Process Engineering Control & Manufacturing - Issue 40 2019

Process

MANUFACTURING

ADVANCED ENGINEERING SHOW PREVIEW - 40 What companies are doing to drive positive change

Control &

Engineering

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Inside...

Sections Editors Choice Advanced Engineering Show Preview Northern Manufacturing Show Preview PPMA Show Preview Contamination Expo Series Preview Sensors and Instrumentation Show Preview Boilers & Maintenance Connections & Fittings Control & Automation Electrical & Electronic Facilities Management Fast Live Show Preview Fluid Handling Gears, Drives & Motors Health & Safety Hydraulics & Pneumatics Machining & Machinery Measurement & Monitoring News & Events Process Technologies Software & Systems Storage, Handling & Distribution Training & Recruitment Valves & Flow Control

Control &

Engineering Inside Issue 40 6 40 48 52 57 60 66 72 74 86 95 100 103 107 112 120 121 132 155 166 170 180 183 188

ABB Darcy Simonis, food and beverage group vice president at ABB, explains how to optimize cooling towers.

ADVANCED ENGINEERING SHOW PREVIEW

PAILTON

Jeremy Whittingham, Head of Marketing at Advanced Engineering, the UK’s leading industrial trade show, explains five ways businesses are managing uncertainty.

Can 3D printing be used in the manufacture of safety critical vehicle parts?

NORTHERN MANUFACTURING SHOW PREVIEW

ROTAMEC Rotamec rewind service helps a leading brewery to keep its fizz.

AGGREKO Manufacturers can now start the process of implementing a decentralised energy solution to their facilities, after Aggreko officially launched its bridging gap service.

With around 250 companies expected to take part this year, an anticipated 3,000 visitors can expect to see a good number of familiar faces, plus some exciting new companies taking part for the first time.

FANUC Zeeko Ltd has bucked the trend and established itself as the go-to global supplier for ultra-precision polishing and metrology machines.

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Issue 40 PECM

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Process

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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.

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Issue 39 PECM

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EDITOR’S CHOICE

SWITCHGEAR MANUFACTURING RITTAL

RITTAL OFFERS OPPORTUNITY TO TEST DRIVE THE PERFOREX SOLUTION Rittal is offering UK customers the chance to ‘test drive’ its Perforex machining and automation systems before they buy.

Rittal Perforex machining centres are a major advance for switchgear manufacturing. They are designed to automate the creation of bore holes, cut-outs and threads in mounting plates, enclosure doors and side panels. It means that the timeconsuming and mechanical processing steps required for the preparation of enclosure panels can now be accomplished in a single work step to an extremely high degree of accuracy. The work can be simply programmed into the Perforex to be repeated multiple times for fast, effective batch processing.

Customers are being invited to Rittal’s new Working Demonstration Centre in Rotherham to see a working demonstration model of the Perforex. They can bring examples of their own enclosure modification projects using Rittal AE enclosures and compare the quality of finish they’re currently achieving, as well as the time a job takes, with that delivered by the Perforex.

“The Perforex really is a game-changer for panel builders,” says Rittal’s Product Manager Mark Guest, “Automation of mundane and routine tasks improves accuracy and quality, as well as increasing productivity and customer satisfaction.

“We’ve heard of projects that would have taken up four hours, now completed in 20 minutes to a consistently high standard of finish, whether the order was for one panel, or 100. And because it’s cleaner and there’s less waste, it can also transform the working environment.

“This is the first time we’ve been able to offer a no-obligation opportunity for customers to see it in action and ‘test drive’ it in the UK. We’re looking forward to demonstrating it to them.”

Rittal’s Working Demonstration Centre also includes a RiMatrix Rig – Rittal’s integrated modular solution for IT infrastructures - and a working IT chiller, which demonstrates Rittal’s ongoing commitment in preparation for IoT demands and delivering edge computing solutions.

The Perforex is one of a range of automated tools, developed by Rittal, to support panel building and switchgear manufacturing.

They include tools to help with: • handling and ergonomics in the assembly of mounting plates and panels • cutting centres for effortlessly cutting cable ducts, cable duct covers and support rails • automated wiring to automatically wire enclosure mounting plates, which is a huge time-saving advance – potentially saving 15 working hours per enclosure To book a Perforex Free Trial customers should contact their Local Rittal Area Sales Manager, or email information@rittal.co.uk.

