail® / Hucktainer® / Magna-Grip® / C6L®). In addition, it boasts exceptional quality for superior reliability and durability (tested to 50,000 installations). The high pull force is adjustable and it features a long stroke length, providing considerable versatility. What’s more, there’s crosscompatibility with Huck nose assemblies and Makita 18v batteries.

WORKSHOP SERVICES With a fully equipped workshop and experienced team, Star Fasteners tool workshop services are reliable and timely, so there’s minimal down time and a quick turnaround for every job.

Star Fasteners’ comprehensive range of spares and genuine components ensures a timely service, with large stocks of spares from leading manufacturers such as Huck®, FAR® and VVG®.

Star Fasteners can arrange to pick the tool up by its van or courier. A quote detailing all parts and costs is raised. If required, Star can guide you through a process to make a decision and find the most economical outcome. Each tool gets a unique reference so Star Fasteners can view its full maintenance history.

SERVICE AND MAINTENANCE A regular maintenance programme supports every production environment.

• Helps to ensure that fasteners are being installed properly • Satisfies health and safety obligations • Keeps production moving and ensures tools are operating correctly

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If tools are brought back into the workshop, a typical tool service will involve a complete strip down, de-greasing and cleaning of all parts with a specialist hotparts washer. Once assessed, if necessary, Star will replace seals and worn parts.

Finally, the tool is re-primed, re-set as required and thoroughly tested. Servicing can be arranged to fit in with shutdowns or down time to suit factory schedules.

The firm’s extensive stocks of tooling spares (including for many obsolete models) are also on hand for those who prefer to carry out their own servicing and

repairs. Generally, Star can offer next day delivery and talk you through some simple preventative maintenance measures to get the most out of your tool and ensure minimal downtime, as part of the service.

HIRE AND SERVICE HIRE Should your workshop suddenly become busy, or a specialist tool is needed for a specific contract, Star Fasteners can offer short or long-term hire tools. The firm also offers service hire whilst a tool is in the workshop for service or repair.

Hucktainer® C6L Huckbolt®

Bobtail®

SALES Star offers quality tools that can stand up to the rigours of a busy workshop environment and can demonstrate the latest models and provide advice on tool options best suited to the application and the environment.

Star Fasteners is committed to continuously improve and expand its tooling product portfolio to ensure that it remains at the forefront of modern assembly requirements.

“As the UK’s largest Huck® fastener distributor, Star Fasteners has become synonymous with the constant quest for innovation. We offer factory visits to tailor a tooling package that can address issues

Magna-Grip®

such as noise reduction and trip hazards.

When standard solutions do not fit, we work together to find a resolution.”

TRAINING And that’s not all – Star Fasteners is happy to send an expert member of the team to provide on-site training in your own workplace or you can visit the purpose-built workshop: “Our team are experienced in working in production environments and understand the complications that tool downtime brings.

“We can take the training back to basics.

From checking optimum air pressures, to knowing what to look for when inspecting

equipment, this knowledge then leads onto detecting and correcting potential problems ideally before they occur. Major downtime is then avoided.

“If you partner with Star Fasteners, we can solve fastener installation issues, boost production output and therefore profitability. We are confident that our fast and reliable repair service will meet your requirements.”

For more information on Star Fasteners tool services, call on +44 (0) 115 9324939 or alternatively email sales@starfasteners.co.uk Issue 37 PECM

103

THE COMPLETE, QUALITY ASSURED, BOLTING SOLUTION Rollstud has identified the Chemical Industry as a target market to assist with our growth strategy.

We have gained vast experience in dealing with the industry, both at home and Internationally over many years & through support of significant projects.

A COMPLETE RANGE Rollstud offer a complete range of bolting solutions, and we identified that this was perfectly aligned with the Chemical Industry’s requirements. … fast, reliable, competitively priced range of quality assured products…

Rollstud provide a fast, reliable, competitively priced range of quality assured studbolts and fasteners (ISO 9001), with full traceability, predominantly for the Oil, Gas, Power Generation and Petrochemical industries. From manufacturing facilities in Scotland, England and the Middle East. We also supply to many other applications and industries. We also offer complete piping packages, and gaskets are also available from stock, which enables us to provide a “one stop” solution that can meet practically every need.’

Th So Bo

Rol com ass pre Gen but Com and ena tha

Rollstud

www.rollstud.com www.rollstud.com Units 1, 2, 5, 6 & 7 Denm

Bridge of Don, Aberdeen, Scotland

‘From an extensive stock range, consisting of materials such as Carbon Steel, Stainless Steel, Super Duplex, Inconel etc, we offer a complete range of Imperial and Metric diameters.

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www.rolls

he Complete olution For All Your olting Requirements

llstud aim to provide a fast, reliable, mpetitively priced range of quality sured studbolts and fasteners, edominately for the Oil, Gas, Power neration and Petrochemical Industries t we also supply to many other industries. mplete Piping Packages are also offered d Gaskets are available from stock, Rollstud Ltd ablingTelus provide a “one stop” solution 01224to 425300 at canwww.rollstud.com meet every need.

We offer in-house electroplating and PTFE coating, alongside a comprehensive range of coatings that are supplied regularly in accordance with industry standards and client specification. We even offer a 24 hour call out service!’

Rollstud will be attending Chem UK on the 1st and 2nd May and would be delighted to meet clients both new and old, to discuss future business opportunities and answer any questions that they may have in relation to our offerings.

The Complete Solution For All Your Bolting Requirements more Industrial Estate Rollstud aim to provide a fast, reliable,

Limited

d, AB23 8JW | 01224 425300

stud.com

competitively priced range of quality assured studbolts and fasteners, predominately for the Oil, Gas, Power Generation and Petrochemical Industries but we also supply to many other industries.

Complete Piping Packages are also offered and Gaskets are available from stock, enabling us to provide a “one stop” solution that can meet every need.

Rollstud Limited

www.rollstud.com www.rollstud.com Units 1, 2, 5, 6 & 7 Denmore Industrial Estate

Bridge of Don, Aberdeen, Scotland, AB23 8JW | 01224 425300

www.rollstud.com

Issue 37 PECM

105

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FASTENERS & FIXINGS

NEW RANGES OF STAINLESS AND SPRING STEEL FASTENERS SD Products Ltd is a third generation family owned business with over 40 years of experience as a stockist distributor of specialist fasteners, we supply product across all industries. The corner stones of our business are Quality Products at Competitive prices with Service and Supply requirements tailored to our customers’ needs. As our business continues to grow we constantly aim to expand our extensive product catalogue.

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A brand new range of 12-150mm safety clips is now available from SD Products website.

These fasteners are manufactured from high grade spring steel, offering excellent stress and corrosion resistance, as well as ability to withstand considerable forces without any distortion. High yield strength of spring steel in our safety clips allows them to return to their original shape, even after substantial deflection, twisting or compression, without suffering any significant deformation. Safety clips are well suited for both domestic and industrial applications and can be easily installed or removed by hand.

shank of the bolt acting as a dowel, pinning the joint against sideways shear forces. Our connector bolts are suitable for a variety of furniture applications, flat low profile bolt heads allowing for a decorative finish.

Several new lines of stainless steel connector bolts and nuts have been added to our furniture fastener range. Connector bolts are designed to be used with connector caps nuts - nut applying an axial clamping force and the

We have increased our range of mild steel slab base t-nuts and added a new range of stainless steel 4 pronged t-nuts.

T-nuts have a wide range uses – ideal for automotive, domestic, furniture and industrial

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Swivel joint design and m from Rotaflow applications. Durable, reliable and low in cost, these fasteners are designed to securely anchor particle or composite materials like wood and plastic to a workpiece. Produced from high quality mild and stainless steel, t-nuts from SD Products are sturdy and hardwearing.

Rotaflow design and manufacturewww.sdproducts.co.uk a range of swivels joints. Swivel Joints allow fluids to be transferred across rotating interfaces, without leakage. jetpress.com

YOUR GLOBAL SOURCE FOR

FASTENERS & COMPONENTS

Simple single flow units are used in Experts in metal & plastic engineered fasteners many applications including • Extensive stocks available for rapid delivery! loading arms, articulated • Vast range of proven solutions to choose from pipework and hose reelers.

• First class technical support & customer service Some applications require • Bespoke design, development & manufacturing articulated pipe work or hoses to allow fluids; such as Hydraulic Power, Air (pneumatic) control lines, or mixed process fluids to be used on moving machinery.

The strong bearing area, of both ball bea is complimented with a choice of Find yourrollers, solution at for maximum application compatibility. O jetpress.com 30 years Rotaflow have provided design many processing sectors.

sales@jetpress.com

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PECM Issue 37

• 01623 551 800

Swivel joints will allow the movement on drum or remove the damaging effect of t We manufacture in both carbon steel and

KHDWLQJ FDSDFLWLHV IURP :DWWV XS WR N: DOORZ FLUID HANDLING VFDOH XS IURP UHVHDUFK WR SURGXFWLRQ )LQG RXW ROTAFLOW SUPPORTING PRUH DERXW RXU EHVWVHOOHUV THE NEXT GENERATION PLQLVWDWÂ&#x160; XQLVWDWÂ&#x160; PLQLFKLOOHUÂ&#x160; OF ENGINEERS XQLFKLOOHUÂ&#x160; DQG URWDFRROÂ&#x160; ZKLFK GHÂżQH WKH VWDQGDUGV Swivel joint specialists Rotaflow are continuing to strengthen links with Loughborough Universityâ&#x20AC;&#x2122;s RI WHPSHUDWXUH FRQWURO WHFKQRORJ\ engineering department by

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taking on a student for the 6th year in a row.

Each year an engineering student DOHV#URWDÓżRZ FRP is invited to join the Rotaflow

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team for a year in industry, where theyâ&#x20AC;&#x2122;ll combine technical skills with first-hand business experience.

The student will help in the design and preparation of models, liaise with customers and experience the workings of the factory, where theyâ&#x20AC;&#x2122;ll often see their ideas develop into a manufactured piece.

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The placement year with Rotaflow is a perfect chance for the student to gain hands-on factory experience and provides opportunities to experience other disciplines such as R&D, Technical Sales, Metrology, Quality Control and PR/Marketing.

Duncan Pearce, the placement co-ordinator at Rotaflow saysâ&#x20AC;Ś

Fluid Carrying

Flexibility

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Torsion In Hoses

Rotating Cylinders

â&#x20AC;&#x153;We enjoy having the students join the team every year. Itâ&#x20AC;&#x2122;s a chance for us to support the next generation of engineers and it helps us to stay up to date with the latest in engineering educationâ&#x20AC;?.

This relationship has provided students with jobs in the industry after graduation, making an engineering career with Rotaflow a reality.

Swivel joints allow pipework to pressure 1/4â&#x20AC;? to 40â&#x20AC;? and beyond.

Vacuum to over 20,000psi.

Stock and bespoke production.

Unique bearing/seal design for longer life.

PTFE Fluid Handling from Bohlender ISO 9001 CE marked where applicable.

Bohlender offers a vast range of finished and semi finished pr in technical and fluoroplastics.

Tel: +44(0)1663 735003

rotaflow.com

Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY | UK

E-mail:

A variety of different materials like PTFE, FEP, PFA, PEEK and enable innovative products to be produced with excellent ch resistance and high thermal resistance.

PTFE FLUID HANDLING FROM BOHLENDER

Labtex supplies leading laboratory products including HUBER liquid temperature control systems, DIEHM glass reaction systems to 100 litres, PREMEX and AMAR high pressure autoclaves, POPE wiped film or short path evaporators and distillation systems, Nutsche filter dryers, BOLA labware in PTFE and other technical plastics, Vacuubrand vacuum pumps, ASECOS storage solutions for hazardous materials to BS EN 14470-1 and SICCO desiccators.

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

tures reaction vessels up to 6 litre capacity in PTFE or PFA. All parts exposed to the medium are either made completely of PTFE/PFA or jacketed like the thermometers.

Screw joints and ground joint components, tubing and conn The BOLA catalogue also includes allow an infinite number of combinations to create sophis a wealth of technical information on the materials used including systems of fluid transfer using standard laboratory bottl physical properties and chemical Screw joints and ground joint resistance and the safe use and containers.

arings and needle also work with LLG GermasealingWematerials ny, the 3rd largest lab supplies care of fluoroplastic labware. components, tubing and connecFurther advice on the pressure tors allow an infinite number of Over the passed distributor in Europe and have and the cor- products combinations to create sophisof strong acidsresistance or of tubing alkaline a catalogue of 20,000 items from over 200 For respecteddistillation brands. solutions within rect choice for pressure or vacuum ticated systems of fluid transfer

n a slowly rotating twisting on hoses. d 316 stainless

manufactures reaction up to 6 litre applications makecapacity the catalogue a in PTFE using standardvessels laboratory bottles useful reference. and containers.

All parts exposed to the medium are either made comple For distillation of strong acids or www.labtex.co.uk PTFE/PFA or jacketed likeBOLA the thermometers. alkaline products manufac-

The BOLA catalogue also includes a wealth technical Issue 37 of PECM 107 infor on the materials used including physical properties and ch

HOSE MANAGEMENT

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JET PRESS

A NEW SUPPLIER FOR AN OLD FAVOURITE Heyco, the US based manufacturer of cable and hose management products since the 1920’s started the search for an additional UK and Europe distributor in 2017.

They know their reputation for quality depends not just on the performance of their products but on distributors who understand the needs of customers and provide a totally reliable service.

under the Component Program of the Underwriter’s Laboratory (UL) and by the Canadian Standards Association (CSA).

These are recognised around the world as some of the highest quality standards.

Core products include a range of Bushings including Strain Relief Bushings along with Dome and Vent Plugs. Details of all the core products are on the JET PRESS website.

So JET PRESS was very pleased to be selected as a distributor in 2018.

For core products JET PRESS offers a rapid turnaround ordering service and all the products in the Heyco catalogue are available through JET PRESS. Perhaps more importantly for many potential customers, JET PRESS not only has engineering resources in-house to support customers, they also have access to the significant design, engineering and prototyping resources of the Heyco plant in New Jersey. JET PRESS is currently working with Heyco on a series of bespoke parts destined for use in a complex electronic component for a luxury car manufacturer.

JET PRESS is happy to supply samples or take your orders for core items and anything else from the Heyco catalogue.

They are particularly happy to hear from anyone with challenges - the JET PRESS engineering team and the Heyco R&D people really enjoy cracking a tough problem.

Call: +44 1623 551800 jetpress.com | jetpress.de

WHY CABLE MANAGEMENT MATTERS

... always an intelligent solution

Engineers understand the value of good cable management; a single failure in an electrical, data or signalling cable can lead to failure of the device or of an entire system. But it is important to strike the right balance, specifying something that has all the right performance criteria without adding unnecessary weight, cost or introducing manufacturing issues.

Heyco specialise in products for automotive and electrical appliances.

Vehicles move so there is always a requirement for varying levels of strain relief. However domestic appliances vary considerably. A fridge freezer gets moved maybe twice a year; by comparison a toaster is moved around all the time. The people at a well-known electrical goods brand - famous for their toasters - are reputed to whirl them around their head to test the cable fixture! And yes, they use Heyco components.

COMPRESSION FITTINGS ORIGINAL RANGE Sizes 15 -100mm

BENEFITS BEYOND THE FINISHED PRODUCT The huge experience Heyco has of working closely with customers mean they understand manufacturing demands. For instance, their bushings only require finger pressure to install. This means operatives can work swiftly and there is less chance they will develop Repetitive Strain Injury (RSI) or Carpal Tunnel Syndrome (CTS) with consequent disruption and costs for the manufacturer.

QUICK RANGE Sizes 15 -50mm

The bushings also lock in fractional increments so they fit snugly into the aperture and there is a small amount of tolerance to the panel thickness, though of course they are all available in a wide range of sizes.

LEAK SEALING CLAMP Sizes 10 -100mm

THE CORE RANGE FROM JET PRESS

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

All the core products are made from industry standard Nylon 6/6, have a flammability rating of 94v-2 and a temperature range -18°C to 105°C. Because they are US manufactured they are recognised

108

Malleable

DZR Brass

TAPPING CLAMP

Malleable

DZR Brass

PECM Issue 37 PECM Quarter page, CABCO.indd 1

10/03/2016 10:38

4-6 JUNE 2019 NEC BIRMINGHAM

THREE EVENTS, ONE COMPLETE MANUFACTURING SOLUTION 15

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70

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MACHINING & MACHINERY

FAST ROTOR REPAIR SULZER

CRACKED STEAM TURBINE ROTOR REPAIRED AND REINSTALLED WITH 8% IMPROVEMENT ON PERFORMANCE

When a damaged steam turbine rotor needed to be repaired, a power generation plant in Indonesia turned to Sulzer for an expert service. Rather than wait for at least a year for a new rotor from the original equipment manufacturer (OEM), the plant opted for a repair that took only sixteen weeks. This swift and effective repair also managed to achieve an 8% improvement in efficiency.

The Indonesian geothermal power plant had been experiencing some issues with one of its 60 MW steam turbines. During the previous two years, the pre-existing maintenance provider had repeatedly tried to repair the turbine, but the vibration issue had persisted. Despite several attempts to low speed balance the rotor at their premises, it still exhibited high vibration levels.

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PECM Issue 37

INITIAL INVESTIGATION During one of these off-site balancing procedures, the plant engineers discovered deep cracks that were suspected to have been caused by a previous repair by another service company. As well-known experts in the repair of steam turbines, Sulzer was called in to resolve the problem.

Sulzer’s initial inspection revealed that the rotor had cracks on the radius section between the last stage disk and the gland seal area located on both the governor and the generator sides. In addition, there was considerable evidence of erosion on the blades, the disks and the balance correction holes.

REPAIR RE-EVALUATION The initial plan was to machine out the material until the cracks were removed and

then rebuild the shaft using submerged arc welding before machining it to nominal dimensions. However, after comprehensive inspection at Sulzer, the crack propagation already had a spiral shape through the center of the shaft, making it impossible to machine out the crack area only. Sulzer then came up with a repair proposal that involved designing a stub shaft that would be used to join the two pieces together before the shaft was rebuilt to its nominal dimensions.

Andrianto Hapsoro, Head of Engineering, Sulzer Indonesia, explains: “There was always a customer representative in the workshop, which helped maintain excellent communications and keep them up to date with progress. Any rotor repair is timecritical, with lost revenue making every day count in this project.”

With the location of the repair being so close to the 6th disk, some additional repairs would be needed to this disk, which would extend the overall time to complete the project. in order to save time, Sulzer proposed both stage 6 disks would be removed and possibly reinstated at a later date. This was then agreed by customer.

REPAIR EXPERTISE Joining two sections of a turbine rotor requires considerable expertise, including computer modelling and finite element analysis (FEA) to ensure that the proposed design would withstand the stresses of normal operation. The FEA was also carried out at an overspeed of 3’600 rpm to ensure that the centrifugal loading on the disks would not cause any damage to the rotor

shaft after the repair. With all the necessary analyses completed, the machine shop started to prepare the two rotor shaft sections for the addition of the stub shaft.

In-house precision machining enabled the stub shaft to be shrink-fitted into the prepared connections before the whole joint area was preheated prior to the welding process. Using precision-controlled, submerged arc welding equipment, the stub shaft was built up to a level that would allow it to be machined back to the required dimensions. Once the original dimensions had been achieved, a series of nondestructive tests (NDT) was carried out to ensure there were no flaws in the completed rotor assembly.

These processes were repeated to remove the cracks in the thrust end of the rotor

as well, bringing the completed assembly back to finished dimensions. Once all the machining was complete, the rotor was dynamically balanced before being shipped back to the customer.

IMPROVING PERFORMANCE While the repairs were being completed on the rotor, the field service team was working at the customer’s site to repair the diaphragm and improve the sealing of the casing. This work would be influential in improving the efficiency of the steam turbine.

Prior to the project being started by Sulzer, the turbine required 393 tonnes of steam per hour to produce the 53.4 MW of energy.

Despite one set of disks being removed, the repair to the static and rotor components of the turbine delivered by Sulzer, enabled it to maintain an output of 55.1 MW but using only 374 tonnes per hour of steam, which is an 8% improvement in efficiency.

When the repaired turbine rotor arrived back on site, the field service team carried out the installation and commissioning, which included vibration testing at full load. All the results were well within the original specifications and the generator has remained at full capacity ever since.

Andrianto concludes: “The customer was very impressed with the results of this project. In total, the whole repair took only 16 weeks, which is considerably less than the estimated lead time for a new rotor from the OEM, which is closer to 52 weeks.” www.sulzer.com Issue 37 PECM

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TRANSMISSIONS LTD “ Part of your drive ” PUTTING PRODUCT QUALITY & CUSTOMER SERVICE ABOVE ALL Apex Apex Transmissions Transmissions Ltd Ltd is is a a leading leading supplier supplier of of precision precision planetary planetary gearboxes gearboxes and and Bosch Bosch Rexroth Rexroth linear linear motion motion components components in in the the UK UK market. market.

Having Having a a passion passion for for providing providing customers customers with with only only the the highest highest quality quality goods goods and and a a strong strong drive drive to to offer offer an an unrivalled unrivalled customer customer service, service, Apex Apex Transmissions Transmissions Ltd Ltd has has earned earned a a reputation reputation as as a a trusted trusted supplier supplier right right across across the the UK UK and and beyond. beyond.

In In house house machining machining and and processing processing facilities facilities were were developed developed and and specifically specifically tailored tailored to to offer offer their their customers customers exceptionally exceptionally short short lead lead times times on on Rexroth Rexroth linear linear products products from from the the stock stock held held at at their their UK UK factory. factory.

To To this this day, day, Apex Apex Transmissions Transmissions Ltd Ltd continues continues to to develop develop and and improve improve upon upon their their range range of of Bosch Bosch Rexroth Rexroth linear linear motion motion products products and and services. services. Their Their current current portfolio portfolio focuses focuses on on machined machined ballscrew ballscrew and and nut nut assemblies, assemblies, finished finished linear linear ball, ball, roller, roller, stainless stainless ball ball and and miniature miniature guideways guideways and and linear linear ball ball bushes. bushes.

Apex Apex Transmissions Transmissions Ltd Ltd offer offer full full design design support support service service for for all all of of their their products. products. A A fully fully equipped, equipped, in-house in-house technical technical department department features features the the latest latest 3D 3D CAD CAD software software and and a a team team of of qualified, qualified, experienced experienced engineers engineers can can offer offer free free calculations calculations to to support support your your machine machine design design process process no no matter matter the the scale scale or or complexity complexity of of build. build.