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

The Perforex solution ENCLOSURES ENCLOSURES

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SOFTWARE SOFTWARE & & SERVICES SERVICES

EDITOR’S CHOICE

INDUSTRY 4.0 REVOLUTION SCHNEIDER ELECTRIC

FUTURE PROOFING YOUR MOTOR MANAGEMENT STRATEGY

By Martin Walder VP Industry Schneider Electric Manufacturers sit at the cutting edge of the Industry 4.0 revolution. Technology is changing the industry as we know it – and manufacturers need to prepare for the impact advancements in tech are set to have.

To do so, manufacturers need a clear vision as to how digitalisation is going to impact their sector. Whilst this isn’t easy, and there’s no set answer – manufacturers can take the opportunity to embrace new and innovative technology. In doing so, they’ll benefit from increased insights, and greater productivity.

One of the ways they can do this is in their motor management strategy.

In today’s market, the manufacturing industry dominates the industrial sphere. Within the sector, an incredible volume of power is used to convert raw materials into finished goods.

What’s more, more than 60% of the energy in the industry is being used specifically to power motors. Crucially, this is only set to increase if we’re to sustain the production rate for years to come and futureproof the industry.

Whilst this volume of energy consumption may not come as a surprise, the amount of companies without a motor management strategy in place is surprising. What’s more – an intelligent motor management strategy is crucial if we are to reduce our overall energy consumption and increase plant uptime. In fact, the manufacturing sector is dependent on motors, so it’s essential to ensure that they are protected and fit for purpose now and in the future.

Think of it like this – with more and more smart Industrial Internet of Things (IIoT) compatible products available on the market, if part of the motor were to break, replacing like for like products would not always provide the best operational results.

WHAT’S WRONG WITH LIKE FOR LIKE REPLACEMENT? Motors starters can be complex pieces of technology – and like all technology, they are at risk of faults, damage or breaking down all together.

There are several different conditions in the

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industry to watch out for that can create a motor starter failure. This includes, high or low voltage supply, phase unbalance, continuous excessive loading, jam or stall conditions, ground faults, single-phasing, seized motor bearing or binding mechanical linkages.

businesses will suffer from a lack of insight and will get left behind in the plant process information technology race.

When impacted by one of these situations, many plants are re-ordering a like-for-like starter. Prior to its failure, it worked well and it’s a product they know and feel comfortable with. This however is a short-term solution.

The issue here is that the technology and capability of the said motor may not be fit for the long-term. Without smart capabilities,

The solution therefore, is to implement a smart motor management strategy. This isn’t something that is needed purely for new machines, but also for upgrades and retrofit.

A smart strategy offers the manufacturer additional digital based benefits above simply opting to implement energy saving technologies.

ENTER: SMART MOTOR MANAGEMENT STRATEGIES

A great example of this in play is Schneider Electrics motor starting product, VSD’s and TeSys island with EcoStruxure Machine Expert configuration and commissioning software and the EcoStruxure Motor Configurator tool. The tool helps OEMS to accelerate the time to market by enabling multiple teams to simultaneously program and control the quality of design. By enabling a more efficient integration, it becomes 40% faster to integrate and reduce installation costs by 30% compared with traditional solutions.

By utilising these technologies, product and process information is automatically generated. This allows businesses to open up to the world of plant digitisation and enjoy all the benefits it brings. Benefits include reduced energy consumption,

increased productivity, more empowered operators, preventative maintenance scheduling and asset management. Not only this, but access to smart data is key in increasing uptime, improving overall quality.

All of these contribute to the same end goal – to increase the overall equipment performance (OEE) and ultimately, business profitability.

A FUTURE-PROOF STRATEGY At present, a smart motor management strategy may not be the first thing on everyone’s minds. But, in three to five years’ time, when the senior leadership team are requesting insights into why downtime on the plant floor is high, or into how many stop/starts a motor has done – we need to be prepared to give informed and data-

driven answers. The only way to do this is by improving our traditional technology, and replacing it with smarter, more innovative and more connected motors.

The question is, how do we get the most out of our manufacturing plants? The answer is simple. It’s time to embrace change and opt for smarter, more innovative starter technologies that provide us with the analytics and business insight we are going to need. By preparing a smart motor management strategy now – it’s possible to remain competitive – and ready for the future changes technology is yet to bring.

www.schneider-electric.co.uk Issue 40 PECM

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EDITOR’S CHOICE

AUTOMATED DISTRIBUTION LOBO SYSTEMS LTD

DISTRIBUTION FULFILMENT CENTRE: KEY PROBLEMS Material handling system solutions require planned and reactive maintenance programs, often in elevated and awkward to access areas.