Originally Originally founded founded as as the the official official UK UK agent agent for for Apex Apex Dynamics Dynamics products, products, and and with with a a team team of of experienced experienced staff staff with with a a thorough thorough understanding understanding of of the the specific specific requirements requirements of of the the UK UK market, market, Apex Apex Transmissions Transmissions Ltd Ltd were were able able to to offer offer customers customers exceptionally exceptionally short short lead lead times times on on gearboxes gearboxes from from stock stock at at the the Apex Apex UK UK head head office office facility facility located located centrally centrally in in Tamworth, Tamworth, Staffordshire.

Staffordshire.

This This helped helped many many companies companies across across the the UK UK struggling struggling with with excessively excessively long long delivery delivery times times from from other other leading leading gearbox gearbox manufacturers manufacturers to to finish finish their their projects projects on on time time and and under under budget, budget, reinforcing reinforcing the the reputation reputation of of Apex Apex Transmissions Transmissions for for customer customer service service and and earning earning customers’ customers’ trust. trust.

CHANGING DIRECTION

Soon, Soon, the the reputation reputation of of excellent excellent customer customer service service and and an an in in depth depth product product knowledge knowledge and and market market understanding understanding earned earned the the attention attention of of Bosch Bosch Rexroth Rexroth UK. UK. After After some some discussion discussion between between the the two, two, Apex Apex Transmissions Transmissions Ltd Ltd began began to to stock, stock, process process and and distribute distribute Rexroth Rexroth linear linear motion motion products products into into the the UK UK market. market.

For For 2019, 2019, Apex Apex Transmissions Transmissions Ltd Ltd are are proud proud to to offer offer their their new new range range of of precision precision planetary, planetary, spiral spiral bevel bevel and and hypoid hypoid gearboxes. gearboxes. Featuring Featuring improved improved quality quality and and solid, solid, robust robust construction, construction, their their new new gearbox gearbox range range reflects reflects their their commitment commitment to to the the market market to to continuously continuously improve improve product product quality quality and and the the service service provided. provided.

The The new new range range offers offers full full helical helical gearing gearing across across the the range range for for smoother, smoother, quieter quieter operation operation and and higher higher torque torque density density compared compared to to a a gearbox gearbox with with straight straight gearing. gearing.

As As well well as as this, this, all all gears gears are are case case hardened hardened and and ground ground to to further further improve improve the the torque torque capacity, capacity, speed speed and and service service life life of of the the unit. unit.

TEL: TEL: 01827 01827 253340 253340 sales@apex-trans.co.uk sales@apex-trans.co.uk

FAX: FAX: 01827 01827 253390 253390 www.apex-trans.co.uk www.apex-trans.co.uk

From From the the substantial substantial stock stock supply supply at at their their midlands midlands based based facility, facility, Apex Apex Transmissions Transmissions Ltd Ltd offers offers an an exceptional exceptional production production process process and and with with fast fast delivery delivery times. times. This This helps helps to to reduce reduce the the construction construction time time of of customer customer machine machine builds builds and and the the express express delivery delivery service service also also reduces reduces productivity productivity losses losses to to production production companies companies as as a a result result of of gearbox gearbox breakdowns. breakdowns.

The The range range of of gearboxes gearboxes offered offered by by Apex Apex Transmissions Transmissions Ltd Ltd includes includes drop drop in in replacements replacements for for the the vast vast majority majority of of established established gearbox gearbox manufacturers manufacturers and and so so offering offering an an alternative alternative to to the the long long lead lead times. times.

Apex Apex Transmissions Transmissions Ltd Ltd are are proud proud to to offer offer their their service service and and products products for for distribution distribution throughout throughout Europe.

Europe.

BOSCH REXROTH LINEAR MOTION

PLANETARY GEARBOXES

TRANSMISSIONS LTD “ Part of your drive ”

“ Part of your drive ”

SERVOBOX GEARBOXES

LINEAR MOTION

STOCK CATALOGUE EDITION 02

“ Part of your drive ”

STOCK CATALOGUE EDITION 01

Precision Planetary Gearboxes Full Helical Gearing Across the Range Quality & Robust Construction Supplied with Individual Test Reports OFFICIAL STOCKIST www.apex-trans.co.uk sales@apex-trans.co.uk

TEL: 01827 253 340 FAX: 01827 253 390

www.apex-trans.co.uk sales@apex-trans.co.uk

Official Bosch Rexroth Linear Stockist

TEL: 01827 253 340 FAX: 01827 253 390

Unrivalled Customer Service

YOUR FREE CATALOGUES

Fast Delivery From Our UK Stock In-House CAD Design & Calculations

QUALITY INSPECTION REPORT FREE WITH EVERY GEARBOX

­

­ ­ ­ ­ ­ ­ ­

­ 7MP-120A-130-A1 2018 11 12

­

­ ­

­

­

­

­

PS SD110-004T-L32

M418B0934

YES

­

YES

­

YES YES YES

≤1

YES YES

≤ 56 dB

YES

YES YES YES

TEL: 01827 253340 sales@apex-trans.co.uk

FAX: 01827 253390 www.apex-trans.co.uk

Issue 37 PECM

115

GEARS, DRIVES & MOTORS

IMPROVED SERVICE LIFE NSK

NSK SOLVES CONVEYOR FAILURE ISSUES AT DRINKS PLANT

By changing to NSK Molded-Oil mountedunit inserts, an international drinks producer has overcome repeated problems of premature insert failures on the drive system of four vital sorting conveyors. The move has improved service life notably, leading to an annual saving of more than €5000.

At the beverage plant, cleaning processes comprising a mix of water and chemicals were destroying the bearing seals and washing out the grease pack on the company´s existing mounted units. As a result, the inserts within the mounted units had to be replaced every 5 to 6 months, and re-greased every 3 weeks. NSK was invited to find a solution to this problem in order to improve service life and reduce maintenance requirements.

After a thorough review of the application, NSK´s team of expert engineers concluded that a switch to Molded-Oil mounted-unit inserts would solve the issue.

NSK mounted units comprise two basic components: the insert and the housing.

Each unit consists of a sealed singlerow ball bearing with spherical external

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diameter and extended inner ring mounted in a pillow block or flanged housing. The spherical fit accommodates any initial misalignment.

Importantly, the lubricant within MoldedOil inserts is durably incorporated inside a stable carrier medium, namely an oilimpregnated polyolefin resin. This type of lubricant cannot be washed away by liquids or steam, and prevents the ingress of contamination. Moreover, as the carrier only releases the lubricant slowly, sufficient lubrication is maintained over a long operating period. A further benefit is that the operating environment remains clean as no grease can leak out and no oil refilling is required.

Made from martensitic stainless steel, Molded-Oil inserts are ideally suited to applications which are in frequent and heavy contact with water.

One year on from installing Molded-Oil mounted-unit inserts, the drinks producer has reported no failures whatsoever, while the need for re-greasing has been eliminated. As a result, annual cost savings have been calculated at €5080.

About NSK Established 100 years ago, NSK (Nippon Seiko Kabushiki Kaisha) is a Japaneselisted company that has evolved from a regional ball bearing supplier to a roller bearing specialist and automotive supplier with a global market presence.

Today, NSK employs more than 31,860 employees in 30 countries. As per March 2018 NSK achieved a turnover of 1020 billion Yen. This result has been driven by ever-increasing investment in research & development, enabling the company to continuously improve the quality of its products and services. This investment supports NSK´s objective of »No. 1 in Total Quality». In addition to a complete rolling bearing portfolio, NSK develops and manufactures precision components and mechatronic products, as well as systems and components for the automotive industry, including wheel bearing units and electric powersteering systems.

For more information, visit www.nskeurope.com

GEARS, DRIVES & MOTORS

THE UNIVERSITY OF WARSAW ROVER TEAM The University of Warsaw’s Rover Team of which British Encoder Products is one of their proud sponsors recently posted their results from the University Rover Challenge.

They said :“A week ago, the University Rover Challenge ended. The PCz Rover Team won, Missouri S&T Mars Rover Design Team finished 2nd and the Mars Rover Kielce “impuls” team was third.

We’ve managed to take the 8th position, so we’re getting better! (last year - 16th) In the task where we had to service a lander’s control panel we scored the best of all teams.

In the astronaut assistance task, despite heavy technical problems, only 4 competitors got a better result than us.

Unfortunately our road to podium was blocked by weaker scores in the two other tasks.

We don’t stop in our activities and continue preparations for the next competitions - the Canadian International Rover Challenge in August and the European Rover Challenge in September.

British Encoder Products are proud to be one of the sponsors of this great team and wish them all the best for their upcoming challenges.

Please visit their Facebook page here www.facebook.com/uwroverteam/

Cross+Morse

Power Transmission Manufacturing Specialists 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 Gears ◊ 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 ◊ ISO 9001 : 2015

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

ABSOLUTELY DRIVEN NEW RANGE OF DRIVES AND VARIABLE SPEED GEARBOXES

For further information and sales contact Greg Smith on 01484 600200 or greg@labtex.co.uk

ATEX compliant to EC Directive 94/9/EC

Distributed in the UK by:

www.labtex.co.uk Issue 37 PECM

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HEALTH & SAFETY

10 YEAR RELATIONSHIP DUPONT

SPECIAL CHEMISTRY BETWEEN DOW AND DUPONT IMPROVES WORKER SAFETY

Ensuring that workers are properly protected and fully engaged in safety procedures is a primary objective for any employer. The health and safety team at one of Dow Chemical Company’s largest production sites has developed a partnership with DuPont Personal Protection over time that delivers ongoing improvements in staff safety and training, as well as more streamlined ordering procedures and related cost savings.

PRODUCT SELECTION CONFIDENCE Covering some 550 hectares, Stade is Dow’s largest German production site.

Every year, around 1300 in-house staff and several hundred contractors produce some three million tonnes of basic and specialty chemicals including propylene oxide, propylene glycol, solvents for paints, perchloroethylene, raw materials for

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polyurethanes, cellulose ethers, chlorine, sodium hydroxide solution and hydrogen in ten plants.

also used during the emptying and cleaning of pipework, which is required for regular official TÜV2 inspections.

Personal protective equipment (PPE), including chemical protection garments, is vital for reliably protecting staff from hazardous liquids and solids. For over a decade now, Dow workers have been using garments made by DuPont Personal Protection to protect them from workplace hazards.

Key to the decision were the comprehensive permeation data that DuPont was able to supply to Dow’s safety professionals. Jens Thiede, SHE Specialist at Dow in Stade with responsibility for the selection and use of PPE, explains: “We have around 2000 different chemicals on our plant here and cannot purchase a dedicated garment for each product. We need products that reliably protect our staff from as many substances as possible. So, we had a good look around on the market and shortlisted a range of options. The permeation data DuPont supplied for numerous organic and inorganic chemicals were very helpful and convinced us that the two Tychem® garments were the best ones to choose for our staff.”

To provide protection from liquid chemicals, Dow makes use of Tychem® 2000 C and Tychem® 6000 F coveralls1.

Typical applications include material transfers or inspection tasks in which lines are opened and there is a risk of personnel being contaminated with a hazardous substance. These garments are

Dow has also been using DuPont coveralls for many years in areas where staff are exposed to hazards arising from solids and dusts; for instance, in the production of cellulose ethers which are used as fillers and binders in construction materials, cosmetics and pharmaceuticals. The suits involved here are primarily from the Tyvek® product line, such as Tyvek® 600 Plus.

TRY BEFORE YOU BUY Before purchasing new or updated garments, Dow carries out comprehensive wear tests lasting several weeks or even months with its front-line staff.

These tests are a useful factor in coming to a decision about which product is most suitable for staff and their specific working conditions and whether the chosen garment can prove its worth under practical conditions.

Thiede explains, “DuPont assists us with these tests by supplying sample garments in various sizes. Our staff enter their ratings on questionnaires covering criteria such as wearer comfort, fit, freedom of movement, handling, size range and, of course, the wearer’s subjective feeling of safety.”

Dow then jointly evaluates these questionnaire responses with DuPont.

Positive and negative feedback about the garments may then be fed into further product development.

Dow’s standard practice originally was to keep stocks of the garments in sizes M to XXL. Over the course of time, the wear tests have increasingly revealed demand for very small and very large sizes as well.

One advantage of working with DuPont is their ability to respond to these changes in demand, because they can offer a wide range of different sizes which are available from stock or made to order.

CONTINUOUS SAFETY IMPROVEMENT Dow and DuPont have now been working together for over ten years on the selection and use of suitable protective garment solutions for specific hazards and applications. The aim is to ensure ongoing, continuous improvement in staff safety on the Stade site. This is why the companies carry out joint workshops to inform heads of department, H&S coordinators, staff from partner companies and apprentices about protective clothing in general, the characteristics of Tychem® and Tyvek® chemical protective clothing, the correct way to donning and doffing and proper disposal after possible contamination.

As Thiede says, “Participants in these training workshops pass on their knowledge to their departments and among their shift colleagues. Our aim is to make sure this knowledge is put into practice and widely disseminated so our staff can work safely.” DuPont has helped to support the dissemination of safety information by providing training videos and step-by-step instructions which Dow staff can access via an intranet platform.

In addition, custom garment solutions were required for some areas of use: such as protective suits with reinforcement at specific points subjected to particular mechanical stress, or specific details such as attached heat-sealed gloves or boot cuffs. “In such cases, DuPont put us in contact with a company which has been able to finish the garments in line with our requirements”, explains Thiede. “Also, we regularly collaborate on optimizing and further developing the products with the aim of continually improving staff protection.”

ROLL-OUT TO OTHER SITES Since Stade manufactures basic chemicals, the safety insights gained there can also be transferred to other Dow sites in Germany and Europe to deliver a number

of benefits. Firstly, broader implementation generates cost savings, since there is no longer any need to select and assess various chemical protection garments and carry out wear tests at each site. Secondly, the resultant synergies can ensure greater harmonization of PPE between sites and so enable uniformly high occupational safety standards across Germany. “This obviously also makes things simpler and more efficient for both parties. DuPont has a single point of contact on the customer side and we are able to take delivery of larger quantities, making it a win-win situation for everyone”, concludes Thiede.

For further information, please visit: ipp.dupont.com or safespec.dupont.co.uk.

Issue 37 PECM

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HEALTH & SAFETY

DRIVING UP STANDARDS ROSPA

A GROWING NETWORK OF NATIONAL AND INTERNATIONAL H&S EXPERTS

The RoSPA Health and Safety Awards, now into its 63rd year, aims to promote best practice in workplaces around the world to drive up standards and ensure that no-one is harmed or made ill while doing their job.

We want to make sure that every worker goes home at the end of every day safe and well to their families.

The Awards scheme is recognised across the world, and currently receives entries from organisations in over 30 countries across the globe, that have a combined reach of more than seven million employees.

health and safety management capability is rooted in the care and concern shown by its culture.

Central to the continuing success and growing influence of the RoSPA Awards is the dedication and commitment of its winners, with several having now picked up the prestigious RoSPA Patron’s Award, given only to those with more than 25 years of Gold-level achievement.

Colas Limited was named winner of the Construction Engineering Sector, with Wessex Engineering and Construction Services being Highly Commended; and Nuvia Limited was crowned winner of the Engineering Services Sector, with Vanderlande Industries UK Limited being Highly Commended.

Entrants large and small come from all sectors, with many having engineering at their core. In 2018 (to name a few!), Gulf Petrochemical Industries Company was the winner of the Chemical Sector Award;

But taking the overall “best in show” prize – the Sir George Earle Trophy – in 2018 was National Physical Laboratory, with the judging panel of industry experts noting that the strength of the organisation’s

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The RoSPA Awards is underpinned and driven by up-to-date occupational safety and health policy, setting it apart from any other industry awards scheme. This policy is informed and shaped by the exclusive Awards Excellence Forum, into which each and every entrant is granted access. The Forum draws on the expertise of practitioners from around the world, allowing them to encourage, support and challenge each other, and raise the standards of those looking to improve their safety cultures.

RoSPA’s vision is one of life, free from serious accidental injury, and through the RoSPA Awards and its extensive and ever-growing network of world-leading organisations, it’s a vision that we’re striving quickly towards.

Join us! See www.rospa.com/awards.

2019

RoSPA Health & Safety Awards LONDON | BIRMINGHAM | GLASGOW

Give your organisation a competitive edge!

The 2019 RoSPA Health and Safety Awards offer you the perfect platform to reward your team’s dedication to safety, plus being a #rospawinner will elevate your organisation’s profile to customers, peers and stakeholders.

Now accepting registrations for the Glasgow Ceremony and Postal Awards.

Call

0121 248 2040

Email

awards@rospa.com

Visit

www.rospa.com/awards

Sir George Earle Trophy winner National Physical Laboratory

HEADLINE SPONSOR

121 www.rospa.com

Issue 37 PECM

HEALTH & SAFETY

OPERATIONAL DISCIPLINE AIR PRODUCTS EUROPE

MAKING THE DRIVE AND RATIONALE FOR OPERATIONAL DISCIPLINE IMPORTANT TO PLANT OPERATORS

By Mike Cawthra F I Mech E – Technical Manager Operations, Air Products Europe Nowadays, you would be hard-pressed to find a manufacturing or engineering firm where health and safety isn’t high on their agenda. But this increased interest at the top of business doesn’t always mirror the reality on the ground. Procedures aren’t consistently implemented as they should be, and accidents are still a major concern.

Research suggests that a staggering 91 per cent of incidents in the sector are down to human error – making them utterly avoidable. So, what’s the solution?

The answer, in my opinion, is to make the drive and rationale for operational discipline important to plant operators themselves, rather than just being something that is imposed from on high. We should seek to build a culture of discipline – continually reiterating its importance and providing regular training to ensure all operators have the knowledge to understand the hazards and how to prevent them.

Communication is key. Operators are being told to follow procedures, but in some cases, they aren’t taught to understand them or why they’re important. Inevitably, this means there will be those who don’t follow them. If we’re going to cut down on dangerous incidents, then it requires a wholesale cultural change. Operational Discipline must be instilled as a core behaviour – one which will ultimately become second nature.

Normalisation of deviance is a case in point.

A high integrity safety instrumented system can be established at a site to protect against hazards. But regardless of how detailed the design process might have been, if those on site aren’t familiar with it then they are far more likely to ignore the system’s warnings. A more effective approach would be to involve plant operators in the development process itself so they fully understand what changes are being made and why. This, in turn, will make them far more likely to want to implement them.

The general rule is that a ‘one size fits all’ approach just doesn’t work. Every site

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will have areas of particular weakness or susceptibility and each will need to have tailored solutions to those issues. Any operational discipline plan should account for this, allowing for site-specific challenges and giving those on the ground the opportunity to identify gaps in knowledge or compliance, and to improve accordingly.

After all, we are all far more likely to adhere to a process or procedure if we have been involved in its creation, especially if it is directly relevant to our day to day work.

At Air Products, we have developed a 10-point plan which has been designed around this idea that operators should be able to own programmes themselves. Under each heading we define what the highest standard of operations looks like, but they aren’t set out as directives. Instead, we task operators with identifying gaps at their site and allow them to focus on these priorities.

In each case we get different gaps, different methods to solve them, and bespoke solutions to suit each site.

We are all working to create safer workplaces and the latest data suggests that progress is being made. But this is no time to rest on our laurels. With such a high percentage of incidents due to human error, we have a clear area of focus for the future. No matter how committed a company might be to this at a corporate level, the impetus must come from those on the ground. We need to do more than issue directives – we need to change on site culture. That will only happen if everyone is on board.

www.airproducts.com

HEALTH & SAFETY

Sven-Philipp Abraham, Product Management –

SMARTER PRODUCT USABILITY

IT’S NOW EASIER THAN EVER TO READ CODES — CAMERA-BASED CODE READER DCR 200i

Product Center Ident + Vision

Using the setup wizard, the new DCR 200i is ready for operation in just a few minutes and can detect 1D- and 2D-codes quickly and reliably even with demanding reading tasks.

easyhandling.

Phone 01480 408 500 – www.leuze.co.uk

Issue 37 PECM

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HEALTH & SAFETY

EXPLOSION SAFETY REMBE

REMBE AT POWTECH 2019

Always a highlight, not only by daylight: REMBE live demonstration at POWTECH

ACCREDITATION OF THE REMBE RESEARCH + TECHNOLOGY CENTER AS AN INDEPENDENT TESTING LABORATORY

The REMBE live demonstrations have been an integral part of the POWTECH for many years. The same applies to the key player Roland Bunse - an established figure in the world of Explosion Safety since the 1990s, who has been at REMBE just as long, and has been head of the REMBE Research + Technology Center GmbH for 2 years. With the accreditation as a testing laboratory according to DIN EN ISO 17025 the team around Roland Bunse the independence and professionalism appreciated by many customers was once again confirmed.

In addition to the REMBE Research + Technology Center, REMBE GmbH Safety + Control will of course also be represented at POWTECH, but no longer in Hall 4 as before, but rather in the “new” Hall 5. At the booth 5-410, REMBE engineers will be presenting a new non-return valve and the Q-Ball E flameless venting device especially designed for elevator in addition to other selected products.

Q-FLAP RX NON-RETURN VALVE

The new Q-Flap RX non-return valve is a joint development between REMBE and the Swiss company RICO. The Q-Flap RX is available up to DN 1250.

The strict requirements of EN 16447 are mainly achieved through the very

high strengths and flexible installation distances. This is made possible by the socalled swivel carriage principle.

Isolation is essential for an effective Explosion Safety. No matter how much operators invest into (flameless) venting, if an isolation is missing the explosion can spread within the system and continue to propagate from one facility part to another.

FLAMELESS PRESSURE RELIEF FOR ELEVATORS: Q-BALL E

The Q-Ball E, which is primarily designed for elevators, uses the principle of the

contour-parallel relief developed by REMBE. Thanks to the innovative design, the weight of the Q-Ball is very low.

While comparable products from other suppliers weigh between 100-200 kg, the Q-Ball is an absolute lightweight with just 25-50 kg. This particularly facilitates the handling during assembly, as well as the requirements for an installation on the systems in the truest sense of the word.

About REMBE REMBE is a global specialist for Explosion Safety and pressure relief.

The company offers customers cross-industry safety concepts for systems and equipment. All products are manufactured in Germany, and meet the demands of national and international regulations. The customers who purchase REMBE products are among the market leaders of various industries, including the food, chemical, pharmaceutical and wood industries.

You will find the REMBE Alliance companies in Hall 5, at Booths 5-407, 5-408, 5-409 and 5-410.

Q-Flap RX DN 710

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Q-Ball E – flame-free pressure relief for elevators

www.rembe.com

T +49 2961 7405-0 info@rembe.de

Made in Germany

Your Specialist for

PRESSURE RELIEF and

EXPLOSION SAFETY

© REMBE® | All rights reserved

Consulting. Engineering. Products. Service.

Gallbergweg 21 | 59929 Brilon, Germany F +49 2961 50714 | www.rembe.de

HEALTH & SAFETY

PRECISION CONTROL BURKERT

FINDING THE BEST PARTNER FOR HYGIENIC PROCESS CONTROL PROJECTS Precision control of fluids and gases is a task that requires technical knowledge and experience. Within this area, hygienic applications, such as those in the pharmaceutical and biotech industries, place even higher demands on the control components and the surrounding infrastructure. So, when embarking on a hygienic process control project, finding the most qualified partner is essential to success.

Ian Webster, Hygienic Processing Field Segment Manager from Bürkert UK, looks at the essential attributes that are required from an engineering supply partner to deliver a successful installation.

Control technology and component designs are constantly changing, introducing new features and benefits, so keeping up with the latest innovations can be a challenge in itself. At the same time, applications in the pharmaceutical and biotech industries often require an investment in reliability and safety as much as cutting-edge technology.

DESIGN RESOURCES Designing, specifying and building hygienic process control projects requires very specific expertise and resources; bringing them together at the earliest opportunity will pay significant dividends in the long term.

For example, many process control projects require a combination of ‘off-the-shelf’ components and bespoke valves or valve blocks to minimise connections and dead volumes. All processes will require cleaning or sterilising procedures that need to be as efficient as possible to maximise the productivity of the line.

Using steam or hot wash processes requires considerable amounts of energy, so innovative manufacturers have created products to minimise energy requirements.

By reducing weight and making components smaller, less energy is needed to achieve the required temperatures and energy usage is optimised.

Once the scope and specification of a project have been finalised, getting into the detail of how the project will be delivered is where expertise really pays off. While it might appear straightforward to just order all the

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The design of process control infrastructure for hygienic applications requires considerable expertise. valves, control heads, sensors and controllers from the incumbent suppliers, it is often worthwhile to challenge this status quo.

REDUCING LEADTIME One of the sticking points for these projects is the lead-time for the more complex or larger valves. In some cases, this factor alone can determine the duration of the project, or at least the earliest start time. By working more closely with the manufacturer, it is possible to establish these milestones earlier and work to minimise their impact.

The next aspect to look at is the dispersal of the purchase orders and what resources are required to design, manufacture, install and commission the project. This applies not only to the external suppliers but also to the amount of in-house support that is required to administrate and manage the project.

By reducing the number of external suppliers, the level of internal resources required can also be minimised. By working with a manufacturer that offers a comprehensive range of products as well as the engineering expertise to develop bespoke products quickly, it is possible to install a fully integrated project in a shorter lead time.

This approach also delivers additional benefits, in that all the products work together seamlessly, use the same

communications protocols and should be delivered in a coordinated manner.

OPTIMISED PRODUCTIVITY Looking at alternative configurations will often bring new insights to design and the layout of process control systems. For example, depending on the application, changing from a centralised control infrastructure using valve islands to a decentralised system, can reduce installation time and offer more flexibility in the design.

Furthermore, new partnerships can reveal innovative products and technologies that improve efficiency or increase productivity.

Without exploring the alternatives, businesses risk closing themselves off from exciting new developments. The alternative simply trusting in the ‘tried-and-tested’ process can lead to a stagnation of ideas.

At Bürkert, specialist designers and engineers continually strive to meet the challenges of hygienic process automation, using the latest technology to deliver state-of-the-art solutions that work in harmony with existing facilities. Extensive industry knowledge and the ability to deliver bespoke components for any scale of project, sets the standard for the industry. www.burkert.co.uk

HEALTH & SAFETY

MODULAR DESIGN BS&B

The extinguishing unit on the IPD system consists of a depressurised, easily replaceable extinguishing agent cartridge and a pressurised container filled with nitrogen

THE EFFECTIVE WAY TO SUPPRESS AND STOP EXPLOSIONS Solutions for chemically suppressing and isolating explosions by BS&B Safety Systems feature a modular design and do away with pyrotechnic triggers. This makes installation, repair and transport easier.

Dust explosions in industrial facilities can be devastating due to the extreme rise in pressure. IPD, the system for suppressing and isolating dust explosions from BS&B Safety Systems, detects critical rises in pressure to the millibar and reacts at lightning speed. The highly effective extinguishing agent smothers any flame in an accumulating explosion in a fraction of a second, long before the explosive pressure is unleashed. When used for isolation, the IPD system stops the explosion spreading to connected parts of the facility. This provides effective protection to people, machinery and the environment.

MODULAR DESIGN MEANS EASY ONSITE RESETTING To make sure the IPD system is ready for use again quickly after being triggered, the designers at BS&B developed a new, modular design. This allows for immediate resetting on site, reducing production downtime to a minimum.

Unlike other solutions on the market, the owner or operator can reset the system independently after triggering.

The extinguishing unit consists of an unpressurized, easily replaceable extinguishing agent cartridge and a pressurised container that is filled with nitrogen during installation or reset.

The lack of a pyrotechnic trigger means that none of the individual components or the completed system are classified as hazardous goods. This makes both handling and spare parts logistics and management much easier. It also shortens delivery times and reduces cost of ownership, as there is no need to comply with the obligatory safety regulations for transport that apply to conventional systems.

Furthermore, the extinguishing unit requires no extra discharge nozzle for the agent. Instead, the integrated rupture disc becomes an aerodynamic outlet when activated. The design avoids the use of plumbing that can become blocked.

Alongside the extinguishing unit, the explosion suppression and isolation system features a control unit with touchpad and the patented Triplex sensor. This ensures constant, real-time monitoring of the process pressure, allowing for fast and reliable activation.

Three highly sensitive pressure sensors are arranged in a way that maximizes sensitivity while avoiding activation from vibrations. In the event of a power cut, the internal battery continues operation for at least eight hours. This provides enough reaction time to establish a secure energy supply.

PROTECTION FOR DUSTY PRODUCTION ENVIRONMENTS The IPD explosion suppression and isolation systems are used in all production environments where flammable dust is created or powdered substances are stored, handled and processed. Examples include the chemical or pharmaceutical industries, as well as the production of foods, feed and engineered woods. By responding to the incipient stage of a dust explosion, the IPD System reduces the pressure developed by the combustion event to a safe low level, as low as 0.2 bar. This is the combined result of having a low nitrogen gas pressure to disperse the extinguishing agent and the use of sodium bicarbonate as a fast heat absorbing agent.

For more information, please visit www.bsbsystems.com.

Issue 37 PECM

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HEALTH & SAFETY

SORTEX F OPTICAL SORTERS BUHLER

ARDO UPGRADES ITS PROCESSING PLANTS WITH POLARVISION TECHNOLOGY TO CONTINUE ENSURING FOOD SAFETY AND QUALITY Quality and food safety are essential for Ardo, one of the world’s largest fresh-frozen fruit, vegetable and herb producers. That is why they have invested in the latest SORTEX F optical sorters from Bühler, featuring the peerless SORTEX PolarVision foreign material detection system. In addition they have taken advantage of the PolarVision upgrade kit and saved significant costs by retrofitting the advanced technology into their existing SORTEX E sorters.

Ardo has 21 state-of-the-art production, packing and distribution sites in nine countries, employing 3,800 employees. It is a hugely successful business, turning over

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€1bn (US$1.13bn) a year, processing 860,000 tonnes of high-quality frozen fruit, vegetables and herbs, which are sold to customers in more than 100 countries.

To ensure high quality and ultra-freshness, Ardo’s production facilities are located near to fertile agricultural centres in Europe, close to where its carefully selected network of 3,500 growers operate. This helps to ensure that produce is as fresh as possible, while food quality and safety also remains high, because Ardo’s production sites are certified to internationally recognised standards, while complying with strict food safety and HACCP standards.

“Food safety is hugely important – it’s the cornerstone of our corporate strategy – and we invest in the most advanced technologies to help us to achieve this,” says Steven Van Engelandt, Ardo’s Group Project Engineer. “We’ve been using Bühler sorting technology for many years and now have their PolarVision technology on our sorting lines around Europe. In our Belgium production facility, for instance, we’ve just finished upgrading our SORTEX Es with PolarVision, as we needed to enhance our ability to remove any kind of foreign material (FM).”

Ardo operates the pioneering SORTEX F optical sorter from Bühler, fitted, as standard, with SORTEX PolarVision – Bühler’s specialist detection system, combining two pioneering proprietary technologies, to deliver unprecedented FM detection. They recently installed another two SORTEX Fs at their processing plant in Benimodo, Spain. Van Engelandt adds: “The SORTEX F perfectly meets our quality, safety and hygiene standards.

Consumers everywhere are becoming more demanding. Quite rightly they expect high quality and safety from a leading brand such as Ardo.

“We cannot fail in that, if we are to meet that expectation and retain our market position. We must take care of each single detail within our supply chain, which means not only using the right technology, but also choosing the right technology suppliers, who share our vision. We see Bühler as our technology partner.

“In our experience, PolarVision technology is one of the best digital-vision technologies when it comes to detecting FM in the industrial frozen vegetables process. It’s a jump forward”, Van Engelandt continues.

“We tested all other options, including laser, chlorophyll, translucency, but PolarVision was unsurpassed and it’s becoming standard in all our plants. When we were testing PolarVision, formerly problematic FM such as snails and dark plastic, became visible, and were removed, with an increase in yields, due to a more precise detection of defects.”

perceive this kind of product as almost ready to eat.”

When asked why Ardo decided to upgrade its SORTEX Es rather than buying new Fs, Van Engelandt replies: “The Es were a great investment at the time. They took our quality to the upper levels of the standards required.

They remain reliable and by upgrading with PolarVision technology, we could achieve a superior sort similar to the SORTEX F but for a significantly lower capital investment,” he smiles. “And, fitting the PolarVision upgrade kit is unbelievably quick. Within a day or two, our machines are back up and running like new.

“In the future, if old machines need replacing, we’ll go straight for the latest generation SORTEX Fs. We aim to have the most efficient technology to ensure quality and protect consumers from risk posed by FM. Safety remains our key challenge, as for all food processors. This is especially true with frozen products, because consumers

Stefano Bonacina, Segment Development Manager for Fruit & Vegetables in Europe and CIS, summarises: “Sourcing the finest local products, investing in the most advanced sorting solutions and upgrading where required ensures that Ardo’s food safety and quality standards remain industry leading.

“Processors who want to achieve a greater sorting efficiency in terms of FM as well as colour defect removal, can choose from the SORTEX F fitted with PolarVision or if they already have the SORTEX E they can upgrade it.

“The PolarVision upgrade kit has been designed to be installed with minimum disruption and downtime, enabling the removal of notoriously difficult to detect FM, for a fraction of the cost of investing in a new sorter.”

Bonacina concludes: “By investing in PolarVision you’ll not only benefit from a greater level of safety and quality, you’ll profit from higher yields and fewer consumer complaints.”

www.buhlergroup.com Issue 37 PECM

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HYDRAULICS & PNEUMATICS ARTEMISINTELLIGENTPOWER

BRINGING HYDRAULICS INTO THE DIGITAL AGE

There’s not been much fundamental innovation in hydraulics for the last 20 years but a new breed of digital hydraulic pump has sparked a rethink on the role industrial hydraulics can play in an Industry 4.0 world. Digital Displacement® pumps are enabling new machine architectures which can capitalise on the ultra-fast and highly-controllable response of digital hydraulic pumps, says Alasdair Robertson, Commercial Director at Artemis Intelligent Power.

It is ironic that what’s being proposed as efficient digital hydraulic systems of Industry 4.0 are reliant on analogue technology developed at the height of Industry 1.0. At the core of many advanced hydraulic machines today is the same basic control mechanism that was first patented in 1893.

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The variable angle swash plate was invented as a simple and reliable way to transform rotational power into motion and has been the main mechanism used to create variable flow output for almost 120 years.

Efforts have been made to digitise the mechanism with feedback and electric control systems and it has served our industries well but itâ&#x20AC;&#x2122;s time for hydraulics to move out of the analogue age and engage with the benefits of true digital control.

a radial piston mechanism and an embedded controller that enables individual cylinders in real time by actuating ultra-fast mechatronic valves.

A fundamental innovation

The control of individual cylinders also allows a single pump to have multiple independently controllable outlets providing industry innovators

Invented by Artemis Intelligent Power, the Digital Displacement Pump uses

The fast acting valves and controller allow for high bandwidth control of pump output. The ability to use only the cylinders required to meet the load results in a pump with an efficiency of greater than 90% over most of the operating range.

a platform to invent new architectures to capitalise on the capabilities of digital pumps.

With inherent digital control, set points and operating parameters can be remotely monitored and controlled to optimise performance. The pump is able to create real time data about the state of the hydraulic system.

Already a number of industries are adopting this new approach and utilising digital hydraulics to explore the savings and new features Digital Displacement can bring.

In industry, it is ideally suited to applications with wide pressure and flow requirements including injection moulding, water jet cutting and hydraulic power units.

The industries of tomorrow will continue to evolve and Digital Displacement technology will be a core component of the smart machines of Industry 4.0 and beyond.

www.artemisip.com Issue 37 PECM

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MACHINING & MACHINERY

PRECISION BENDING TOOLS ADDITION MANUFACTURING

ADDITION MANUFACTURING TECHNOLOGIES EXPANDS BEND TOOL PRODUCTION CAPABILITIES IN PRESTON, UK OPERATION World-leading tube bending and end forming technology specialist Addition Manufacturing Technologies is expanding production capabilities by adding a manufacturing cell for precision bending tools.

not limited to, expanding, reducing, sizing, beading, notching and slotting, parting and endtrimming, and flaring.

Addition Manufacturing Technologies recognizes that the integrated world demands that companies operate seamlessly on a global scale, while delivering locally in customers’ markets. Addition’s European customers have requested local manufacturing of precision tooling used in the bending and end forming processes; Addition is delivering on our commitment to meet customer needs locally by adding a manufacturing cell for precision bending tools made from hard steel, which will be fully operational by January, 2019.

This production expansion is in addition to the work cell added earlier in 2018 for consumable bending tools.

Addition’s complete range of muffler tooling solutions include, but are not limited to, tooling for lockseamers, SRSW’s, ram and “FLO” style flangers, baffle stuffers, ridgelocking equipment, cap assembly and cap seaming machines.

Nicolas Dunand, General Manager of European and Asian Sales, states “It is important that we grow with the constantly evolving needs of our customers. By installing another tooling production cell in our Preston, UK location, we will reduce logistics costs and time in transit for our European customers. Precision tooling is at the heart of every manufacturing process and, at Addition, we understand the critical role quality tooling performs in every bending process.”

Addition’s investment includes Hurco and Mazak machines that will manufacture bend tool components and are capable of producing single or multi-stack bend tool sets up to 80mm diameter.

Precision tooling is at the heart of every manufacturing process and, at Addition, we understand the critical role quality tooling performs in every bending and endforming process.

THE ADDITION ADVANTAGE Addition has the most experienced application engineering staff in the industry to evaluate and provide the best solutions for your needs. In addition to tooling that

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MUFFLER-MAKING MACHINE TOOLING

TOOL STOCKING AGREEMENTS Addition offers Tool Stocking Agreements in order to meet our customers’ demands for shorter lead times, reduced stock, and lower prices. suits equipment in all Addition product lines, our knowledgeable design team provides innovative solutions for all equivalent competitor models.

We use only the highest quality materials and state of the art equipment to ensure the manufacture of quality parts while optimizing tool life. Addition also offers in house tool try-out capabilities and prototype and part development for special applications.

CNC BENDING MACHINE TOOLING Addition offers a full range of CNC bending machine tooling solutions, for tube diameters from 6mm to 250mm and single-stack or multi-stack multi-radius bend dies. In addition to the wiper and mandrel components already manufactured in the United Kingdom, we also offer bend dies, bend die insert and clamp dies, pressure dies, collets, and mandrel assemblies (ball segment and cable style), as individual components or complete sets.

END FORM MACHINE TOOLING Addition offers a comprehensive range of endform tooling solutions for tube manipulation operations including, but

Under tool stocking agreements, highusage consumable tools are manufactured in the most economical batch quantities and stocked at an Addition facility or at an Addition partner facility nearest to the customer point-of-use to ensure extremely competitive pricing and rapid response.

Addition currently has multiple stocking facilities in North America, Europe and Asia.

Addition Manufacturing Technologies is a global manufacturing technologies company specializing in machines and tooling for tube bending, end forming, measuring and silencer making. Among others, the company’s products serve the automotive, aerospace, HVAC, and energy market segments.

With manufacturing facilities in the United States, Canada, Mexico, the United Kingdom, France, and China, Addition currently employs approximately 250 associates. In time this additional production will increase the company’s workforce in the United Kingdom.

For more information, please visit go.additionmt.com/bendingtools or contact Jennifer Rankin, Global Marketing Manager: Tel: +1 513 228 7079 or Email: jrankin@additionmt.com

HYDRAULICS & PNEUMATICS

Highest flow on the coupling market

Connection tools to accelerate sealing and testing methods

FEATURES n

n

n

Safety has been CEJNâ&#x20AC;&#x2122;s top priority for many years, which led them to develop eSafe: a compact one hand operated, high flow coupling that vents downstream air before disconnection, eliminating the risk of hose whip. eSafe is an innovative and patented safety coupling offering the highest flow on the coupling market, combined with a low pressure drop. A low connecting force and easy to grip design makes eSafe the natural choice when choosing a safety product with top of the line features. Contact Tom Parker Ltd for more information on the eSafe range.

Unique pressure assisted gripping and sealing technology increases gripping pressure as pressure increases Floating split collet design eliminates operator adjustment Minimal maintenance, easy seal replacement, long life and ergonomically designed

FasTest is a dedicated manufacturer of advanced engineered connection tools for pressure and vacuum testing applications. FasTest connection tools are easy, safe and reliable. The connectors dramatically lower operating costs through increased operational output.

Make the switch from inefficient, unproductive plugging or sealing methods, to FasTest quick connection tools for testing or filling needs. Call Tom Parker Ltd for more information.

APPLICATIONS n n

n

Leak testing Calibration, filling, pressure and proof testing Ideal for piping, cooling, heating, fluid, hydraulic, pneumatic, refrigerant and fittings

Exclusively available from

Sales: 01772 255109 | Online: tom-parker.co.uk Request a catalogue: marketing@tom-parker.co.uk

Sales: 01772 255109 | Online: tom-parker.co.uk Request a catalogue: marketing@tom-parker.co.uk Issue 37 PECM

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THE FINAL PROCESS FRONTIER ZEEKO

AUTOMATED PRECISION POLISHING ON YOUR CNC MACHINE â&#x20AC;&#x201C; THE ZEEKO ZEPHYR PROGRAMME

Zeeko may not be the most famous name in manufacturing engineering â&#x20AC;&#x201C; but in the optics industry it is a byword for excellence in precision polishing. A 7 axis machine from the UK engineering company Zeeko Ltd., that is based in the East Midlands, is the machine of choice in the optics industry for polishing the most challenging of complex surfaces.

Zeeko has been developing its processes and control software for polishing ultra-precision freeform surfaces for satellite mirrors for almost 20 years. High end applications where tolerances are measured in nanometers and surfaces are prepared to sub-micron precision before polishing. As all engineers know, polishing is difficult and automated

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polishing is particularly difficult. So the news that Zeeko has developed a high removal rate polishing process, which is effective on regular engineering materials, and removes microns of material at unprecedented speed, has caught the attention of production engineers everywhere.

This new process is more akin to grinding than to traditional polishing techniques, but still achieves a highly reflective polished surface. It can impressively be demonstrated on materials like mould and tool steels, tungsten carbide, titanium, Inconel, molybdenum, aluminium and other often difficult materials.

That Zeeko has also released a version of its new polishing software and announced that by writing a simple post processor it can be integrated to any regular 3 axis, 4 axis and 5 axis CNC machine as an automated process is even more exciting. For automated processes this is the final frontier!

Just a few months after its launch, it is already being adopted by the mobile phone industry for moulds, the aerospace industry for turbine blades, mould makers, hip joint makers and by the additive manufacturing / 3-D printing industry which is testimony to its versatility.

For further information please contact info@zeeko.co.uk or call to +44 1530 815 832 Zeeko Ltd, 4 Vulcan Court, Vulcan Way, Coalville, Leicestershire, LE67 3FW, UK Issue 37 PECM

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Anti-Vibration & Noise Isolation Solutions

TICO are the industry leaders in manufacturing off-the-shelf and custom-made solutions to vibration, noise, movement and impact isolation. With over 60 yearsâ&#x20AC;&#x2122; experience, TICO has provided elastomer attenuation and technical excellence to our customers, making us the brand of choice for isolating solutions.

Machine Machine Mounting Mounting

Structural Structural Bearings Bearings

Slide Slide Bearings Bearings

Pipe Pipe Supports Supports

High High Duty Duty Resilient Resilient Seatings Seatings

A A division division of of

Tiflex Tiflex House, House, Liskeard, Liskeard, Cornwall.

Cornwall.

UK UK PL14 PL14 4NB 4NB

Email: tico@tiflex.co.uk Tel: +44 (0) 1579 320808 Web: www.anti-vibration.solutions

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 onsite 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, consistency and the ability to operate in a variety of environments. For over 60 years the TICO brand name has been recognised Worldwide as a sign of reliability in many diverse applications.

With a wide range of off-the-shelf and bespoke manufactured solutions

New TICO Pad Finder App Tiflex Limited are proud to bring you our brand new vibration testing app. Designed around your devices in-built sensors, this helpful app obtains accurate vibration measurements to swiftly determine an antivibration material right for your application.