Maintenance is key to an efficient process; many areas are awkward and therefore difficult to reach; each task often being different from the last.

The complexity of maintenance tasks can range from simple light bulb replacement to highly technical adjustments and calibrations.

Creating a safe work platform is a huge part of making the repair procedure easier and safer.

Working at height must be accomplished safely and traditionally, outsourced scaffolding companies and fixed aluminium tower systems have been deployed.

Outsourced scaffolding labour is expensive and not available 24/7, aluminium frame systems are cumbersome, inflexible, difficult to transport and will not adjust to fit into awkward areas.

THE SOLUTION Using a LOBO Systems solution can dramatically improve logistics system operation by reducing scaffolding labour costs, which in turn improves service levels and increases operator productivity.

The LOBO System can be assembled quickly, easily and safely around, through or above conveyors and restricted access areas – by your own in-house maintenance crew.

This means out-sourced scaffolding labour costs can be reduced without compromising safety. Areas previously considered difficult to get to can now be accessed with ease for maintenance and cleaning purposes. In addition, it is available 24/7 and therefore puts you in control of what and when you schedule your maintenance tasks.

PRODUCT BENEFITS a) LOBO is scalable, adaptable and adjustable to meet your on-going and changing requirements.

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PECM Issue 40

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

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

With this quantifiable reduction in costs comes the added savings associated with reduced downtime and greater productivity from your maintenance department.

Available 24/7, quick to erect – and above all safe – it is immediately adjustable for your next job with no staff waiting time while new fixed-frame structures are built.

Re-configurable, again and again, this product comes with no disposal costs and minimal replacement and on-going training costs.

For more information and to arrange a product demonstation please contact us by email: sales@lobosystems.com or Telephone: +44 (0) 1332 365666 www.lobosystems.com Issue 40 PECM

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EDITORS CHOICE

COOLING SYSTEM ABB

COOLING TOWER OPTIMIZATION

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CM

MY

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Food and beverage production requires a large range of temperatures. This means that plants must have effective cooling systems to deal with the excess heat. Removing the excess heat from the system requires a cooling tower, however, traditional designs require frequent maintenance. Here Darcy Simonis, food and beverage group vice president at ABB, explains how to optimize cooling towers.

Food and beverage manufacturers understand that the industry is becoming a constant production environ-ment, especially with the expansion of technologies like cold supply chains.

Businesses, therefore, require equipment that can work constantly. However, when producing for long periods of time machines tend to overheat, meaning that to become a constantly working operation cooling systems must also work twenty-four hours a day Heating, cooling and pasteurizing are all common steps in food and beverage. Each one of these steps either directly or indirectly produces large quantities of heat. Managing this heat is a priority, because otherwise equipment may be damaged through overheating. As such, it is important to have a cooling system that is reliable, requires minimal maintenance and can extract heat at a sufficient rate.

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PECM Issue 40

How to optimize cooling Traditional fans generally use 1500 rpm induction motors that connect to a driveshaft that connects to a gear-box, the gearbox then connects to the fan.

This makes the system prone to breakdowns as there are many moving parts, also gearbox maintenance is time consuming and, due to the environment, oil leaks are com-mon.

To combat this modern cooling fans need motors that can be mounted directly onto the fan, while be-ing able to resist the conditions within the cooling tower.

Many of these traditional motors can be replaced with more efficient permanent magnetic motors that can be directly installed onto the fan. This reduces the amount of parts in the system, limiting the risk of break-downs.

They are also compact compared to traditional cooling tower motors, reducing the space required by the system.

Furthermore, the motors help optimize cooling towers by reducing noise pollution and as the motor is re-versable allows for the fans to be used to prevent freezing during the colder months of the year.

Adding extra functions like this means that the higher efficiency of permanent magnetic motors, especially at partial loads, in tandem with the drive’s variable speed control ensure fast running of the fans at the required speed saving energy, reducing CO2 footprint and lowering running costs.

Permanent magnetic motors from ABB can also be installed with ACS880-01 industrial drives that are built with cooling tower application control programs. This allows the drive to adjust the speed of the motors to match the process demand, further increasing energy savings while lowering wear and tear rates. Meaning that cooling towers will be able run for longer while further reducing the amount of maintenance required during its lifetime.