MACHINING & MACHINERY

DS-OCT12-BLACKFAST_Layout 1 20/09/2012 16:28 Page 1

CNC ROUTERS & LASER CUTTERS Introducing the NEW Fibre Laser Marker

Features • High-speed galvanometer • Compact and light weight • Low power consumption, less than 500W • Air-cooled • The machine can increase production and reduce costs Typical Applications Industry: Gold and silver jewellery, sanitary ware, food and beverage packaging, pharmaceutical packaging, medical devices, eyeglasses, clocks, automotive parts and electronic hardware.

Materials: Gold, silver, stainless steel, ceramic, plastic, glass, stone, leather, fabric, wood etc.

Introducing the NEW CNC Laser Cutters The NEW ATACAM range of Laser Cutters includes models for both metalic and non-metalic materials. They are equiped with co2 laser tubes, which can be used for cutting metalsheet such as carbon steel, stainless steel and non-metalic materials such as acrylic, MDF, plywood, etc.

Model AL1390 (pictured) for Non Metalic cutting and Model ALM1390 for Metalic and Non Metalic cutting.

Call for more information or a demonstration, or visit www.atacam.co.uk

Tel: 0208 339 7370

ATA Engineering Processes Ltd ATA House, Unit B, Boundary Way, Hemel Hempstead, Herts, HP2 7SS t: 01442 264411 e: sales@ataeng.com www.ataeng.com

462 Ewell Road, Surbiton, Surrey KT6 7EL, England

Fax: 0208 339 7371

Email: sales@blackfast.com Web:

www.blackfast.com

COMPLEX COMPONENTS MACHINED IN ONE OPERATION CMZ TX Range

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

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MACHINING & MACHINERY

QUALITY MANUFACTURING HARMONIC DRIVE

WHY COMPANIES NEED TO BE STRINGENT AND AVOID CUTTING CORNERS

We exist in a consumer driven world where product development and innovation moves rapidly. In the fight to keep pace, manufacturers can be tempted to compromise on quality and here, Graham Mackrell, managing director of Harmonic Drive UK, explains why companies need to be stringent and avoid cutting corners.

Industrial gears are vital components of the industrial equipment used for steel manufacturing and in the machine tool industry. At Harmonic Drive, we’ve found that the significant growth in these industries has resulted in a surge in the demand for high precision strain wave gears.

The idea that all production has moved to China is a misguided view according to the Office for National Statistics. In the UK, the demand for high-skilled production has gained much greater prominence in the last decade, especially when considering high precision manufacturing.

To meet the wide range of requirements for manufacturers, we have continuously developed our servo actuators in the LynxDrive® series. Now, we have further extended the series to include the LynxDrive® -25C, which is designed to be considerably more compact than traditional gear and motor combinations.

The issue for most manufacturers is the pressure of bringing products to market within constrained timeframes. The pressure intensifies when the product is quality sensitive as is the case for precision manufacturing, and so the importance of employing the right gears for industrial equipment has never been greater.

The LynxDrive® -25C is a high precision strain wave gear with output bearing, combined with a permanent magnet servo motor that is specifically customised to the actuator. Extremely robust and offering a high overload capability, the motor’s design, with its vacuum encapsulation

winding, supports almost unlimited maximum performance, even at link voltages of 320 VDC. More importantly, the series is available in five sizes with six gear ratios between 30 and 160:1, providing accelerating torques between 50 Nm and 176 Nm. This makes the servo actuators ideal for modern manufacturing machines that aim to reduce costs and increase productivity.

With high protection ratings and corrosion resistance, the series is perfectly suited for use in harsh and demanding environments like the industrial manufacturing plants of today. With accurate positioning, Harmonic Drive’s actuator ensures stable machine characteristics and short cycle times without jeopardising quality.

www.harmonicdrive.de/en/home/ Issue 37 PECM

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SPECIALISTS IN TOOLS & GAUGES WISEMAN THREADING TOOLS LTD

WISEMAN THREADING TOOLS LTD SPECIALISTS IN TOOLS & GAUGES FOR SCREW THREADS We 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.

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 '.

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.

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

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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 37 PECM

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CLAMPING TECHNOLOGY SCHUNK

POLYGONAL CLAMPING DELIVERS RESULTS IN TURNING APPLICATIONS For years, customers have been using TRIBOS polygonal clamping technology to achieve excellent results in applications such as micro cutting and to lower tool costs. With TRIBOS ER, SCHUNK is now bringing the patented technology of polygonal tool clamping to sliding and fixed headstock lathes and rotary transfer machines. Pilot users, such as Zisterer Präzisionsdrehteile GmbH in VillingenSchwenningen, Germany, are impressed. The company has reduced machining time in demanding milling applications by one third while significantly improving surface quality.

There are good reasons why SCHUNK is now unlocking the potential of polygonal clamping technology for lathe chuck technology. For one, the requirements for sliding headstock

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lathes are constantly growing. At the same time, customers are facing considerable pressure to lower prices, particularly for high-volume parts. For Zisterer Präzisionsteile GmbH in Villingen-Schwenningen, SCHUNK’s decision to standardise the TRIBOS ER came just in time. The manufacturer of complex hydraulic components was regularly experiencing process disruptions due to tool breakages as tools with a long overhang and cutting diameters of 2mm could not withstand the vibrations that occur. Halving the speed was the only way to ensure the process stability required for high-volume production.

Instead of 12,000 to 15,000 RPM, the company had to accept speeds of 6,000 RPM and the resulting reduction in cycle time.

MACHINING TIME REDUCED BY A THIRD

“Until now, our maximum speed was 6,000 RPM,” explains Uwe Walikewitz, Head of CNC longitudinal turning at Zisterer. Everything beyond that would inevitably lead to tool breakage, unless the company had switched to expensive special tools with reinforced shanks. “The TRIBOS system saved us around 200 seconds at a total machining time of just below 600 seconds,” says the machining specialist. “The rotational speed was only reduced by 500 to 1,000 RPM as compared to the recommended cutting parameters, and lo and behold, it worked perfectly.”

The fact that SCHUNK primarily designed the TRIBOS-Mini used in these milling operations for drilling, rather than milling, has hardly any effect on small cutting diameters. On the contrary, “The slim interfering contour of the toolholder mounting allows excellent accessibility without excessive tool overhang. It stabilises and dampens the vibrations on the tool,” says Uwe Walikewitz. “We tested the mounting and immediately installed it on three automatic lathes.” For Uwe Walikewitz, the investment quickly paid off, not only because it has reduced cycle time, it has also improved process reliability in automatic mode, lowered tool costs and improved the quality of surfaces. “With

TRIBOS, the surface is much finer than with collet chucks,” says the lathe chuck expert.

QUICK SETUP AND PRECISE ADJUSTMENT

Tools can be preset in the TRIBOS mounting at an accuracy of 0.01mm in length and exchanged in the collet chuck in just a few steps. In this way, the user benefits from fast set-up times and much higher repeat accuracy in the clamping system in terms of run-out accuracy and projecting lengths compared to ER collet chucks. A complete tool change only takes 20 seconds.

SLIM OR POWERFUL

TRIBOS polygonal toolholders with ER tapers come in two different versions: The slim TRIBOS-Mini ER is ideal for micro cutting, and sets the benchmark when it comes to small shank diameters. It is available in sizes ER 11 (clamping diameter 1 to 4mm), and ER 16, ER 20, ER 25, and R 32 (clamping diameter 1 mm to 6 mm).

TRIBOS-RM ER, on the other hand, is perfectly suitable for precise high-volume machining at high rotational speeds.

www.gb.SCHUNK.com Issue 37 PECM

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MANUFACTURING SOLUTIONS UNISIG

UNISIG ADDS FIVE NEW MODELS TO ITS PROVEN RANGE OF DEEP DRILLING AND MILLING CENTERS

With the new range of UNISIG’s USC-M deep drilling and milling centers, mold makers now have seven powerful and versatile solutions for workpiece diameters of up to 3.600 mm and workpiece weights of up to 30 t. All machines combine several processes in one machine: the deep hole drilling and milling on all four sides of a workpiece, while at the same time reducing setup times and increasing accuracy for mold makers. All machines support the high feed rates of modern indexable gundrill tools.

In addition to the use of gundrill deep hole drilling tools, some models can even support the more effective BTA deep hole drilling tools for the high performance drilling of waterline holes. A CAT50 quill allows you to perform all deep hole drilling and machining operations within the machine’s working range. The machines are equipped with a 360-degree rotary work table and a programmable deep drilling and machining spindle. These can be aligned via

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a pivot axis with 30 degrees down and 15 degrees upwards. The latest Heidenhain TNC 640 CNC controller and Heidenhain motors and drives are used. A full guarding with oil mist extraction completes the equipment.

This machine series has now been extended by 4-6 axis machines, for deep hole drilling with gundrilling tools and milling, with a universal spindle and a short changeover between deep drilling and milling operations for the efficient production of small to medium sized workpieces.

In addition, 5-7 axis machines are available for the use of gundrilling and more efficient BTA deep hole drilling tools, each with a dedicated spindle for deep drilling and milling, to dramatically increase performance for mold makers.

High-end solutions include 7-axis machining centers for highly dynamic motion control, powerful milling spindle

with gear reduction and optional pallet changer. With the model USC-M38, workpieces with a length of up to 2.000 mm can be conventionally machined and deep-drilled in one clamping. The larger USC-M50 can handle up to 3.000 mm long workpieces.

The machines can be equipped with an automatic tool changer with up to 120 tool positions, a laser tool presetter, workpiece probes, Heidenhain glass scales for increased accuracy, as well as an automatic pallet changer.

Further information on the USC-M series and the complete UNISIG machine program available at: www.unisig.com or at Moulding Expo 2019 21 – 25.05.2019 in Stuttgart, Germany, Hall 9 D04

www.unisig.com

Increase your mold manufacturing versatility using the power of gundrilling with the leaders in deep hole drilling, UNISIG. OďŹ&#x20AC;ering complete solutions for everything from simple to complex mold components, UNISIG machines help moldmakers improve eďŹ&#x192;ciency, throughput and precision with outstanding part-processing versatility at an exceptional value.

Take your moldmaking operations further with UNISIG today. Find out more at www.UNISIG.com

21.05.-24.05.2019 MESSE STUTTGART - Hall 9 D04

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MACHINING & MACHINERY

Machining

CNC ROUTERS & LASER CUTTERS Introducing the NEW Fibre Laser Marker

Features â&#x20AC;˘ High-speed galvanometer â&#x20AC;˘ Compact and light weight â&#x20AC;˘ Low power consumption, less than 500W â&#x20AC;˘ Air-cooled â&#x20AC;˘ The machine can increase production and reduce costs Typical Applications Industry: Gold and silver jewellery, sanitary ware, food and beverage packaging, pharmaceutical packaging, medical devices, eyeglasses, clocks, automotive parts and electronic hardware.

Materials: Gold, silver, stainless steel, ceramic, plastic, glass, stone, leather, fabric, wood etc.

Manufacturer of High Quality

Introducing the NEW CNC Laser Cutters The NEW ATACAM range of Laser Cutters includes models for both metalic and non-metalic materials. They are equiped with co2 laser tubes, which can be used for cutting metalsheet such as carbon steel, stainless steel and non-metalic materials such as acrylic, MDF, plywood, etc.

Anti Vibration Products

Model AL1390 (pictured) for Non Metalic cutting and Model ALM1390 for Metalic and Non Metalic cutting.

Call for more information or a demonstration, or visit www.atacam.co.uk ATA Engineering Processes Ltd Email: bet.co.uk ATA House, Unit B,sales@fi Boundary Way, Hemel Hempstead, Herts, HP2 7SS t: 01442 264411 e: sales@ataeng.com www.ataeng.com

Visit: www.fibet.co.uk | Tel: 01282 878200

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

Tech Group â&#x20AC;&#x201C; 119 Mould Heaters

It is a fact that mould heaters are not the most interesting â&#x20AC;&#x201C; or expensive â&#x20AC;&#x201C; pieces of equipment that you will find in a plastics processing facility. But without mould heaters, the much more interesting and expensive injection moulding machines will not operate properly.

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

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

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

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

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

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

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

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IssueIssue 37 PECM 147 24 PECM 75

MEASUREMENT & MONITORING

TEMPERATURE SENSORS LABFACILITY

TEMPERATURE AND PROCESS TECHNOLOGY

Labfacility will be present at the below Exhibitions; HCA 10th – 12th April 2019 Celtic Manor Stand No. 50

TEMPERATURE SENSORS

Labfacility manufacture a wide range of temperature sensors to suit your application. An extensive range of Thermocouples in IEC or ANSI calibration, PRT’s, Detectors, Environmental Sensors and Hand-Held Sensors / Thermometers are available to buy via our ecommerce website.

VERIGO COLD CHAIN DATA LOGGERS

Labfacility are now UK distributors of the Verigo Cold Chain range of Data Loggers for monitoring temperature, humidity and food storage quality - Introducing the new Pod Range. Cold Chain Monitoring - Easier than ever. Save time, ensure quality, and increase visibility of your temperaturecontrolled logistics operations. NO wires or Wi-Fi required.

L60 THERMOCOUPLE & FINE WIRE WELDER

The Thermocouple Welder, manufactured

by Labfacility, is a compact, simple-to-use instrument designed for thermocouple and fine wire welding.

THERMOCOUPLE CABLE / WIRE

THERMOCOUPLE CONNECTORS

We are Europe’s largest manufacturer of thermocouple connectors and accessories in IEC, ANSI and JIS Colour codes. The full range of connectors are available from stock for immediate despatch.

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Northern Manufacturing 2nd – 3rd October 2019 Manchester Advanced Engineering 30th - 31st October 2019 NEC Birmingham Stand No. N16

About Labfacility Labfacility are the UK’s leading manufacturer of Temperature Sensors, Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables.

BI-METAL THERMOMETER TEMPERATURE GAUGES

Bi-Metal Stainless Steel Thermometer with bottom or back entry and ‘anyangle’ versions available. Use our custom configurator to send us your specific requirements, made to order.

Nuclear Solutions 15th May 2019 Birchwood

We offer a wide range of thermocouple, PRT and extension cable / wire in stock for immediate despatch.

Thermocouple cables are available in IEC or ANSI Colour codes.

Insulation types include PFA, PTFE, PVC & Fiberglass.

In addition to the stocked items, Labfacility also offers bespoke Temperature Sensors.

We are specialists in the design and manufacture of custombuilt temperature sensors at our 12,000-square foot Yorkshire plant located in Dinnington Quality and Service are key elements in the continued growth of Labfacility; technical support for both sensing and instrumentation is always freely available from our experienced technical sales teams. www.labfacility.com

Leaders in temperature measurement

Temperature Measurement Specialists

Thermocouple & PRT Cable Thermocouple Connectors Temperature Instrumentation Temperature Sensors Sensor Fittings www.labfacility.com Bognor Regis tel: +44 (0)1243 871280

sales@labfacility.com ShefďŹ eld tel: +44 (0)1909 569446

MEASUREMENT & MONITORING

OPERATIONAL RELIABILITY IRISS

FIND IT AND FIX IT BEFORE IT FAILS: CONDITION BASED MAINTENANCE STRATEGIES FOR ELECTRICAL ASSET RELIABILITY Companies continuously search for ways to reduce operating costs, increase productivity and mitigate safety risks. With electrical assets, maintenance personnel safety is paramount. Electrical equipment requires periodic inspections to maintain normal operations; however, these inspections must be performed with the assets under full load.

Using the latest technology advances, these critical electrical assets can be monitored safely and efficiently.

With low cost handheld Condition Based Maintenance (CBM) test equipment and the Industrial Internet of Things (IIoT), companies are adopting CBM programs using innovative techniques to predict when an asset will fail. IRISS is a global leader in providing products and services to help companies implement and maintain an effective CBM protocol. Electrical Maintenance Safety Devices [EMSDs] maintain an energized compartment’s closed and guarded condition during the inspection process. No special Personal Protective Equipment (PPE) is needed so inspection times are significantly reduced, and more frequent inspections can be performed without increasing maintenance resources. In addition, creating an IIoT searchable health history record of assets enables the maintenance team to track and act upon data trends. Finding a problem and fixing it before it fails allows a company to realize reductions in both downtime and operating costs.

enclosure’s interior temperature and the second to monitor the ambient room temperature where the enclosure is located.

The data is wirelessly transmitted for analysis and trending and warns the operator of temperature issues within the electrical enclosure long before a failure occurs.

IRISS’s EMSD Devices include the following: Maintenance Inspection Windows: Maintenance Inspection Windows enabling viewing in the visual, ultraviolet and infrared spectrums. The CAP-ENV Series is the toughest, most reliable infrared window in the world. This series features a reinforced, environmentally sealed door design able to withstand the harshest industrial conditions.

The FlexIR Series offers custom-sized, large format windows that make previously uninspectable assets safe and easy to inspect.

Ultrasonic Detectors: IRISS’s versatile range of handheld ultrasound testers offer choices for any size facility and any sophistication level of maintenance program. The Sonus

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XT is ideally suited for routine plant maintenance whereas the Sonus PD is designed for detecting partial discharge (PD), airborne emissions (AE) and Transient Earth Voltage (TEV) on medium and high voltage switchgear.

Online Temperature Monitoring Systems: The patented Delta-T Alert™ System is a wireless, self-contained temperature and humidity monitoring system placed on an electrical enclosure. The system is simple to install and comprises two temperature sensors – one to monitor the electrical

Intelligent Asset Tags: The E Sentry Connect ™ platform is an intuitive asset information tagging system using Near Field Communication (NFC) contactless Smart Card technology. Smartphones easily access critical data and save up-to-date inspection data directly to the asset’s E Sentry Connect Tag via a free App from IRISS. Data back-up and complete access to the current status of all assets provides historical data to the inspector so that asset tracking, maintenance history and trend analysis are available at the time of inspection Conclusion: Improved operational reliability and productivity is accomplished by implementing condition based inspection strategies using IRISS’s products to safely and proactively detect problems with electrical systems before a failure occurs. www.iriss.com

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GREATER FLEXIBILITY ABB

ABB TOUCHSCREEN PAPERLESS RECORDER GETS POWERFUL NEW FEATURES ABB has expanded the capabilities of its RVG200 paperless touchscreen recorder with the addition of new functions providing users with greater flexibility in collecting, displaying and accessing data.

The RVG200’s simplicity and range of features including high security data storage, easy remote access and scalability, has made it a popular choice in a wide range of applications, from water abstraction and treatment through to heating, cooling and batch recording in food and beverage production.

Amongst the new functions added to the recorder is the ability to create usercustomisable views, including plant mimics that can be populated with process values and status.

Using a PC tool, users can now create customised views and populate them with bitmap images, text, numeric values and function buttons. Up to seven custom views can be uploaded to a single recorder, with one for each of the RVG200’s six configurable process groups and the seventh as an overview. Together with the existing chart, bar-graph and digital indicator views already present in the RVG200, the new customisable view function helps to gives users a much deeper insight into their process data.

For applications where energy consumption needs to be allocated to specific departments or operations, the RVG200 now also offers an optional energy calculation function. Using predefined equations for closed and return-less systems for water, saturated steam and superheated steam, the energy calculation function enables accurate calculation of heat energy in water and steam flows. The calculation can be used to produce mass, power and enthalpy values that can then be trended and totalised as required to produce an accurate overview of energy usage.

As a way of enabling users to achieve a realtime indication of energy use, the energy calculation function is ideal wherever an end user needs to be billed for using a centrally generated supply of steam or hot water. Examples include district cooling and heating and manufacturing processes,

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as well as monitoring and targeting programmes, where data is used to help identify potential measures for greater energy efficiency.

Another new feature incorporated into the RVG200 is remote operation, giving users convenient access to their recorded data whenever and wherever they need it.

Included as standard, the remote operation function is easy to set up and use, with users able to connect over the internet to an enabled RVG200 via a PC, tablet or smartphone. By eliminating the need to deploy engineers to physically visit one or more installed recorders, this new feature can help organisations to save cost and utilise their staff resources more effectively.

With stringent legislation around everything from product quality through to discharges to air and water, it is vital for industrial and utility operators to be able to prove that their recorded data was collected using a properly configured device. Previously, to document a recorder’s configuration, operators needed to manually create and keep a report of their device’s settings.

This process has now been simplified by the addition of configuration report generation function into the RVG200, which allows users to quickly and easily export configuration settings in a CSV format. Once created, the CSV file can be printed or incorporated into an electronic report.

“As industry increasingly moves towards introducing digital technologies into their processes, the ability to collect, access and utilise data is becoming ever more important,” says Martin Binney, Global Product Line Manager - Recording and Control for ABB Measurement & Analytics.

“With its new range of functions, combined with its core features such as touchscreen operation, scalable I/O and secure data recording, the RVG200 provides an ideal solution for any application where fast and reliable access to accurate process data is needed.”

For more information about the RVG200, visit www.abb.com/recorders.

Alternatively, email enquiries.mp.uk@. gb.abb.com or call 0870 600 6122 ref.

‘RVG200’.

MEASUREMENT & MONITORING

IMPROVED TR7 SERIES SIMPLIFIES ACCESS TO DATA T&D Corporation has extended the original TR7wf series with a Bluetooth feature designed to improve connectivity between data loggers and mobile devices such as smartphones and tablets. The new TR-7wb is ideal for temperature and humidity monitoring, and designed for people who require a broad range of measurement tasks. Recorded data can automatically be uploaded to T&D’s free of charge WebStorage Service, which is accessible anywhere and any time by computer, smartphone or tablet via the mobile ThermoApp connection.

The ThermoApp has also been redesigned with a new look and easier to use interface. “T&D Thermo” enables the use of mobile devices for viewing data recorded by TR-7wb/nw series data loggers, as well as direct communication with the TR71wb, TR-72wb and TR-75wb. The simplicity of these applications allows uncomplicated and costeffective protection of various goods and processes, for example, in public buildings, warehousing of sensitive products or the supervision of laboratories and refrigerators.

PHOENIXTM LTD - PHOENIX TEMPERATURE MEASUREMENT

PhoenixTM Ltd design and manufactures ‘thru-process’ temperature monitoring systems for the heat treatment industry.

For further information, please visit: www.tandd.com www.webstorage-service.com www.facebook.com/ TandDCorporationEurope

Providing solutions for various industrial sectors including heat treatment of aluminium and steel, ranging from raw materials (Slab, billets etc) to finished products, such as carburizing automotive components. Other applications include Paint and Powder Coating, Food Processing (HACCP), Glass Processing and Ceramic Firing. Protected by a thermal barrier, the data logger travels through the process and

thermocouples measure the product temperature.

A historic temperature record (Profile graph or TUS) is collected which then can be analysed using Industry specific software to generate AMS2750E and CQI-9 compliant reports.

Understand, Control, Optimize and Certify your furnace process to guarantee product quality, process operation efficiency and regulatory compliance.

Tel:+44(1353)223100 | sales@phoenixtm.com www.phoenixtm.com

STATE-OF-THE-ART UV PYROMETRY TECHNOLOGY MOCVD Processes Temperature Sensing Solution for Yield Improvement and Efficiency Gains for LED Production The UV 400 and UVR 400 pyrometers by LumaSense Technologies are the latest generation of non-contact temperature measurement instrumentation for Metal Organic Chemical Vapor Deposition (MOCVD) processes in the growing LED industry.

These highly accurate instruments are in a unique position to help manufacturers using MOCVD improve efficiency and reduce waste in their LED manufacturing process.

Using a center wavelength in the UV spectrum (400 nm) these pyrometers enable to measure real wafer surface temperature, while traditional pyrometers are only capable to measure the susceptor/pocket temperature under the wafer.

This allows the most accurate and repeatable control of the wafer temperature which e.g. in LED production is critical to the final product wavelength and manufacturing yields.

measurement of fast processes. True photoncounting instrumentation guarantees the best achievable signal to noise ratio and stability.

The wide temperature range of 650 to 1300 °C allows for measurement of various applications such as GaN buffer layer growth or multiple quantum well growth. The fast response time of up to 8 ms allows the

In addition to the UV 400 pyrometer, the UVR 400 features a 635 nm Laser Reflectometer, which enables the real-time measurement of the thickness and growth rate of the GaN layer during epitaxy growth.

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LumaSense Technologies GmbH An Advanced Energy Company www.lumasenseinc.com LTI-info@aei.com

MEASUREMENT & MONITORING

BROAD RANGE OF PRODUCTS RHEINTACHO GROUP

THE RHEINTACHO GROUP – A JOURNEY THROUGH A COMBINED HISTORY OF OVER 350 YEARS! When RHEINTACHO Messtechnik from Freiburg, Germany acquired Foundrometers Instrumentation of Leeds, UK in the year 2000, two long established companies joined forces to establish a new international instrumentation and sensor company specializing in measuring, recording and monitoring rotational speed and other rotation relevant parameters. RHEINTACHO Messtechnik, the German parent company founded in 1901, is now specialized in the production of high-tech rotational speed sensors. They also produce and distribute a wide range of high-performance stroboscopes and digital tachometers.

With double-digit new sensors in development, RHEINTACHO is second to none in innovation in rotational speed measurement. And to serve its customers even more, RHEINTACHO sensors are now becoming more versatile. The newest addition to the sensor family is called, M8. It now also integrated temperature measurement into this extremely small sensor. Another sensor called ABZ goes even a step further than only adding temperature measurement; it also detects position and direction. The FA, FC and FE sensors of RHEINTACHO are the products of choice in environments presenting challenges in temperature change and range. Their functionality is ensured due to clever design and most modern electronics at temperatures ranging from -40°C to 140°C, depending on the model. And the future will bring even more functionality into many new sensor developments.

The RHEINTACHO range of stroboscopes includes both portable and stationary solutions, both available in LED or xenon versions. The future will include the integration of the newest generation of LEDs, enabling the RHEINTACHO strobes to be considered among the brightest now available worldwide.

In the UK, RHEINTACHO UK, which was formerly called Foundrometers, was founded in 1919, i.e. we will be celebrating 100 years of precision instrumentation in the UK. When Foundrometers took over Hardings of Leeds in in 1980, they acquired another instrumentation company which was founded in 1872! Believe it or not, RHEINTACHO UK’s “SPARES AND REPAIRS” team is still able to repair and refurbish instruments which are returned as old as the company is. And

not only RHEINTACHO, Foundrometers or Hardings instruments can be serviced or repaired, but any make of any company, most of which no longer even exist.

Today, RHEINTACHO UK is responsible for the manufacture of mechanical and electric instruments and tachometers. Back at the beginning of the last century, revometers as tachometers were then called, Foundrometers and Hardings were the market leaders in precision, documentation and range of products. This tradition is both a blessing and a burden for RHEINTACHO today. We will continue to provide the market with solutions for the old instruments, but at the same time, we also offer reengineering services in case a repair is no longer possible.

The company today specializes in handheld mechanical tachometers in metric or imperial versions, both of which are available in intrinsically safe versions for hazardous environments, such as in mines. Another important product group are our eddycurrent tachometers, also intrinsically safe if required. These tachometers can also be combined with a wide variety of gearboxes to enable easy attachment to a shaft. Typical applications include mixing or production equipment in the chemical industry, machine industry and fuelling equipment. Many aircraft refuelling stations or vehicles are equipped with eddy current tachometers from RHEINTACHO. In mining facilities, our tachometers can be used for maintenance purposes, and also to monitor the speed of lifts, gearboxes and motors used to transport both staff or material, even in hazardous environments.

A further product group of RHEINTACHO UK is tacho generators. These tacho generators reliably measure the rotational speed of motors or engines. The signals produced are most often sent to a RHEINTACHO indicator and depending on the requirements, they are offered with normalized voltage, current or pulse output, i.e. the right model for the right application. RHEINTACHO adapts its solutions to the application. These products are also very robust providing a high degree of shock resistance. Another advantage which they have in common with the eddy current tachometers is not needing any external power supply, making their use interesting in surroundings where power is missing or unreliable.

The RHEINTACHO Group has been complemented by the newest edition to the family, RHEINTACHO Vision Systems underlining the strategic direction of RHEINTACHO to become even more diversified in the future.

RHEINTACHO competence and experience, modern and history, flexible innovation and tradition; all characteristics making the group even stronger to face the challenges of tomorrow with a highly motivated staff in 4 locations whose pleasure it is to serve customers and develop long-term partnerships with suppliers.

Feel free to contact us at RHEINTACHO UK Ltd. Tel.: +44 (0)113 287 4411 sales@rheintacho.co.uk Issue 37 PECM

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MEASUREMENT & MONITORING

OPTIMAL GAS IMAGING TECH FLIR

FLIR SYSTEMS ANNOUNCES THE FLIR GF77 GAS FIND IR, ITS FIRST UNCOOLED THERMAL CAMERA DESIGNED FOR DETECTING METHANE This new handheld camera offers inspection professionals the features they need to find potentially dangerous, invisible methane leaks at natural gas power plants, renewable energy production facilities, industrial plants, and other locations along a natural gas supply chain. The GF77 provides methane gas detection capability at roughly half the price of cooled gas inspection thermal cameras, to empower the oil and gas industry to reduce emissions and ensure a safer work environment.

Based on the award-winning design of the FLIR T-Series camera platform, the lighter weight GF77 features an ergonomic design, a vibrant LCD touchscreen, and a viewfinder to make it easy to use in any lighting conditions.

The camera is engineered specifically to detect methane in order to improve gas inspections and reduce the chance of false readings. The GF77 also offers FLIR’s patented High Sensitivity Mode (HSM), which accentuates movement to make tiny gas plumes more visible to the user.

FLIR designed the GF77 to include its most up to date technological features, including laser-assisted autofocus to help inspectors target leaks better, and one-touch contrast improvement that makes gases stand out clearly against the background. Additionally, a rapid-response graphical user interface helps professionals increase efficiency by allowing them to organize job folders, record notes, and add GPS location annotation on the camera.

“Optical gas imaging technology is a real benefit to industries that use or produce methane, but the cost of the technology has been a barrier for some customers,” said Jim Cannon, President and CEO of FLIR Systems.

“The FLIR GF77 Gas Find IR gas detection camera is built around an uncooled, longwave infrared detector, which costs less to produce than our higher performance, cooled cameras, and therefore we can provide it to customers at a more attractive price point. By providing the industry with access to this groundbreaking technology, we can help improve the safety of professionals on the job.”

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FLIR Systems, Inc. is a world leader in the design, manufacture, and marketing of sensor systems that enhance perception and awareness. FLIR’s advanced thermal imaging and threat detection systems are used for a wide variety of imaging, thermography, and security applications, including airborne and ground-based surveillance, condition monitoring, research and development, manufacturing process control, search and rescue, drug interdiction, navigation, transportation safety, border and maritime patrol, environmental monitoring, and chemical, biological, radiological, nuclear, and explosives (CBRNE) detection.

For more information, go to FLIR’s web site at www.FLIR.com.

To learn more, please visit www.flir. com/GF77. or contact FLIR Systems on +32-3665-5100 / gasimaging@flir.com.

CODEL Monitoring Solutions

Continuous Emission Monitoring

Road, Rail and River Tunnel Monitoring

Biomass and Raw Gas Monitoring

Safety and Process Control

EnergyTech TunnelTech

sales@codel.co.uk

SmartCem CODEL live

www.codel.co.uk

+44 (0)1629 814351

from £ 225

01.04.-05.04.2019 Visit us in hall 11, stand A61.

Thereʼs no two ways about it: our IR sensors of the optris CT series can be used in short and long wavelength measure areas.

Also interested in really fast, rugged, light, accurate, customised and inexpensive pyrometer models for temperature ranges between –50 °C and +3000 °C? Or in infrared cameras?

Visit www.optris.co.uk

Universal.

MEASUREMENT & MONITORING

Innovative Infrared Technology

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ASSET MANAGEMENT CAPTION DATA

HOW IIOT GETS YOU CRUCIAL DATA FOR INSIGHTFUL ANALYTICS The movement towards and development of Internet of things technology has already considerably improved many organisations ability to manage their assets better. As organisations continue to develop themselves in their given field their ability to monitor their assets needs to remain agile to meet ongoing change. The way in which we get data and information from our assets must continue to provide rapid solutions and even swifter responses ensuring proactive rather than reactive intervention. Whatever your asset is however, machinery to man power, the ability to get them working as efficiently and effectively as possible is crucial to success.

To keep up with the rapid changes and requirements of any business the way we access internet of things must move forward to. It is no longer sufficient for most businesses to rely on mains powered, large data logging units that arenâ&#x20AC;&#x2122;t easily transferrable and often lead to questions around costs to deploy. Development of battery powered, cost effective, cellular devices providing flexibility and agility must be addressed to answer these requirements.

Many of our clients require solutions that help them manage their assets over large locational areas or with assets that are in difficult places to reach once deployed.

The challenge is to allow insight remotely whilst management remains local, deploying their people effectively and safely to resolve any issues. Development of Bluetooth (BLE) within remote monitoring units is a vital development in allowing field asset communication.

As we are currently working closely with the water industry, the intricate and vast pipe networks require a smart approach to monitoring and reacting. Typically to access certain points of the network it involves disrupting traffic whilst you protect your people who manually have to take readings. Via IoT devices and BLE this same gathering of data could be done in seconds with no need to intervene unless anomalies are detected. Cutting time on investigative work and being able to deploy key people in the right location at the right time gaining huge business

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savings as well as having the collation of ongoing data. This example can be transferred to numerous industries with numerous assets.

The powerful insight of data manipulation and analysis can develop the ability to work on a greater understanding and predictive modelling that can maintain an organisation at the forefront of their industry. The art of effective analysis comes down to the ability to acquire quality data.

The data is the foundation to realising many aspirations around insight and knowledge that most organisations require

for their future strategies. Of course, IIoT requires investment, but investment in the foundations can only lead to a strong base to build upon.

If you would like to know more about our Industrial IoT solutions and how we can help you monitor your assets, please call us +44 (0) 1905 754 078 and ask for one of our IoT Application Specialists. info@captiondata.com www.captiondata.com

MEASUREMENT & MONITORING

TME LAUNCH NEW THERMOMETER WITH 1D & 2D BARCODE RECOGNITION Since launching its NEW hand held barcode scanning thermometer with 1D & 2 D barcode recognition, UK manufacturer, TM Electronics Ltd (TME) hasn’t looked back.

The MM7000-2D - packed full of extra features, including a new fast acting scanner and a compact waterproof casing - is transforming temperature recording in diverse industries from food processing to water management.

TME’s MD, Tom Sensier: “We’re bowled over by the response from our customers; the MM7000-2D is a real game-changer, providing intelligent paperless recording literally in the flash of an eye.”

Unlike a standard data logger which logs temperature, time and date, this unique instrument uses its in-built barcode scanner to also log exact information on the product or location which has been tested – not against set parameters but according to the customer’s own programmable variables.

The MM7000-2D is suitable for a wide range of manufacturing and processing operations as it is entirely portable and waterproof, is compatible with any thermocouple temperature probe, and can operate without a Wi-Fi connection, using standard batteries.

MAIN FEATURES

• New barcode scanner for 1D&2D barcodes on paper, plastic cards, mobile phones, LCD displays • Compact, IP65 waterproof case which includes a protective rubber boot • In-built Bluetooth for download and export of data to Excel/CSV file • FREE software supplied for translation of barcodes and assigning of alarms • Visual alarm options for corrective action user display prompts Ideal for spot check measurements, the MM7000-2D is also compatible with TME’s combined 24 hour wireless monitoring system, offering an all-in-one temperature test and monitoring solution.

About TME A UK manufacturer of temperature test and measuring equipment with over 25 years’ experience, offering robust, high accuracy thermometers, probes and sensors for high performance temperature monitoring in every workplace. 100% British-made, exported worldwide.

www.tmethermometers.com sales@tmethermometers.com +44 (0)1903 700651

We give you access to a fully integrated and supported end-to-end IoT solution to effectively manage your assets.

Combining hardware from our NanoULTRA range that seamlessly connects to our cloud based application, the CDLSmartHub™, allows you to turn raw data into actionable insights.

We are an agile company that delivers our customers an Industrial IoT solution, from hardware and software-as-a-service through to implementation and support.

Our purpose is to harness the Industrial Internet of Things to help power your business

www.captiondata.com solutions@captiondata.com Issue 37 PECM

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MEASUREMENT & MONITORING ULTRAFLO U1000MKII-FM THE NEW ALTERNATIVE TO CUTTING PIPES AND MECHANICAL METERS FROM MICRONICS, FOR SIMPLE, LOW COST FLOW MEASUREMENT FROM OUTSIDE THE PIPE!

New from Niton UK

XL2 Plus

NEW!

Pipe range has been extended to 6" pipes.

Verify metals more easily in the dust and wet. www.nitonuk.co.uk 01256 397860 info@nitonuk.co.uk

Visit us at RWM Stand 4J34

SepOct2018_Advert_PECM.indd 1

20/08/2018 14:04:53

The U1000MKII-FM is an ultrasonic permanent/ fixed clamp-on flow metering solution for measuring flow rate and total flow with a volume pulse output and optional Modbus or 4-20mA flow proportional output, which can be used as a stand alone meter or as part of an integral management system.

Simple to install – connect power and enter the pipe inside diameter, adjust the sensors and clamp-on the pipe – no specialist skills or tools required!

A cost effective alternative to traditional in-line meter installation, plus dry servicing, providing minimum downtime and maximum availability!

OIL CONDITION MONITORING FOR INDUSTRIAL APPLICATIONS Tan Delta Systems is the global leader in oil condition monitoring technologies. Unique full spectrum holistic monitoring allows owners and operators to improve the financial return on their equipment investments and improve operational reliability and safety.

Tan Delta have developed application kits which can be 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

With an average investment returned in under four months followed by many years of net financial and operational benefits, contact Tan Delta today to find out more.

Chris Greenwood (Managing Director)

+44 (0)845 094 8710 info@tandeltasystems.com www.tandeltasystems.com

Suitable for: Steel, Plastic and Copper pipe, 25mm – 180mm OD

Compact, rugged and reliable, the U1000MKIIFM has been designed to provide sustained performance in industrial environments.

MADE IN BRITAIN

For fur ther information call us on

+ 44 ( 0 )1628 810456

or email sales@micronicsltd.co.uk w w w.micronicsflowmeters.com 1247-Micronics U1000 MkII HM Ad 98 x 268mm Sept 2016 v1.indd 3

Issue 37 PECM

13/09/2018 19:55

161

NEWS & EVENTS

NEW JASIC TIG WELDING INVERTER

Gilberts Airs Make-to-Order Production Benefits with Infor

Liberty Speciality Steels Forges Ahead with Infor-First Policy

Jasic, one of the leading manufacturers of inverter welding equipment have introduced the TIG 315P AC/DC Multi Wave Inverter.

This highly advanced AC/DC inverter offers superior multi wave versatility. Key features include TIG AC/DC with digital control, programme memory storage of up to 50 sets of data and microprocessor control of a wide range of functions. The current range offered on TIG is 30-315 amps and on MMA 10-270 amps. Other key features include VRD function, remote control interface and intelligent fan and cooler control. This TIG 310 P Multi Wave comes complete with TIG torch and adaptor, gas regulator, work return lead and clamp. The machine is supported by an industry leading 5 year warranty; registration is simple and easy at www.jasic.co.uk. Additional accessories include trolley, water cooler and a foot control unit.

Infor, a global leader in business cloud software for Enterprise and SMB companies, has announced that air distribution product manufacturer, Gilberts (Blackpool) Ltd. has deployed Infor Configure Price Quote (CPQ) in an effort to help boost capacity, enhance production and improve customer service.

Integrated with Infor CloudSuite Industrial, Gilberts expects to use the application to help support its initiatives to speed up the customer estimation process, expedite production, and reduce inventory.

Infor, a global leader in business cloud software for enterprise and SMB companies, today announced it has become a key technology supplier to integrated steel producer Liberty Speciality Steels UK (now part of the Liberty House Group). Based on a deployment of Infor CloudSuite Industrial Enterprise that was completed ahead of a demanding 12 month schedule, Speciality Steels plans to use an ‘Infor-first’ technology policy as the basis of a growth strategy following Speciality Steels’ separation from Tata Steel. The applications are structured to help deliver a single ecosystem with end-toend functionality, minimal customisations and simplified processes. This is designed to help improve efficiency and visibility of data around products and customers, which can be used to help Speciality Steels compete globally by contributing to consistent on-time, first-time delivery of products.

For more information please visit www.jasic.co.uk

Lemo expands the high performance Anglissimo range of Interconnect Solutions at Southern Manufacturing & Electronics 2019 LEMO exhibited its latest addition to the high performance Anglissimo range of interconnect solutions at Southern Manufacturing Exhibition, 5th to 7th February 2019 at FIVE, Farnborough Stand E180. This versatile range of push pull connectors offers designer engineers the ability to configure cable exit angles during installation and is now available with a watertight IP68 protection rating suitable for outdoor applications.

For further details, contact: LEMO (UK) Ltd, TEL: +44(0)1903 234543, WEBSITE: www.lemo.com

Gilberts is already seeing benefits with a 50% line entry improvement on quotations and orders placed. In turn, this has led to faster quoting, increased capacity and greater accuracy. This higher degree of control and confidence has not only boosted productivity but training in the estimation process has reduced from around six months to just a few weeks.

To learn more, please visit www.infor.com

Horne Engineering Instantaneous hot water - for rapid tank and vat filling or wash-down purposes across a variety of food and beverage, chemical and pharmaceutical industries can be easily and safely achieved using Horne Engineering’s Steam and Water Mixing Valve.

The SWM1 produces temperature controlled hot water to a maximum flow rate of 50 L/ min and is unrivalled in both its safety and temperature control. Uniquely, it is both thermostatic and pressure balanced and, without cold water flow, steam cannot enter the valve, ensuring user safety. A real-time video demonstrates its remarkable performance under varying and challenging inlet conditions: goo.gl/sqp9f3 www.horne.co.uk

To learn more, please visit www.infor.com

Denso SteelcoatTM Protects Ayr Pipe Crossing George Leslie Ltd recently carried out a contract for Scottish Water to remove sections of an existing coating and carry out Non Destructive Testing on a Pipebridge near Ayr. After the testing was complete, these areas were then protected with the Denso Steelcoat 100/400TM System.

Having examined the system applied to the test areas, Scottish Water then decided that as scaffolding was already in place they would take the opportunity to wrap the whole section of pipe which crossed the River Ayr. Denso Steelcoat 100/400 System consists of Denso Hi-Tack PrimerTM, Denso Profiling MasticTM , Denso Hi-Tack TapeTM, Denso Ultraseal TapeTM and Denso Acrylic TopcoatTM. For further details visit www.denso.com/global/en/

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PECM Issue 37

NEWS & EVENTS

REAL COST REDUCTIONS WANNER

WANNER HYDRA-CELL® SEAL-LESS PUMPS GENERATE HUGE INTEREST AT PETROTECH OIL AND GAS SHOW 2019

Wanner International has just had a very successful demonstration of its seal-less pumps for applications such as salt water injection, crude transfer, polymer injection, condensate transfer and a seal-less artificial lift solution at this year’s Petrotech show in New Delhi.

For over 40 years, Wanner has been designing, manufacturing and supplying its’ unique range of Hydra-cell® seal-less diaphragm pumps that deliver real cost reductions to customers in over 70 countries.

Wanner was exhibiting with its sales partners, Machinomatic Engineers. They showcased the Wanner Hydra-Cell® pump range, including an artificial lift seal-less jet

pump and surface pump solution for oil & gas wells.

Karan Mansukhani, Director of Business Development of Machinomatic Engineers said: “We were very pleased with the number of visitors to our stand this year. There was particular interest in our Hydra-Cell T100 demonstration pump which made its debut at this top international oil & gas conference.”

Designed to be robust and reliable in demanding environments, the T100 heavy duty, multi-diaphragm seal-less pump was shown alongside a number of other pumps in the range that included: the MT8, a highpressure rig demonstrating the multiple-

diaphragm design providing virtually pulse-free, linear flow without the need for expensive pulsation dampeners and the P200, a metering seal-less multi-diaphragm pump.

Petrotech celebrated its 13th year as the flagship event for the bustling Indian hydrocarbon sector, hosting international oil and gas industry experts to share knowledge and explore areas of growth in petroleum related technology.

For more information on the Wanner Hydra-Cell pump range for oil & gas applications visit: www.hydra-cell.eu/.

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163

NEWS & EVENTS DENSO SCHOLARSHIP IN HONOUR OF GROUP CHAIRMAN

FLEGG PROJECTS AND INSTALLATION SERVICES

Denso Australia recently announced their sponsorship of an educational scholarship, called the ‘Denso Award’, for members of the Australasian Corrosion Association (ACA). The award is in honour of Denso Australia’s co-founder, David Winn OBE, and was announced at the ACA’s Corrosion & Prevention Conference held in Adelaide in November 2018.