Overall, upgrading cooling tower systems can lead to major savings and create a platform for constant produc-tion that can help drive business growth. Traditional cooling systems, especially cooling fan motors are no longer up to par with the requirements from the system. Optimizing them through the introduction of new technology is the only way to improve production.

www.abb.com

CMY

K

Level probes - extended Several new variants of ifm's popular LMT point level sensors have been added to the range.

Longer probes, up to 250 mm, are particularly useful in overfill applications.

Internal timer functions can be set using standard IO-Link accessories.

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

EDITOR’S CHOICE

Laser Engraving Workstation Large, modular floor-standing workstation for direct laser engraving of large or multiple components for permanent part traceability Pryor Fibre Lasers: • Fast and easy to operate • Non-contact, fixtureless marking • Permanent, high-contrast engraving • Reliable, low power consumption fibre laser Pryor Laser Workstation: • Scalable, Class 1 light-safe workstation • Different enclosure access options available • Supplied with Traceability and Data Capture Software • Mark unique ID codes; alphanumeric, 2D Data Matrix Codes, logos, automated serial numbers.

PRYOR UK designed and manufactured since 1849 https://www.pryormarking.com info@pryormarking.com +44 114 2766044

Improving manufacturing competitiveness: a new white paper from BOGE

Sourcing custom parts overseas need not involve huge quantities or high risk

A new white paper from leading compressor specialist BOGE Compressors discusses the important role that compressed air systems must play in the development and management of the ‘Flexible Factory’.

The white paper, which is available via free download from the BOGE website, explains how world-scale manufacturing plants that are common in China and India are now a thing of the past for UK enterprise. A new manufacturing paradigm based on the so-called ‘flexible factory’, is now needed to boost UK manufacturing efficiency and provide the agility required to move away from a narrow mass production model to one that enables rapid change from one high-value production run to the next.

Due to its extensive experience in working with trusted suppliers in the Far East, Blue Diamond Technologies, now part of TRITEC Performance Solutions, can offer custom parts in low minimum quantities (500 pieces) without the need for high minimum orders that run into thousands of pieces. This allows customers to source a custom part with very little risk and minimum cost. “There are many ways we can help our customers get the best outcome from sourcing low cost custom parts. Using our services removes many of the problems and risks associated with sourcing directly from suppliers in the Far East.” explains Mike Doel, Business Development Manager, Blue Diamond Technologies.

Download the free white paper from the BOGE website: uk.boge.com/en

Further options include the provision of labelling, bar codes and packaging, which can also be incorporated into customer agreements. www.blue-diamond.co.uk

Spillcare Products Contain, control and clean up spills in and around the workplace

No matter what industry you’re in, we can manufacture the custom parts you need

Over 40 years experience manufacturing custom parts 023 8025 8966 • www.blue-diamond.co.uk

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PECM Issue 40

View our range and order online at www.darcy.co.uk

E/M Coating Services www.emcoatingsuk.co.uk COMPANY PROFILE At the forefront of the latest designs, materials and technologies, E/M Coating Services pride themselves on offering high quality coating applications and processes to improve performance and extend the life of critical components and fabrications of all shapes and sizes for a wide range of industrial sectors. With specialised facilities we are able to design and manufacture bespoke coating systems and have in-house NACE Level 3 trained Inspectors.

Quality is at the heart of our business and we operate under the highest quality control procedures including AS9100 Rev C, NADCAP, ISO9001/9008 and NACE.

New Anti-Corrosion Coating for Rare Earth Magnets Neodymium Iron Boron magnets are utilised in a wide number of industries, including the highly demanding wind turbine industry.

A multitude of these magnets are bonded together to increase the overall level of magnetism. This process leads to two potential issues: Firstly, any adhesive or coating between the magnets acts as an air gap and thus reduces the level of magnetism and secondly NdFeB magnets corrode extremely aggressively. This corrosion issue is exacerbated by the environmental conditions that the wind turbines face.

The corrosion mechanism for NdFeB magnets is detailed in Figure 1. This shows that when exposed to water or humid conditions, the Neodymium rich layers at the grain boundaries react to form Neodymium Hydroxide. The effect of this conversion from Nd to Nd(OH)3, is a large

volume increase along the grain boundaries, leading to cracking and degradation of magnet properties.

Curtiss-Wright Surface Technologies (CWST) has been working on a solution to these issues. This involved developing a high grade anti-corrosion coating with minimal coat thickness (effective air gap).