Flegg Projects and Installation Services is home to a wealth of expertise in machinery installations, removals and relocations.

The ACA actively encourages its members to further their understanding of corrosion mitigation by attending training courses and conferences – which contributions from the Denso Award will help cover the associated costs. Paul Fortune, MD of Denso Australia, revealed that the company had made AU$50,000 available to ACA members over the next 5 years, with AU$10,000 to be awarded annually to reward academic excellence. Recipients of the award will be selected by an independent panel of judges.

The scholarship celebrates David Winn’s continued affiliation with the ACA – a relationship that has developed over the last five decades. Since co-founding Denso Australia with Bill Rogers AO in 1968, David Winn has personally

Our specialist teams have over 40-years industry experience operating across a wide of process industries including manufacturing, healthcare and engineering.

Over the years we have developed a reputation for providing a bespoke service utilising our own staff and equipment to complete single machine deliveries to complete factory re-locations. Our resources include engineering, transport and storage. We have achieved ISO9001 and safe contractor accreditation as well as FORS Bronze.

So, whether you are looking for a partner to give you an ongoing deliver and install service or you need some support with a major project we would welcome the chance to talk with you.

attended over 45 ACA conferences and continues to contribute to the success of the association through Denso Australia’s attendance and sponsorship of annual dinners and conferences.

Denso Australia are leading manufacturers of corrosion prevention and sealing products.

In 2018 they celebrated their 50th anniversary and moved to a new purpose-built premises located in Campbellfield, Melbourne. They are members of the Winn & Coales International Group, chaired by David Winn OBE.

To find out more about our company and how we can service your requirements please visit www. fleggprojects. co.uk or call us on 0845 4584958.

www.denso.net

News & Events

AHT wate

Looking for advice on process analysis and process performance monitoring and control?

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PECM Issue 37

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NEWS & EVENTS

NEW JOBS CREATION MAVEN

MAVEN MANAGED FUNDS LEADS £1.95M INVESTMENT IN DYER ENGINEERING Maven Capital Partners (“Maven”), one of the UK’s most active private equity houses, has, through its management of two regional funds, provided £1.95 million of capital to Dyer Engineering Ltd, the largest independent engineering business in County Durham. The North East Development Fund, supported by the European Regional Development Fund and the Finance Durham Fund, established by and using funds from Durham County Council have respectively invested £1 million and £750,000, with an additional £200,000 sourced from a local private investor. The investment will support the company’s growth plans to exploit new opportunities in multiple industries and will create up to 100 new jobs in the region.

Dyer Engineering specialises in the machining and fabrication of complex metalwork and components for the rail, marine, power, automotive and offshore sectors. The Company’s three distinct divisions offer a full suite of services, from at Treatment (AHT)initial are delighted to product be involved design to manufacture. uicksilver World Water Speed Record project. The BatchLine manufactures high-integrity metal a collaborative venture uniting highly-skilled people s from across the components broad span of for British theindustry, automotive and rail gether by the man who founded the project, author sectors; TechProjects fabricates complex, cknight. larger structures, from design concept to he UK’s first and only specialist in the heat treatment production the oil and nium alloys. With over 40 yearsfor experience as agas and renewable actor focused solelyenergy on the heat treatment of aluminium alloys, theyand are the sectors.

JobShop provides repair destination for companies within all sectors of the light metal industry. maintenance engineering services to support ctor, Ian Perks explained: “We are extremely proud to sponsor the Quicksilver with their manufacturing n its aim to bring theclients World Water Speedin-house Record back to Great Britain, and it great to be a part and of that.

It is brilliant that there is a concentration of local process operations.

T supporting Quicksilver er-speed project

es that are also supporting the project.” AHT’s support of the Quicksilver will be highlighted when they exhibit between 11-17th July at MAA stand 1/ Several of the International markets that Dyer Engineering 1, UK Pavilion) at the Farnborough Airshow.

serves are experiencing growth with Rail

44 (0)1384 456777 in particular www.alloyheat.co.uk being a very active sector

underpinned by government funding. Dyer

Engineering’s kers Advice on client base includes a number of large companies, including Hitachi Rail, at To Wear OnBAESite’ Siemens, Systems, Cummins and Nexus.

Winter The seven individuals who form the senior management team have more than 150

cing the NEWEST Working Clothes that years’ combined experience across a range of your winter workdays - in Snickers’ relevant businesses and industries. Managing 8 page FREE magazine.

Director, Parkins, has over 30 years’ nd all need to know aboutGraeme the world’s in engineering working for Rolls novative range ofexperience working clothes, the e that will your fitRoyce your workday on site and Tharsus before joining Dyer ter long.

Engineering in 2011. Richard Bradley, Finance

advice on choosing thehas right Director, overWork 15 years’ experience in s and Jackets to suit yourfinancial trade – RUFFWork, LITEWork, FLEXIWork senior roles including as European LROUND workwear. They’re working clothes that deliver superb Head of Finance for Formica before joining nality, comfort, protection and are equipped for any task at hand.

of the Entrepreneurs’ Forum, an Investment Committee Member for NEL Fund Managers and has worked in the NorthEast for over 30 years.

Graeme Parkins, Managing Director of Dyer Engineering, said “We are absolutely delighted to have received this investment into our company. We have a vision to create a world class engineering business here in the heart of County Durham providing world class metal components and structures to our customers and world class jobs to our employees. Our ethos of SmarterStrongerTogether™ is all about who we are and how we do things on our journey to becoming a world class company. This investment is a rubber stamp of our plan and will allow us to turbo charge the business’ progression over the next few years towards our goals.”

Jamie Fraser, Investment Manager of Maven, said, “Dyer Engineering is a leading manufacturing business serving a number of high growth markets, driven by a strong management team with real vision and dedication. The joint investment is a fantastic example of how Maven’s regional funds can work together effectively to provide a local business with a substantial funding package to enable it to grow significantly. We look forward to working with the team and supporting their vision of becoming a world class engineering business.”

Sarah Slaven, Operations Director at Business Durham said: “The Finance Durham Fund was created to support business to achieve their ambitions. We are confident these investments in Dyer Engineering will position them for growth into the next decade.

County Durham has a significant engineering and manufacturing sector of which Dyer Engineering is an important part, we look forward to continuing to work with them as they expand and create new jobs. I hope this news will encourage other businesses in Durham to consider applying for funding to enable them to reach their potential.”

Cllr Carl Marshall of Durham County Council said: “We are delighted to be able to support another County Durham business in its efforts to grow through our Finance Durham Fund.

Dyer Engineering. James Robson MBE, Nonhe catalogue visit the website at www.snickersworkwear.com Executive Director, was the founder of Exwold The money we have given along with that ively, call the Snickers Helpline on 01484 854788.

Technology in Teesside, North East Chairman provided by other agencies is allowing the

to automated ehouse forms core of

company to create jobs which will in turn boost the local economy. Dyer Engineering has a proud history in County Durham from its early days servicing the mining industry to a business which has really adapted and innovated as it has grown. We wish the firm well in playing its part in making County Durham a truly great place to live, work and visit.”

About Maven Capital Partners UK LLP Maven Capital Partners UK LLP (Maven) is a lower-mid cap private equity house focused on the provision of growth capital and mezzanine finance to SMEs across the UK. It is one of the most active private equity fund managers in the country, managing over £415 million of assets for a variety of client funds, including Venture Capital Trusts, UK regional debt and equity funds, and Maven Investor Partners – a syndicate of institutional, family office and experienced investors.

Headquartered in Glasgow, and with ten other offices throughout the UK, Maven has nationwide coverage of the market for SME finance and is introduced to around 400 deals per year through 20 regionally based investment executives.

With over 50 staff and partners, Maven executes a range of private company transactions, offers hands-on proactive portfolio management to investee companies and provides a fully integrated back-office support function to client and third party fund managers.

Since 2009 Maven has invested over £285 million in SMEs across the UK. www.mavencp.com About Business Durham Business Durham is the economic development organisation for County Durham, working on behalf of Durham County Council to deliver the environment for business and economic growth. www.businessdurham.co.uk

Issue 37 PECM

165

PROCESS TECHNOLOGIES

DIGITAL TRANSFORMATION ABB

DIGITALIZATION AND THE FOOD AND BEVERAGE INDUSTRY Wikipedia, the world’s largest free-content encyclopedia, now has over 41,000,000 articles in 294 languages. If printed, the English articles alone would form an impressive, but unrealistic 2,512 volumes.

Without digitalization and the widespread use of computers, this amazing wealth of knowledge would be impossible. Here, Robert Glass, global food and beverage communications manager at ABB, explains the opportunities digitalization presents for the food and beverage industry.

Digitalization encompasses a transformation in the way industrial environments work.

For the food and beverage industry, this means companies can better comply with legislation through a transformation in areas including connectivity, smart sensors, traceability, cloud computing and monitoring.

LEGISLATION The Centre for Disease Control and Prevention (CDC) estimates that one in six Americans suffer with a food-borne disease each year, and 3,000 deaths are attributed to food-borne illness. When people’s lives are at stake there is no room for error.

Therefore, one of the largest concerns for the food and beverage industry is using technology to find the best method to keep well maintained traceability records, which show the journey of food from farm to fork.

SMART SENSORS Well-kept traceability records and sensor data can increase transparency between businesses, producers and consumers. This allows plant managers to respond faster in emergencies and use evidence to rebuild public trust following recalls.

The processed and raw data can be stored and recalled if there are any issues further along in production. Cloud technology has made it easy to store and analyze data, removing any potential for human error by raising alerts and red flags immediately.

Sensors can aid traceability in two ways: they improve the accuracy of automated processes and they can track and store a variety of manufacturing data. Time-

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PECM Issue 37

temperature history, physical shocks and other important credentials can be continuously measured and synchronized across the factory thanks to the IIoT. Sensors used during food production can monitor products throughout the manufacturing and distribution supply chain. Sensors can form part of a device such as a smart container, or act standalone, depending on the needs and conditions of the manufacturing process.

CONNECTIVITY For the first time in 2016, over half of the world’s developing population had internet access. As internet access widens and the price of networked devices drops, the volume of network traffic will rise.

Alongside this, the falling cost of producing devices such as WiFi-enabled temperature sensors mean they will become ubiquitous in industrial environments. However, more sensors lead to more raw data. This higher rate of data production presents issues of how to store and use the data.

CLOUD Although almost sixty per cent of US food and beverage manufacturers use the Internet of Things (IoT) to track and trace ingredients, less than half are using the advanced analytics the IoT makes possible.

Cloud analytics, real-time monitoring, virtual

commissioning and digital twinning — the ability to recreate the plant virtually — are just some of the techniques now helping plant managers in the food sector reduce unplanned downtime, improve safety and mitigate food emergencies.

MONITORING The huge amount of data produced by the connected factory can be used for many purposes in the food and beverage sector.

For example, understanding why one machine is running hotter than another, or why one is not picking as many products, can help operators understand the efficiencies of each machine, data that can be used to improve plant maintenance.

Many plants are using their own mobile networks to take monitoring to the next level. For example, on farms, sensors are used to monitor soil conditions, using the data to predict when animals are in heat and text the farmer with the information.

Although many businesses will be wary of the perceived complexity of undergoing digital transformation, it can bring about a true competitive advantage. Plant managers of the future should not only recognize the trend toward digitalization, but they should embrace the opportunities it brings, just as approximately 70,000 active contributors have wholeheartedly adopted Wikipedia, an opportunity produced by consumer digitalization.

PROCESS TECHNOLOGIES

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

Engineered technologies Surface treatments for critical components

Process Cooling Solutions for Food & Beverage Systems A range of non-toxic high performance heat transfer fluids, with antifreeze function, for use in food and beverage cooling systems.

tel: 01792 586800 www.hydratech.co.uk

Issue 37 PECM

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

K

ecol Pumping Systems Ltd are manufacturers of Air driven, Positive Displacement Piston Pumps and Priming Devices in polished stainless steel or carbon steel, for transferring high viscosity nonflowable products from drums and containers as used in the cosmetic, food, pharmaceutical, chemical and general industries.

Products in drums or similar sized vessels that normally need to be heated in order to reduce the viscosity - can be transferred cold. Products with a viscosity up to 10,000 Poise can be transferred (cold) using the Kecol Maxiprime Pump and follower plate system and is also used to transfer pastes and products that stick to the inside of an open top drum, wiping the inside of the drum or vessel, eliminating product waste.

Kecol Air Powered Drum Pumps and transfer systems are suitable for all standard size closed top or open top drums and can be adapted to suit open top containers with an internal diameter up to 1200mm.

Non contact parts as well as contact parts are available in polished stainless steel, clamp - type construction is also available for hygienic applications.

Typical applications in the food industry include transferring tomato

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

puree, concentrated fruit juice, honey, fruit pastes, biscuit creams, jams, butter, margarine, sweet mince meat, sausage meat and meat pie fillings with cooked vegetables.

Applications in the pharmaceutical and cosmetic industries include transferring mascara, petroleum jelly, face creams, base creams, magnesium hydroxide, aluminium hydroxide, toothpaste, lip-gloss waxes and suntan lotions.

Kecol’s articulated pump systems

Kecol’s articulated pump systems

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

Applications in the chemical and general industries include the transfer of paints, resins, adhesives, polymers, latex, high viscosity grease, mastic’s and inks – all pumped cold without pre-heating the products.

As manufacturers, Kecol Pumping Systems can offer solutions to your particular product transfer problem, by offering a bespoke system designed to exceed your particular production requirements for single drum/vessel use or multi drum use.

Kecol Pumping Systems Ltd Faraday Drive Bridgnorth Shropshire WV15 5BJ T: 01746 764311 E: sales@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

Induction Heater Hire

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BETEX 24RLDi Turbo – The Portable Heater for use in workshops and on site.

Induction Induction heating heating is is aa swift, swift,

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heating. heating. ItIt is is aa safe safe and and

Maximum Maximum Width: Width: 135mm 135mm

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environmentally-friendly environmentally-friendly

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alternative alternative to to traditional traditional heating heating

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methods methods such such as as ovens, ovens, oil oil baths baths or or

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cause cause smoke, smoke, fumes fumes and and oil oil waste waste

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Highly Highly versatile, versatile, BETEX® BETEX® induction induction heaters heaters can can be be used used in in conjunction conjunction with with many many assemblies assemblies including including gear gear wheels, wheels, bushes bushes and and couplings. couplings.

BETEX 40RSDm Turbo – The Mobile Heater that can tackle almost any job.

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Minimum Minimum Inside Inside Diameter: Diameter: 30 30 // 160mm 160mm Maximum Maximum Outside Outside Diameter: Diameter: 790mm 790mm

methods methods extends extends bearing bearing life, life, whilst whilst

Maximum Maximum Width: Width: 315mm 315mm

balanced balanced and and consistent consistent heating heating

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retention retention of of the the original original lubricant. lubricant.

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The The advantage advantage of of the the TURBO TURBO series series over over the the Standard Standard series series is is that that larger larger components components can can be be heated heated in in aa relatively relatively short short time time without without any any increase increase in in energy energy consumption. consumption.

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Hire Rates & Options

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Induction Induction Heater Heater Hire Hire rates rates are are per per day day // 24hrs.

24hrs.

Rates Rates vary vary depending depending on on Heater Heater model model and and Yokes Yokes required. required.

Hire Hire Periods Periods of of 55 days days or or more more attract attract aa 20% 20% discount. discount.

Customers Customers who who hire hire an an Induction Induction Heater Heater for for aa period period of of 20 20 working working days days or or more more have have the the ‘Option ‘Option to to Purchase’ Purchase’ for for 20% 20% of of the the RRP. RRP.

S Siiggnneett IInndduussttrriiaall D Diissttrriibbuuttiioonn LLttdd || U Unniitt 33 B Buullllrruusshh B Buussiinneessss P Paarrkk || B Buullllrruusshh G Grroovvee || D Doonnccaasstteerr || S Soouutthh Y Yoorrkksshhiirree || D DN N44 88S SJJ TTeell:: 00884455 112244 77334444 || ssaalleess@ @ssiiggnneettiidd..ccoo..uukk || w ww ww w..ssiiggnneettiidd..ccoo..uukk

Maintenance & Hydraulic Tools

Signet Industrial Distribution is the UK’s sole distributor of BETEX Maintenance Tools.

Temperature or Time Controlled Heating

Other PRODUCTS and

Digital electronics ensure

SERVICES AVAILABLE

optimum control during the

from Signet Industrial

heating process by regulating

Distribution in clude:

the most efficient use of

The full BETEX Range

power and ensuring both even

Bearings

and rapid heating. This

Transmission Products

prevents explosive heating

Sealing Solutions

and prevents discolouration or

Motors & Inverters

pitting of component

Gearboxes & Pumps

materials.

Pneumatics & Hydraulics Lubricants & Adhesives

Demagnetisation

PPE & Workshop Consumables

Fail-safe demagnetisation is essential for bearings and transmission parts. The proven quality of BETEX®

Call us now for details of the BETEX Specialist Tools designed specifically for the Rail Industry.

induction heaters guarantees maximum demagnetisation (< 2A/cm). This has a major positive effect on the life span of bearings, gears, etc.

Quality & Reliability BETEX® induction heaters have a proven track record for reliability. Their sturdy styling and ergonomic design delivers sustained and problem-free operation even in the harshest of industrial environment s.

• •

All Hire agreements are subject to Signet Industrial Distribution Ltd’s Terms and Conditions, a copy of which will be provided.

Customers will be required to complete and sign a ‘Tool Hire Agreement’. This indicates their acceptance of the aforementioned T&C’s.

Signet Industrial Distribution Ltd | Unit 3 Bullrush Business Park | Bullrush Grove | Doncaster | South Yorkshire | DN4 8SJ Tel: 0845 124 7344 | sales@signetid.co.uk | www.signetid.co.uk

PROCESS TECHNOLOGIES

DISCOVER A RANGE OF WEIGHING SOLUTIONS TO ENHANCE YOUR PRODUCTION PROCESSES Weighing is one of the most economical and accurate measuring methods. In engineering, getting the right measurement in the right location is critical to providing reliable solutions in production processes.

METTLER TOLEDO supplies instruments and components that can be easily integrated into systems to improve productivity, accuracy and quality. These innovative solutions are application and industry specific, designed to support international compliance standards.

Download the Weighing Components Catalogue which provides an extensive overview of METTLER TOLEDO products such as: • High precision weigh modules • Precision weighing platforms • Load cells • Weigh modules • Weighing electronics

UVC STERILISATION - CLEAN, DRY & EFFECTIVE SANITISING

Whatever your weighing needs, discover how companies similar to yourselves have discovered their process improvement potential and maximised productivity. www.mt.com/oem-catalogue

Cutting Edge Services are proud to work in partnership with SterilAir, the world-leading manufacturer of revolutionary UVC sanitising technology for the food industry. SterilAir’s UVC sanitisers are HACCP and FDA compliant solutions, providing clean, safe, chemical-free disinfection with minimal costs and energy usage. Our exclusive range includes evaporator disinfection systems to directly target any type of surface, air recirculation systems for rooms with low convection, belt surface disinfectors designed to integrate perfectly into your production line

HIGH QUALITY SURFACE TREATMENTS FROM CURTISS-WRIGHT SURFACE TECHNOLOGIES Curtiss-Wright Surface Technologies (CWST) provides high quality surface treatments which will improve the life and performance of critical components through its global network of over 70 operating divisions and specialist onsite teams.

Our surface treatments have been successfully used by OEM’s in major industries such as aerospace, automotive, oil & gas and power generation for many years.

We are only too aware of the logistical challenges and costs faced by our customers and so we can offer a “One Stop Shop” solution providing a wide range of surface treatments including Controlled Shot and Laser Shock Peening, bespoke and trade Coating Applications, Thermal Spray Coatings and Parylene Coatings for metal, alloy, plastic and electronic components as well as Analytical Services.

We offer our customers a single source solution and point of contact for all their

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surface treatments, supporting their requirements through our global network of over 70 worldwide facilities and on-site field teams, improving and reducing turnaround times and costs.

We are specialists in protecting components from common failures and reducing maintenance costs for key industries such as aerospace, oil and gas, automotive, medical and general industrial markets.

Building on the unique heritage of Glenn Curtiss and the Wright brothers, CurtissWright Surface Technologies has a long tradition of providing innovative solutions and building solid and trusted customer relationships.

Full quality and customer approvals including NADCAP, ISO 9001:2008 and AS9100 Rev C. To find out more please visit www.cwst.co.uk.

and fully submersible immersion systems ideal for sterilising water tanks and cooling towers.

Our expert team of specialists and field service engineers provide full installation and servicing to meet your exact requirements.

SterilAir UVC solutions are available now exclusively from Cutting Edge. www.cuttingedgeservices.co.uk 01772956249

PRODUCT NEWS

CUSTOMERS NO LONGER HAVE TO CHOOSE BETWEEN PERFORMANCE AND SAFETY

Safety has been CEJN’s top priority for many years, constantly striving to develop safe and high performing products. This led them to develop the eSafe: an ergonomic one hand operated, compact, high flow coupling that vents before disconnection, eliminating the risk of hose whip. eSafe is an innovative and patented safety coupling offering the highest flow combined with a low pressure drop. A low connecting force and easy to grip design makes eSafe the natural choice when choosing a safety product with top of the line features.

The eSafe range features real craftsmanship.

It is the only coupling on the market that

allows operators to get maximum capacity out of their tools. Jobs are completed faster, use less energy and the result is higher productivity, cheaper energy bills and lower environmental impact.

Strong and durable with a long service life, the eSafe range complies with ISO Standard 4414 and EN 983. eSafe is a new generation of premium couplings for premium performance.

For more information, contact the Tom Parker Ltd Business Development Manager: John Pomeroy. Tel: 01772 255113. Alternatively email Business Development: business.development@ tom-parker.co.uk

“Spacers have made this job easy for us”

Car Manufacturer opts for Contour Filter

Retrofit Filtration System Benefits Coatings Manufacturers

This is a comment that FT Pipeline Systems hears a lot in relation to our pipe casing spacers. They are a simple, yet effective solution used to centre water and sewer pipes in casings. The spacers are virtually corrosion proof, require no special tools and are easy and efficient to install. They are available with polymer runners or rollers which facilitate a reduction in the size of equipment needed and time spent installing the pipe. This, in turn, leads to huge cost savings. Typical uses include river, canal and bridge crossings, as well as road and rail crossings. The pipe spacers provide insulating protection from a possible electrical shorting between the carrier and pipe casing. FT Pipeline Systems offers two ranges of spacers: a custom-made range in steel or an off-the-shelf range manufactured from injection moulded high density polyethylene.

Amazon Filters has received a further order from a leading car manufacturer to deliver an optimised filtration system to ensure the quality of the electrophoretic paint stages on their production paint line.

Amazon Filters reports that coatings manufacturers are installing their SupaClean contained filtration system prior to filling lines to remove impurities such as skins, coagulants and undispersed pigments from their final product.

With the success of previous installations, the leading car manufacturer wanted to use the same combination of Amazon Filters 63 Series industrial inclined filter housing fitted with Contour large diameter melt-blown cartridge filters to protect their paint baths.

With over 30 years’ experience of supplying filters specifically designed for the Automotive Industry throughout the world, Amazon Filters is able to offer a solution to meet all your filtration needs.

Faced with declining support and patchy availability of a discontinued enclosed filtration systems from an alternative supplier, the SupaClean system is widely reported to produce better-quality product with a reduction in filter / labour costs for both solvent and aqueous based coatings production processes. Sharing the same dimensions as the discontinued filtration system the SupaClean system also provides the benefit of being a direct retrofit.

For further information visit https:// www.amazonfilters.com/products/filtercartridges-and-capsules/depth-filters/ contour/ or contact Amazon Filters on +44(0)1276-670600 / sales@amazonfilters.co.uk.

For further information on SupaClean contained filtration systems please visit https://www.amazonfilters.com/products/ filter-cartridges-and-capsules/supaclean/ or contact Amazon Filters on +44-(0)1276670600 / sales@amazonfilters.co.uk.

www.ftpipelinesystems.co.uk Tel: +44 (0)1543 416024 enquiries@ftpipelinesystems.co.uk

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PROCESS TECHNOLOGIES

REFRIGERATION SOLUTIONS CARTER THERMAL INDUSTRIES GROUP LTD

PROUDLY BRITISH AND FAMILY OWNED

When it comes to energy efficient, sustainable Refrigeration solutions, the Carter Thermal Industries Group provides a wide range of services, products and systems to help your business.

Carter Refrigeration was initially established

by Mr John Carter back in November 1945, with their headquarters in Birmingham.

By 1959, Carter Thermal Industries Group was born and today, they are an industry renowned name with a number of different subsidiaries, including: Carter Retail Equipment, Cater Synergy, KB Refrigeration, Carter Environmental Engineering, CPC UK, and Franklin Hodge Industries. The group also has locations in London, Hereford, Liverpool and Glasgow.

Proudly British and family owned, the commitment of the various group companies to providing sustainable and efficient solutions is clear to all. Through a commitment to constant innovation combined with a reputation for listening to their key customers the group continues to lead in the development of highly efficient solutions.

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One of the group subsidiaries, Carter Retail Equipment are specialists in the manufacturer of refrigerated display solutions. They have worked with clients around the globe and are consistently seen as one of the worldâ&#x20AC;&#x2122;s leading suppliers of retail refrigeration display equipment.

From their factory in Birmingham, CRE manufacturers and supplies refrigerated display cabinets for some of the worldâ&#x20AC;&#x2122;s largest & most prestigious retailers. Their diverse range includes Hydrocarbon, water cooled and Co2 based cabinets. Their quality and superior design have seen their cabinets installed across Europe, North America, Asia and Australia.

Their wide range of display cabinets are built to last and specially designed for impressive energy efficiencies.

Another subsidiary is Carter Synergy Ltd, which provides refrigeration, mechanical, and electrical services across a wide variety of markets in the United Kingdom.

The specialist contractor works with clients from retail, commercial, corporate and government sectors, to design, install, commission and take the lead on projects of any size. Their commitment to sustainable and energy efficient solutions has made Carter Synergy an industry leader in the sale, installation and support of a large number of Co2 based refrigeration installations. They are also well recognised for their excellent commitment to health and safety and are 8 time winners of the highly regarded ROSPA Gold award.

Among their latest ventures, Carter Thermal Industries Group and their subsidiaries have made huge strides in providing sustainable refrigeration solutions, providing over 200 green, energy efficient Co2 solutions for Refrigeration and Air Conditioning systems across the United Kingdom. As a whole, Carter Thermal Industries have seen significant success over the many decades, and have now expanded into both North America, and Australia.

KEY GROUP SOLUTIONS Wide range of highly efficient, industry leading refrigerant leak detection systems to reduce the environmental impact from any system leaks.

Small charge Hydrocarbon refrigerant integral display cabinets for retail / commercial sector.

Manufacturer of a range of highly energy efficient water cooling systems for commercial and industrial process cooling.

Small charge Integral cabinets with integrated Plate Heat Exchangers for connection to either dry air coolers or Chilled water loop systems.

Air quality, Noise as well as fume / dust testing, extraction and monitoring solutions for ensuring workplace air quality standards are maintained.

Site assembled Water storage solutions for efficient management of drinking water, fire suppression systems and other bulk liquid storage requirements.

Food security solutions with bulk grain storage and handling systems.

Industry leading provider of preventative maintenance, reactive service and installation of energy efficient technologies in refrigeration, air conditioning, process cooling and heating solutions.

If you would like to find out more about Carter Thermal Industries, then be sure to get in contact using the details below. Alternatively, you can find out more information by checking out the website.

T: 0121 250 1000 sales@cti-ltd.co.uk www.cti-ltd.co.uk

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SOFTWARE & SYSTEMS

CALLING ALL PASSENGERS… PRODUCTS4AUTOMATION

SCADA TAKES GATWICK’S PUBLIC-ADDRESS SYSTEM TO NEXT LEVEL Gatwick is one of the busiest airports in the world with over 50 aircraft movements an hour and 35-40 million passengers annually.

Photo: Gatwick Airport Media Centre

Gatwick Airport has incorporated Movicon SCADA software from Products4Automation (P4A) in its North Terminal public address system to handle alarms and provide an interface to an older legacy system.

Gatwick is one of the busiest airports in the world with over 50 aircraft movements an hour and 35-40 million passengers annually.

As such, its public-address system is vital for both passenger awareness and safety.

The PA system in Gatwick’s South Terminal is relatively new, but there was an older system in the North Terminal which the management team wanted to upgrade. They set the goal of developing the most advanced automated PA at any airport in the world. This would improve customer service by providing more information with better quality audibility when conveying general information and for emergency announcements. It would also mean a single user interface could be developed for use on both terminals’ PAs, simplifying operational procedures and introducing new operator features.

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To achieve these aims, Gatwick required the ‘most advanced text-to-speech system, including multi-lingual capabilities’ available.

This would be used to make automated announcements, driven by events, rescheduling, time etc. It would also be accessible by ‘mobile’ information assistants mingling with the public on the concourse using a simple interface on a handheld tablet.

At the time the project was conceived, an existing solution was not available, so a contract was awarded to Gloucestershire’s Microwatt Ltd to develop and install such a system. Microwatt was already known to Gatwick because it had developed the technology behind the airport’s Priority Lane VIP services and some of the catering operations. It has also developed and installed innovative systems for MoD bases, fire and rescue control centres and automotive production lines.

The automated PA - called Phonetica - is a Linux based software package that interfaces

to the existing PA. Microwatt developed an ‘alarm back indication system’ for the PA system which logs alarms such as speaker faults, and amplifier cut outs. The alarm back indication uses Movicon SCADA as a platform which connects the concourse, engineering control room, and six separate rack rooms into a single network. The Movicon system monitors 48 different alarms (eight in each rack room), monitors the temperature at nine different locations and interfaces with the old PA system that has been retained as a backup resource.

Movicon SCADA (supervisory control and data acquisition) is a control system architecture that uses a network of interconnected computers and graphical user interfaces to provide efficient real-time high-level management. Other devices such as programmable logic controllers and discrete PID controllers can interface with the SCADA network and in recent years this has come to include mobile devices such as tablet computers and smartphones.

Movicon is used on every continent in applications from manufacturing and process control to energy and water distribution, building automation, infrastructure and traffic monitoring. UK representative, Products4Automation, has supported installations in steel mills, dairies, distilleries, refineries, factories and biomass power plants.

For the system integrator Movicon’s exclusive “XML-Inside” technology offers an all-in-one development environment for managing HMI, SCADA, soft-logic and statistical production data analysis applications. It provides unrivalled openness, simplicity and can interface with web services, SVG graphics, OPC, SQL, ODBC, .Net and the java technology. In short, Movicon is a truly universal SCADA/HMI platform, independent from hardware, adaptable and - as Gatwick demonstrates - deployable anywhere.

A critical function of the system for Gatwick is that it automatically sends text and MMS alerts to appropriate management level staff so that they are always kept up to date with events and warned of any unusual occurrences.

Following installation of the new Automated PA system, Gatwick was able to close all its fixed information desks and redevelop the space as retail outlets, while the mobile assistants provided more and better face-toface interaction with the public. Staff gave the system a thumbs-up and it was soon extended to handling agents and other companies’ personnel working at the airport.

Gatwick Airport has incorporated Movicon SCADA software from Products4Automation (P4A) in its North Terminal PA system.

Photo: Gatwick Airport Media Centre

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SOFTWARE & SYSTEMS CAPM347 HIGH SPEED 24VDC EMBEDDED PRINTER FOR RETAIL, VENDING AND KIOSK APPLICATIONS BVM, official distributor for Seiko Instruments’ printer mechanisms and portable printers for the UK and Ireland, has announced the CAPM347, a 24VDC high-speed rugged thermal print and cut unit optimised for use in ticketing and vending machines, receipt printing, lottery terminals, ATMs or other industrial, retail or medical applications. Two versions are available: for Point-of-Sale receipt printers and similar uses, the “Easy Load” version with a removable thermal head that enables simple drop-in roll replacement.

The integral cutter has a hardened V-shaped blade specified to two million operations of either complete or partial cuts that leave a small centre point attached between receipts.

The “Auto Load” model has a hinged thermal head assembly for embedded designs such as kiosk and ticketing machines and an optical sensor that automatically initiates replacement paper loading. Both versions offer print speeds of 300mm/s on standard 58, 60, 80 and 83mm wide paper up to 90 micron thickness; the thick paper model prints at 280mm/s on paper up to 150 micron thick.

The communication interface with the host machine is via parallel, serial or USB with Seiko’s interface boards or control chips; Windows and Linux drivers are available.

The units feature an all-metal body, powerful motors and wide gears throughout to ensure reliability. They are designed to output more than 1.3 million x 150mm receipts with up to 640 dots/line. 16 x 8, 16 x 16, 24 x 12 and 24 x 24 characters are supported, resolution is 8 dots/mm.

Web: www.bvm.co.uk/CAPM347.html Email: info@bvmltd.co.uk

IP66/IP69K-RATED STAINLESS STEEL PANEL PC FOR FOOD, CHEMICAL, PHARMACEUTICAL AND OUTDOOR APPLICATIONS BVM announces the latest addition to the GOT800 family of stainless steel touch panel computers. With the addition of this 17” unit there are five models in the range covering sizes from 10” to 17”. The GOT817-511 is a 17” unit and has a full IP66/IP69K-rated water, dust and corrosion-proof enclosure which guarantees this all-in-one industrial panel PC can be deployed in harsh operating conditions. It supports a wide operating temperature range from -20°C to +50°C and can withstand vibration up to 1G. The GOT817L-511 is an ideal HMI for use in food and chemical factories, pharmaceutical industry and other applications where hose down cleaning is required. It is equally at home in heavy-duty outdoor applications.

The GOT817L-511 supports the Intel® Core™ i5-7300U KabyLake CPU. This industrial panel PC has a 17-inch SXGA TFT flat bezel LCD display with LED backlight. It comes with the choice of a projected capacitive touchscreen or 5-wire resistive touchscreen. The 316 stainless steel enclosure enables it to be used in critical environments that require a high level of resistance to corrosion. In addition, the 17-inch rugged panel computer comes with IP66 and IP69K rated enclosures, five IP66-rated M12-type I/O connectors and wide range power input of 9 to 36V DC, ensuring reliable operation.

www.bvm.co.uk/GOT.html | info@bvmltd.co.uk

RACK-MOUNT PCS FOR LONG TERM RELIABILITY BVM offers a range of industrial 19” Rack Mount PC systems designed and tested for applications in harsh and challenging environments. The carefully selected components that make up our Rack Mount PCs utilise industrial grade components that are designed to run 24/7 in a wide range of temperatures and environments and offer long-term supply availability of up to 7 years avoiding expensive re-design mid project. Available in 1,2 or 4U our industrial systems are built to perform and offer the latest CPU and storage options.

A comprehensive design and customisation service is available including operating system support. All units are CE certified, tested and ready to run. bvm.co.uk/rack-mount.html info@bvmltd.co.uk

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OEM Design and manufacturing services BVM specialises in:-

● Electronic & mechanical design & CAD services ● Functional, environmental & compliance testing ● Manufacturing - OEM label, BOM control, warranty

Some examples of our work:-

Rugged Transportable Test System

Small Fanless PCs Embedded or Din-rail mounting

Customised Rack-mount Computer

Panel PC and HMI

Specialist Custom I/O Controller

Specialist PCB for I/O control

At BVM we have many years experience in the design and manufacture of embedded PC systems, panel PCs and HMIs. Whatever your application, talking it over with an experienced engineer might just give you the inspiration you need. Very likely we can provide that resource you’ve been searching for to ensure your project is a success.

Why not call us today to discuss your project?

What have you got to lose?

Call: 01489 780144 Web: www.bvm.co.uk Email: info@bvmltd.co.uk

SOFTWARE & SYSTEMS

PORT introduce a new SoM (System on Module) industrial real time communication board Based on a RIN32M3EC CPU in combination with GOAL technology from PORT, this SoM offers PROFINET, EtherNetIP, EtherCAT and CANopen on board. Simply connect via the SPI of your host controller - and your applications are already multi-protocol capable. One Hardware, many real time solutions.

The SoM - RIN32M3 module offers you a cost effective and easy to integrate communication solution. With just one module you have the for market leading real-time communication systems. The open interfaces allow you to react flexibly in the connector area. RJ45, M12, M8 or Mini I/O - no problem. An extensive tool offer for management and integration makes the design very efficient. With the integrated update service, you are always up to date.

More information you will find here: www.port-automation.com/en/products/ som-module-embedded/som-iot-based-onrenesas-rin32m3.html

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Robust and reliable manual machine function switching: Herga Technology launches new multi-function industrial footswitch range Herga’s new 6256 series footswitches will suit applications where durability, reliability and long working life are key factors for plant & equipment OEMs and machine builders. Using Herga Technologies unique development gate process, the modern and aesthetic high impact injection moulded ABS/PC housing design has been extensively validated for durability, temperature, environmental conditions and is a significantly cost-effective but highly capable alternative to more expensive castmetal footswitch solutions. Applications areas include operator enabled function switching where hand control is not feasible or safe in metal or plastics processing, laser machining, hydraulic press, welding, riveting stamping and more.

For further details of the new 6256 series visit www.herga.com or email sales@herga.com or call +44 (0)1284 701422

State-of-the-art Industrial IoT communication solutions IoT applications have traditionally relied on higher bandwidth cellular or wired connections but new technologies are emerging. MultiTech has a long history in IoT connectivity innovation and leads in both traditional cellular and new Low Power Wireless Access technologies; co-founding LoRa Alliance™ and launching NB-IoT and LTE Cat M1 devices worldwide.

We make industrial connectivity EASY minimising cost, time and risk; FLEXIBLE scaling from the very simple to the complex; SECURE allowing you to trust your assets and data; and COMPATIBLE offering networking for Industry 4.0 today and in the future.

Get in touch and let us show how we solved our customers’ IoT connectivity problems in a number of industry verticals!

Multi-Tech Systems (EMEA) sales@multitech.co.uk +(44) 118-959 7774 www.multitech.co.uk

SOFTWARE & SYSTEMS

IT INFRASTRUCTURES RITTAL

GREATER SECURITY IN MANUFACTURING IT Rittal’s teams work closely with leading industrial companies to create IT infrastructures for use with Industry 4.0 technology, including edge computing platforms. We’ve put together the following tips to help companies implement fastdeploying and secure IT for production environments.

The first step when starting any Industry 4.0 initiative or digital transformation within a manufacturing environment, is to define the common goals and consistent use of terms.

One goal should be to achieve real-time processing of measured values through the use of more IT and additional sensors. This will enable innovative applications, such as machine learning, process optimisation and predictive maintenance, which can only be done via big data analysis. Deviations can be recognised very quickly, increasing the reliability of these environments.

FIND A SECURE LOCATION FOR THE IT SYSTEMS Another consideration where to put any IT systems (such as an edge computing system) within a production environment. This requires input from a range of different departments: facility management, fire prevention and safety managers, production managers, IT managers and other specialists in network technology and production planning.

Project managers should therefore start planning with the relevant departmental managers at an early stage to identify any issues. It may mean finding an alternative space or even building a whole new facility to house the additional IT systems, but it’s just as likely that a business will be able to retrofit IT systems in the manufacturing hall.

In one recent project, Rittal’s team installed the necessary IT for automated production on the second floor of the production hall. As part of the project, special security rooms were used for the IT racks. It works extremely well, however, because this arrangement used a water-based IT cooling system, it carried the risk of a leak onto the manufacturing facilities located below. To prevent this happening, leak detectors were installed in the IT racks and throughout the building to alert the facility management team of any problems at an early stage, increasing operational reliability.

In general, companies should select the best possible locations for IT systems from a technical security perspective as well as to support well thought-out network cabling.

Ensuring there is sufficient distance to the manufacturing devices will protect IT systems from heat, dirt and vibrations.

INCREASE SAFETY WITH MONITORING Small and medium-sized companies often find that the IT systems can send detailed alarm messages to control centres within the company, but not outside of it, as these alerts are blocked by the firewall.

The process of monitoring IT systems and sending an alert to relevant technicians also needs to be addressed collectively by all of the project participants, starting with a review of the existing organisation-wide IT security strategy.

For example, we worked with a manufacturing company to upgrade the IT cooling systems in its production hall to lower energy costs and increase the reliability of the IT system.

Modern cooling systems are now able to send status messages directly to the manufacturer.

In this instance, the firewalls had to be configured according to the data protocols used, otherwise the message would not have got through and the cooling systems would not be able to function in accordance with the designated levels of safety and efficiency.

SECURE MONITORING SOFTWARE Monitoring software (DCIM) used to oversee production-related IT systems should be subject to special protection. Such a solution has a large number of interfaces and supports

a variety of protocols, so it can be vulnerable to cyber-attacks.

To make the whole installation more robust, including the server platform, we recommend using software to conduct a security analysis. So-called network vulnerability tests check the systems for known but still open security weaknesses.

Without this protection, in extreme cases, attackers could shut down the fans in intelligent cooling systems or turn off switchable power distribution units (PDUs).

SET UP EDGE COMPUTING QUICKLY AND SECURELY If areas of a production plant cannot be shut down while work is in progress, then it may be advisable to install pre-configured IT containers which are equipped with the required active IT components. Companies can therefore expand their IT capacities to decentralised production sites quickly and safely using what are termed “edge” data centres.

To set up an edge computing infrastructure for Industry 4.0 initiatives, partners Rittal and iNNOVO Cloud offer turnkey IT module and container solutions.

These contain IT environments in sturdy steel containers that house power distribution units, UPS, IT cooling systems, racks and, optionally, active components. This provides a quick and secure start to production, in locations across the world.

For more information visit www. rittal.co.uk, www.friedhelm-lohgroup.com, or on twitter @rittal_ltd.

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SOFTWARE & SYSTEMS

VIRTUALISING FACTORIES TECHNIA

HOW DELMIA 3DEXPERIENCE CAN DIGITALLY TRANSFORM YOUR FACTORY Stefan is a Production Manager at an industrial equipment manufacturer. He and his team are responsible for building enormous equipment.

To build that equipment, they are dependent on their own heavy machinery. The more ergonomic that machinery is - the more perfectly adapted to Stefan’s workers - the more efficient Stefan and his team can be.

But efficiency can only be evaluated in action.

Adjustments made for the next, expensive, iteration. Right?

DELMA 3DEXPERIENCE virtualises entire factories. It simulates workers. The objects they’ll interact with. Their surrounding environment. Individual machine parts can be evaluated virtually, any production issues flagged pre-manufacture. Approved parts can be manufactured automatically using NC machine paths generated within the program.

DELMIA 3DEXPERIENCE simulates production manufacturing, manufacturing processes, machine operations and human operations.

Users can identify process modifications during the planning and manufacturing phases - accelerating product development and bringing your product to market faster.

DELMIA 3DEXPERIENCE creates a collaborative workspace for every phase of the product life cycle. Manufacturing and production users can communicate and contribute within an integrated platform that encompasses virtual process and system definition, optimisation, scheduling and operation, and maintenance of real-time production systems.

DELMIA 3DEXPERIENCE KEY CAPABILITIES: # Additive Manufacturing Use DELMIA to plan, simulate and program additive manufacturing processes, to ensure optimum efficiency in the real-world. # Ergonomics Assess working conditions, ensure compliance and verify assembly across multiple platforms.

Realise ideal ergonomics and improve your workers’ productivity.

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# Lean Manufacturing Make lean manufacturing practices an integral part of shop floor operations. Virtual pre-planning ensures you only ever use what you need. # Machining Automate manufacturing by programming CNC machine tasks. Free your workers to focus on tasks that only a human can do. # Manufacturing Operations Management (MOM) Evaluate and adjust the entire manufacturing lifecycle as one. In real-time. DELMIA collects systems information to give you visibility and control of global production operations in a single system. # Process Engineering Create and optimise build-to-order manufacturing techniques, before going into production.

# Robotics Perform reachability studies, interlock analysis and offline robot teaching, and deliver optimised robotics programs to the shop floor. # Virtual Factory Create a complete 3D digital twin of your factory. Use pitch-perfect simulations of prominent systems to inform real-world decisions.

Welcome to Industry 4.0. Upgrade your factory with DELMIA 3DEXPERIENCE.