The current market leader for corrosion protection is CWST’s own Everlube 6155 providing 500 hours protection in the ASTM B117 salt spray test.

After extensive studies and trials, CWST is pleased to announce they have successfully developed a coating system which will provide 1,000 hours salt spray resistance for NdFeB magnets at a coating thickness of just 25um. This NEW coating system – Everlube 1155 is environmentally friendly, easy to apply and a cost effective solution to this critical problem. Please call on +44 (0)1386 421444 for further details.

Nd rich phase

Exposure to humidity or salt spray

Nd2Fe14B

Thick Grain Boundaries

E/M Coating Services are a business unit of Surface Technologies, a Division of Curtiss-Wright, who are global specialists in surface treatments to improve the life and performance of critical components and preventing premature failures through their network of over 75 facilities worldwide. www.cwst.co.uk

Thin Grain Boundaries

Figure 1: Shows the corrosion mechanism for NdFeB rare earth magnets.

Nd(OH)3

Exposure to humidity or salt spray

E/M Coating Services Curtiss-Wright, Enterprise Way, Vale Industrial Park, Evesham, Worcestershire WR11 1GX, UK l Tel: +44 (0)1386 421444

For more information on all our services and full worldwide contact details: www.cwst.co.uk

EDITOR’S CHOICE

BLH NOBEL’S G5 ELECTRONICS BLH NOBEL

THE VERY LATEST ADDITION TO THE G5 RANGE

The G5 series is the latest generation of BLH Nobel weighing instruments. BLH Nobel is a global leader in the process weighing force measurement market and a brand of Vishay Precision Group, Inc. (VPG). The G5 series are all built on a new, future-proof hardware platform, the units feature extensive communication capabilities to support a wide range of applications in chemical, food and pharmaceutical industries and are also used in factory automation and high dynamic force systems.

BLH Nobel’s G5 electronics are now available in three different mounting options: a panel mount version for 24 V DC or 115/230 V AC operation, a DIN Rail mount version and DIN Rail mount with OLED display for 24 V DC operation. The new G5 DIN Rail Mount with Display (G5-RMD) offers a user interface for quick and easy set up and visibility of live process data such as weight and status interface – in the plant, right where the operator needs it.

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PECM Issue 40

The web server embedded to any product version enables remote operation from any PC or mobile device with Ethernet connection.

Weight and status are displayed alongside other parameters and diagnostic information via a HDMI or user-friendly operator interface.

The G5 family of instruments offers many industrial communication interfaces, including Modbus/TCP, Ethernet/IP, FTP, HTTP, ProfibusDP, PROFINET, DeviceNet, ControlNet, and Modbus RTU as well as the traditional RS485 and analog outputs. The user can configure the G5 digital I/O signals according to his discrete control requirements.

Software upgrades can quickly be made in the field using an SD card. Parameter backup and restoration is made easy via the G5’s USB port, SD card, and internal memory.

The G5 and G4 instrument families are fully compatible with BLH Nobel’s manufactured load cells, weigh modules and junction boxes to create complete weighing solutions or integrate with larger process systems.

Our unique Double Cantilever shear beam load cell modules are simple to install, rugged, insensitive to side loads, extremely accurate and feature a moveable load point.

Plus all are available as ATEX versions and offer special cable adaptions for high ingress environmental protection levels. Our weigh modules and load cells come with a range of certification including FM approval, IECEX, OIML, CSA, NTEP and for certain applications SIL/PL capability as part of a safety critical system.

BLH Nobel load cells are also used for force measurement in the paper and steel industries as well as aerospace and onboard offshore platforms and vessels. Force measurement of paper and sheet steel as it is rolled during manufacture is critical to monitor consistency, accuracy in aerospace manufacturers testing engine thrust and durability in offshore cable and pipe laying applications monitoring tension in telecoms and electrical cables.

BLH Nobel offer a variety of load cell designs from single and double shear beams, S-beam, pancake and canister load cells to cover wide industry and application needs. BLH Nobel is your reliable partner to engineer the best solution tailored to your specific requirements!

Please visit our web site at blhnobel.com or contact us at blhnobel.uk@vpgsensors.com

The KIS technology advantage - virtual insensitive to:

Vibration from agitation

Thermal expansion

Twisting moment caused by agitator Issue 40 PECM

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EDITOR’S CHOICE

FASTER TOOLING & ASSEMBLY 3DPRINTUK

THE EXTREMES OF ADDITIVE MANUFACTURING When Norway based Kongsberg Maritime, a specialist in technology for use in extreme conditions, was designing a chassis for a subsea measurement instrument, it turned to 3DPRINTUK to help with the manufacture of key components. MEPCA found out more.