Visit www.technia.co.uk/software/ delmia/. Email us at info@technia. co.uk. Call us on +44 (0)1908 776776.

DISCOVER DIGITAL MANUFACTURING INTELLIGENCE Streamline product development and drive innvovation for a competitive advantage, with DELMIA® powered by the 3DEXPERIENCE® platform.

Speak to TECHNIA today to get started! Email info@technia.co.uk, call +44 (0)1908 776776, or visit www.technia.co.uk/software/delmia.

Dassault Systèmes 3DEXPERIENCE and DELMIA are registered trademarks of Dassault Systèmes or its subsidiaries in the United States and/or other countries. All other trademarks are owned by their respective owners. All other trademarks are owned by their respective owners. Use of any Dassault Systèmes or its subsidiaries trademarks is subject to their express written approval.

Make Reliability a Reality What is the difference between successful reliability improvement programs, and the very high percentage that failed? We know. And we have put all the keys to success in iLearnReliability.

The most successful reliability improvement initiatives are owned and controlled by a team within the company. They do not involve large consulting or software companies.

They did not start with extensive (expensive) reliability analysis. They did not start with huge budgets. But they did start with passion and knowledge.

If you have the passion and desire to succeed, we can provide you with the knowledge.

What else made programs successful? They always have senior management support. iLR will help you achieve that.

They all have a transformed culture, with people at all levels in the company understanding the value of reliability and contributing to the initiative. iLR will help you achieve that. They all have a plan, with goals, with knowledgeable and skilled people involved in maintenance, design, operation, and engineering. iLR will help you achieve that.

What is iLearnReliability?

Imagine a suite of e-learning modules, filled with animations and engaging interactions, that have been specifically designed to help people at all levels of the organization, from the front-line operators and tradespeople (with Toolbox Talks), to the managers (with Manager Briefings), to the reliability engineers, planners, and many others (with Program Management Training

modules), through to the people who needs special skills (with Skills Training).

The entire process is delivered on-line via your own customized “Learning Management System”. It is affordable to ensure that you can train everyone – because you really do need to train everyone!

OK, so what’s the alternative?

You could pay consultants to fix your problems – but that often ends up being expensive and ineffective. You have to take responsibility and ownership of this process.

You could develop the training for all of your staff. Do you have time for that (or the skills)?

You could have someone come in and train everyone once.

Those who receive the training will receive a short-term lift, but six-months later it will be back to the old way of doing things.

Or you could start a small vibration program, add some other technologies, tackle a few issues like shaft alignment, lubrication, and so on. You will benefit, but it will be a fraction of what is possible. No, you need to engage everyone, train everyone, and then update that training.

And you need a proven, detailed roadmap that will help you avoid the roadblocks and enjoy real success. iLearnReliability is the only way to do that.

Please visit www.mobiusinstitute.com/reliability to learn more, or e-mail dave.hupperich@mobiusinstitute.com.

You can join other leading companies across all industrial areas that are on their way to improving reliability in their plants.

ASSET

IABILITY

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iliR�l�lrs.1'3 & CERTIFICATION CATEGORY- I

ADVOCATE

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CATEGORY - Ill

PROGRAM LEADER

• CATEGORY llx / lllx PROVEN PRACTITIONER

ACCREDITED CERTIFICATION FOR RELIABILITY PRACTITIONERS Practitioners and leaders involved with the important role of improving the reliability and performance of an industrial facility should be recognized for their knowledge, experience, and contribution.

MOBIUS INSTITUTE's Asset Reliability Practitioner (ARP) training and certification recognizes the knowledge and basic experience of people at three levels; the Advocate who contributes to the initiative, the Reliability Engineer, and the Leader of the program. Additionally, the certification scheme separately recognizes reliability engineers and program leaders who have proven competence through verifiable experience. ARP CATEGORY llx and lllx are the only certifications in reliability which provide the highest and most important recognition; your experience.

The ARP CATEGORY 1-111 training is aligned and available through global Mobius Institute training centers and via online learning. Our certification is accredited and recognized worldwide. ARP certification is quickly becoming recognized as the highest standard in reliability certification.

GET STARTED TODAY! Visit our website at www.mobiusinstitute.com to learn all about the ARP training and certification program, and to see our current course listings. Or simply contact us at learn@mobiusinstitute.com for details.

www.mobiusinstitute.com/arp l'!/ilMOBIUS - INSTITUTE

You may also attend our ARP CAT-I workshops and sit the exam at any of the upcoming CBM Conferences; coming to Abu Dhabi, Antwerp, Indianapolis, Manchester and Melbourne in 2019. For questions about attending a CBM Conference near you or to reserve your seat, contact Becky Partipilo by email at bee . arti ilo@mobiusinstitute.com.

Issue 37 PECM

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TRAINING & RECRUITMENT

PLANNING FOR THE FUTURE BOULTING

THE IMPORTANCE OF LEARNING AND DEVELOPMENT PLANS For many British manufacturers, the issue of skill shortages remains at the top of their ongoing concerns. While the industry continues to call on the UK government to step up and tackle the potential crisis, many businesses are looking internally to see how they can do their bit. Here Lucy Speed, HR advisor at engineering solutions provider Boulting Ltd, looks at the importance of learning and development plans in tackling internal skills gaps.

All jobs require some level of training when employees start a new role, whether that be because they are fresh to the company or they are entering a new field in the organisation.

For some businesses this introductory training is as far as it goes, with many showing no further commitment to their employees.

According to research, two out of three UK workers have changed jobs because of a lack of training and development. In fact, out of 2,500 people surveyed by jobs website total jobs, two thirds say training is more important today than it was two years ago.

With unemployment rates standing at an all-time low, employers are facing a significant challenge to retain their workforce.

Technical skills, knowledge and experience are critical to many roles in the field of engineering. As Industry 4.0 technologies are implemented, employees across all levels are being required to undergo extensive on-the-job training. This is to not only ensure they understand the technology, but how it can benefit the business, which is particularly important for white collar workers.

It’s important that we attack the skills gap from several angles. We should not just focus on the short-term issue but also work from the roots up and identify strategies that will secure the longevity of the industry. At Boulting we are diversifying who and where we recruit from, including becoming a Tier 2 sponsor company. This has helped us to tackle some of our skills gaps, but much more needs to be done to back fill many of the skills that the industry is set to lose.

ON THE JOB LEARNING A focus needs to be placed on retaining the skills in the UK to ensure that we have people that can impart their knowledge with those who aspire to achieve a career in engineering.

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One way to achieve this is by implementing a robust learning and development plan across all areas of the business.

A learning and development plan acts as a road map for employees and helps to support their career and personal development. It helps the company identify key roles and grow its talent to fill skills gaps. These gaps may include the operation of new industrial technologies, but also help engineers make the shift from blue collar to white collar roles.

One area of Boulting that has benefited has been the skilled system integration team.

Through a combination of learning and development plans and focused mentoring programme, graduates and trainees have been nurtured and developed into highly competent engineers much faster and more effectively than in the past.

This process is important as it allows for a focus on career management and helps us ensure that there is a two-way communication and dialogue, assisting both the company and employee achieve a common goal.

The plans can be used to manage performance and demonstrates to staff that their employer is keen to invest both time and resources in their career development.

CREATING YOUR PLAN There is no one-size-fits-all solution when it comes to learning and development plans as every employee is different. Each plan should be tailored to meet the needs of the individual and their current and future role.

The plan should be made up of key objectives that the employee should achieve during the lifetime of the document. These objectives can include anything from technical to behavioural and leadership skills. Staff can also be supported further through mentor programmes as well as ongoing assistance from their line manager and wider HR team.

Development plans should consist of a mix of on and off the job learning. For many industrial companies there can be a lot of tacit knowledge locked away. It’s important to open up this knowledge and ensure it is shared with the next generation of employees and leaders in order to develop the business.

On the job learning and shadowing play a key role in the plans as they provide people with the opportunity to experience real life situations and put the theory in to practice in a safe environment. Whereas off-the-job learning gives employees an opportunity to undertake further education or training that is specific to their role, something that their existing employer may not be able to offer.

FUTURE LEADERS With fewer people entering the field of engineering at blue collar level, there is an impact further up the chain with the industry’s future leaders. Learning and development plans can assist with identifying future leaders through appraisals and careful succession planning.

Boulting offers relevant employees’ formal supervisor and line manager training including Institute of Leadership & Management (ILM), Institute of Directors (IOD) and Association for Project Management (APM), as well as other recognised management training to aid with development.

For those making the shift from blue to white collar roles, mentoring from current job holders and senior managers is integral to managing the change and proves to be very effective. This is also important for people with experience that have made the move from other companies or sectors. When people do move between organisations or sectors, it’s important to capture their experiences and views as often they can lead to innovative changes to your business’ approach and processes.

For more information about Boulting Ltd and potential careers, please visit www.boulting.co.uk/careers.

TRAINING & RECRUITMENT

Pro-Reliability Solutions Pro-Reliability Solutions help and support manufacturing companies who are looking to improve the way they perform and deliver maintenance from an engineering and operations perspective.

We have selected some best in class elements that can support an organisations journey of Reliability. We have named these elements ‘Reliability Focus™’.

We deliver value to our clients by providing training, mentoring and facilitation services within the Reliability Focus™ elements.

Easy access to training materials and simulation helps engineers be more effective in their daily activities Good engineers understand the challenges and work environment of their customers- the plant operator.

Traditionally used by plant operators, forward thinking companies are using simulation to train their engineer staffs to be better engineers that have an operational perspective.

Please feel free to give us a call and we would be happy to discuss any questions you may have regards any of the elements of Reliability Focus™

Simulation training is typically time and resource constrained, but EnVision OnDemand provides anytime, anywhere access to content used by the world’s largest oil and gas companies.

See www.Pro-reliabilitysolutions.com or contact info@pro-reliabilitysolutions.com for more information

Our simulations provide plant engineers with a foundational understanding of upstream and refining processes so that their design decisions drive true operations value. www.gses.com/envision

The MTC – training the next generation of engineering technicians The Advanced Manufacturing Training Centre (AMTC), on the Manufacturing Technology Centre campus at Ansty Park in Coventry, is trebling the number of apprentices it trains.

The industry-leading centre, sponsored by Lloyds Bank, is to provide training for 300 high quality apprentices a year by 2020.

AMTC apprentices are trained though a mix of traditional skills complimented with modules of advanced manufacturing and are exactly what manufacturing industry is looking for to fill the high-tech jobs of the future. AMTC apprenticeships have the advantage of not being company or sector-specific, so the result is a fully-rounded apprentice capable of filling the most demanding of manufacturing and engineering positions. The apprentices are fully tutored in work behaviours and engineering basics, but are also exposed to the latest manufacturing technology.

Training & Recruitment the-amtc.co.uk

Safety in Numbers

ON-CAMPUS AND ONLINE PROGRAMMES; WORKING IN SYNERGY

It’s the start of the year and already there is a great example of shared experiences. During January we host an additive manufacturing residential primarily for online students.

During the residential experienced engineers studying on the programme presented the real-world challenges they are facing within their oil and gas business.

This was an opportunity for discussion for undergraduate graduates who are also able to share their ideas and ambitions within the sector. core computing programme in Excel This is aisfabulously versatile tool, but it is not easy to make it just one example our manufacturing programme. clear to users how youroffering spreadsheetChanging reachesa its results. among many of how business process flexible of the on-campus has a knock-on effect in of Do you knowsuite how resultsand you usetypically have been derived?

One onlinetsprograms for generalstrong spreadsheet a number of areas including the benefi of developing skills is thattheyou engineering, manufacturing, supply chain.

Visualising these can lift the lid on the methods employed.

Learn a bit of Visual civil engineering and changes is a key skill to help Basic,and andnow even macros need not stand in your way. the built environment can work businesses gauge the impact.

Nicholson Solutions is a Learning and Performance Institute synergistically together.

accredited learning provider, with a track record of developing It’s not just the students spreadsheet solutions andsharing analysing existing ones. derby.ac.uk/online/ but also one of the reasons we have data visualisation from the

UDOLenquiries@derby.ac.uk

www.nicholsonsolutions.co.uk Issue 37 PECM

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VALVES & FLOW CONTROL

IDEAL OPPORTUNITY BURKERT

MARSTONS IS CHILLING WITH BURKERT EXPERTISE For Marstons brewery in Burton upon Trent, Staffordshire, replacing control valves on the main chiller system would improve reliability. However, the process control components were initially looking expensive - that is until a call to Burkert revealed a much more cost-effective solution.

Replacing ageing equipment or expanding a production line are ideal opportunities to take stock of new technologies and how they can improve productivity and reduce project costs. Marstons has been expanding its production facilities to cater for the increased popularity of craft beers and part of this process called for new chilled storage tanks to be installed. In addition, the pipework and control valves on the existing storage tanks had reached the end of their service life and were due for replacement.

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PROCESS ASSESSMENT The initial enquiry from the production engineers at Marstons was to source some large, electrically actuated control valves, 84 of them in fact. The valves are designed to control a water/glycol mix that cools the storage vessels. As part of a hygienic process, they needed to be stainless steel and the threaded connecting pipework was 2 inches (50 mm) in diameter. The size and design of these valves meant that they would command a premium price, no matter which manufacturer supplied them.

Burkert was keen to offer a more costeffective solution and suggested that one of its engineers visit the brewery to understand the objectives of the process, the requirements for the control valves and the structure of the existing process control system. During the site visit, it transpired that there was an aversion to installing

pneumatic controls because of perceived high costs, following a recent quote from another process control manufacturer.

The Burkert engineers explained that all the aims of the new process could in-fact be achieved using pneumatic valve islands and control valves with a significant saving compared to the electrically-actuated valves. The Burkert solution included its latest valve island, the Type 8652, that would be built into a European Hygienic Engineering and Design Group (EHEDG) panel, enabling it to be positioned close to the process.

Paired with Type 2000 valves, also in stainless steel with threaded connections, each fitted with a CLASSIC actuator, the whole reduced-cost package could be offered with a 2-year warranty, direct from Burkert.

BUILDING FOR THE FUTURE The Type 8652 AirLINE has been optimised for installation at the bottom of a control panel, which in this case, was custom-built

by Burkert at its Systemhaus in Germany.

The compact nature of this valve island would normally reduce the size of the panel required, but in this case, the brewery wanted to include additional space for future expansion as well as its own input/ output systems. To accommodate the future plans for the site, Burkert populated all the valve island control modules, allowing the unused ones to be easily connected as the application expanded.

Due to the choice of positions for the air supply port on the valve island, the air preparation unit, which consists of a filter and a regulator, could also be included within the panel without additional connection points.

Traditionally, this would have been external to the panel, but this design protected it from any washdown processes.

Greg Wainhouse, UK Field Segment Manager for water, explains: “One of the most obvious new features of the Type 8652 valve island is the integrated, back-lit LCD screen that displays pilot valve status, switching status of the process valve, a switching cycle counter as well as a diagnostic report. This simplifies commissioning and operational maintenance including fault diagnosis by providing instant status information for remote components and connections.

“Another feature that really stands out is the ‘hot-swap’ facility that allows control sections in the valve island to be replaced during normal operation. This means production can continue uninterrupted, even if a maintenance issue arises”

SIMPLIFIED INSTALLATION Multiple Type 8652 units could have been daisy-chained together using one gateway to connect directly to the Rockwell PLC. However, in this case, it was a personal preference to install three, hard-wired connections to the valve islands; even with this option, there was still a considerable saving in the amount of wiring that needed to be installed for this project, compared to the original concept using electrical solenoid valves.

Interfacing with the PLC was a very simple process, the EDS file is available from Burkert’s website and the commissioning software is provided free-of-charge.

Khalid Aziz, Project Manager, at Marstons, concluded: “The technical assistance we have received from Burkert has had a very significant impact on this project. The increased functionality means that we can reduce the amount of cooling and have

greater control over the whole process.

We have also made some very significant savings in terms of installation time and overall plant running costs.”

Once this project was installed, commissioned and fully operational, Marstons continued with a further part of the expansion plan that required another valve island and 20 more Type 2000 valves, all of which were ordered from Burkert.

These were installed as part of the project to provide new chilled storage tanks and offered the same simplicity of installation and connectivity.

For those looking to update existing systems or introduce new control technology, the Bürkert solution can reduce installation and commissioning times as well minimise operating costs and downtime. www.burkert.co.uk Issue 37 PECM

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VALVES & FLOW CONTROL

THE VALSTEAM ADCA PROJECT VALSTEAM

A STRONG PASSION FOR DEVELOPING EQUIPMENT AND FOR SOLVING PROBLEMS The Valsteam ADCA project has been in the market of steam equipment for more than 35 years. Valsteam ADCA started as an industrial plant for pipeline and steam boiler house contractors. Already building pressure vessels and auxiliary equipment in-house, Valsteam ADCA has grown up to become steam equipment and valve manufacturers, using the knowledge acquired along the years, and can now assure the complete production cycle: design, machining, welding, assembly, tests, quality and packaging for a very wide range of products.

Right from the start, the family owned Portuguese company had a strong passion for developing equipment and for solving problems. Today, Valsteam ADCA has two production facilities with a total manufacturing capacity of 22 000 square meters, located in a small village in the ocean side of Portugal, and are currently growing again, expanding their main production facility. The team today consists of almost 100 people that together drive this Portuguese caravel along the five continents and more than 80 countries, with the same ambition their ancestors were driven by: to reach more and to give new worlds to the world!

The company started small, with its first manufactured product being the thermodynamic steam trap, followed by float and thermostatic steam traps, pressure operated pumps, humidity separators, and heat exchangers. Up to now, the company consolidated a very wide range of products and solutions for steam and other industrial gases and liquids, present in the process industry. Today, the company stands as a “one stop shop”, with more than 6.000 different products and more than 15.000 product parts for all kind of industries.

From standard and non-standard series to tailor-made products, Valsteam ADCA is one of the European companies with the largest range of products, which can be divided into six sections: steam traps, pressure reducing valves, control valves, pipeline ancillaries, special construction equipment and Adcapure, the hygienic/ sanitary line, a complete range on its own, specially dedicated to industries with high purity standards, such as the food, chemical, cosmetic and pharmaceutical industries.

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Valsteam is nowadays a global company, but kept the best that a family owned business can have: agility in developing new products, flexibility in production and proximity to staff and clients. The requests of customers for different special products meet in the company the willingness and determination to accept new challenges, which is evident in the company’s vision to always look to and invest in state of the art machinery and advanced engineering software, that allow the continuous increase of the factory’s productivity and the quality and efficiency of the products.

For the latest news and to follow the evolution of the new expansion, visit www.valsteam.com

VALVES & FLOW CONTROL

Malaysian refinery trusts Rotork Client Support Programme for tailored valve actuation management The Rotork Client Support Programme (CSP) has been chosen by the Hengyuan Refining Company Berhad for the asset management of Rotork valve actuation equipment at its Port Dickson refinery.

The CSP is designed to meet the company’s specific needs, encompassing 157 Rotork electric actuators, a Rotork Master Station and Pakscan control loop testing facility. The Rotork CSP can increase reliability and availability of actuator and control products via predictive maintenance and asset management. This includes equipment checks, replacement of worn components and partial or complete overhauls at specific periods.

CSP clients have 24/7 access to Rotork Support Centres, with prioritised technical assistance backed by comprehensive resources.

Process Valves & Instrumentation Ltd

ROSS Controls® & Concern for Machine Safety

We are a global provider of an endless selection of process equipment. Established in 2010 and based in Congleton, Cheshire. PVI boast a combined industry knowledge of over 60 years with our team having varying experience with both mechanical and instrument solutions in all industrial sectors such as Chemical, Pharmaceutical, Oil & Gas & Food/ Beverage and have exclusivity with WEIR BDK for their sleeved & Lined plug valves.

The two go hand in hand. ROSS has been designing and supplying the “industry standards” of safety products for pneumatic energy isolation and control reliable valves for the metal forming industry clutch/brake applications and the general manufacturing sectors for decades. These are some of the most safety critical applications in manufacturing today, and ROSS has been there to help make jobs safer for workers, helping to protect our customers’ investments in machinery and increase productivity.

ROSS employs a team of Global Industry Specialists with vast experience in fluid power applications with a special emphasis on SAFETY. Finding the right valve for your safety application is quick and easy with the ROSS Controls Safety Valve Selection Tool available on our website.

We also have partnerships in place with ARI, IFM & Gestra and many more giving us unrivalled access to their many products and global support. In addition, we also work closely with other brands ensuring we are able to offer you the very best products at the most competitive price.

01260 277025 www.pviltd.co.uk www.datastorgroup.com sales@pviltd.co.uk

www.rotork.com/en

Telephone +44 1543 671495 Email info.uk@rosscontrols.com visit www.rosscontrols.com

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

Malaysian refinery trusts Rotork Client Support Programme for tailored valve actuation management

Portable Confined Space Ventilators & Air Blowers Fume & Dust Extractors Where fumes, smells or dust occur, the Miniveyor Air VAF fans can move contaminated air out of a confined space or building.

They effectively exhaust fumes, ventilate confined spaces, and increase the flow of fresh air.

The Miniveyor Air range are tough! The rugged VAF ventilators easily withstand blows without denting, giving less downtime and greater productivity and come with an industry leading 10 year warranty on the body.

The vane axial fans work on positive and negative airflow and are at home either extracting dust and fumes or blowing clean air into a confined workspace. In fact whatever the industry you work in, from marine, construction, mining, telecoms, fabrication or maintenance services, our VAF series fans will take whatever is thrown at them.

VAF-200 (8”)

VAF-400 (16”)

VAF-300 (12”) Pneumatic

For more information contact us today VAF Air Ltd Tetbury Ind. Estate Tetbury, United Kingdom sales@vaf-air.com +44 (0)330 016 0002

www.vaf-air.com

Scan Now with your Smart phone to visit our mobile site

PLUG AND PLAY! SMART SENSOR CSS 014.

STEGO‘s new Smart Sensor is a plug-in solution for Condition Monitoring. The CSS 014 detects ambient temperature and humidity in switch panels. Thus lifting climatisation in enclosures to the next level: Predictive maintenance and remote monitoring allow for immediate response to unwanted and harmful change in environment within your application. See more here.

Visit us HANNOVER MESSE 01 – 05 April 2019 Hall 12, Stand E 45 WWW.STEGO.CO.UK

NE W SMART SENSOR CSS 014