Kongsberg Maritime is an international technology group working in the maritime, defence, aerospace and digital sectors.

Kongsberg is at the forefront of pushing technology in extreme conditions, so it comes as no surprise that additive manufacturing has a role in their design process. As additive manufacturing grows and becomes a viable, recognised option for producing custom parts with a finish close to injection moulded parts, more and more design engineers are exploring and adopting selective laser sintering (SLS) technology to produce innovative products. As a result of this growth, the more engineers demand from the technology, the more investment is made to advance the capabilities of the method.

Kongsberg Maritime delivers products and systems to merchant vessels and offshore installations for positioning, navigation, automation and handling systems, as well as products and systems for seabed surveying and monitoring, and fishing vessels and fisheries research. 3DPRINTUK specialise in low-volume production through additive manufacturing and in particular SLS. By 3D printing parts in SLS Nylon P12, and with very few restrictions in design, manufacturers can create components with reduced weight while maintaining strength.

Users of the innovative method save on manufacturing costs thanks to material savings and assembly time reduction. In addition, clever design means that the number of components gets reduced and prototyping that used to take weeks can be done in days, in multiple variations, all branded with unique part numbers.

Robert Kovacs, Senior Subsea Design Engineer at Kongsberg Maritime approached 3DPRINTUK when they started a new project to design a chassis for a scientific subsea instrument used in underwater positioning and mapping. “The part is a multi-functional product chassis, not just a simple bracket to join two things together. It has clever features and functionality that we would not get from a similar metal or injection moulded part,” explained Robert. “The chassis flexes

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PECM Issue 40

extensively to allow a heat shrink sleeve to be placed around battery cells and a PCB, which simplifies assembly tremendously.

To secure the product during transport and handling, a tiny slide-bolt arrangement allows for a zip-tie to be inserted, again greatly saving handling time and reducing risk.”

Small printed extrusions act as standoffs, screw guides and screw anchors which make the whole assembly extremely rigid. Features such as these cost nothing during printing but save greatly on handling, assembly and repair. “Right from the start, deciding to 3D print this pivotal part in a new design meant that we were able to shrink the size of the product while integrating features and functionality that are simply not available through other manufacturing methods,” continued Robert. Robert was also able to save money on the cost of other products by nesting parts.

As well as price breaks for higher quantities, 3DPRINTUK allow users to nest parts around one another to take advantage of any unused space. The smaller the space users take up within the printer, the less they are charged.

Summing up his experience of additive manufacturing, Robert concluded: “I believe that the biggest advantages when 3D printing parts are the time savings thanks to faster tooling and assembly, along with the ability to make far more intelligent parts.

We would, of course, have these features and advantages if this part was injection moulded. But it is not possible to make an injection mould tool with all these features in one part, as it has too many details and undercuts in too many different directions.”

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EDITOR’S CHOICE

MANUFACTURE OF VEHICLE PARTS PAILTON

MOVING BEYOND PROTOTYPES

CAN 3D PRINTING BE USED IN THE MANUFACTURE OF SAFETY CRITICAL VEHICLE PARTS? In the United States, an epic backyard project will see the creation of a life-size, functional Lamborghini Aventador. The car is not entirely 3D printed, but rather demonstrates the impressive potential of 3D printing for the wider vehicle industry. Here, Kostas Poulios, Principal Design and Development Engineer at Pailton Engineering, explains how 3D printing is used in large vehicle manufacturing and whether this method could play a role in the production of safety critical parts.

Outside of novelty projects, like the Lamborghini example, 3D printing is already an important part of vehicle production.

From tooling, parts manufacture, design and prototyping components, the industry is widely considered a pioneer of integrating 3D printing into processes. However, the same cannot be said for the production of safety critical vehicle parts.

Consider the steering system as an example.

Steering systems are put through intense conditions throughout their lifespan, particularly when used in large vehicles like military, utility and HGVs. Each part of the system, including the drag link assemblies, steering and suspension ball joints, and bevel boxes must be able to withstand heavy shock loads. In an ideal world, these systems should also be designed to last.

Due to high shock loads, components for steering systems cannot currently be manufactured with some of the common materials used for 3D printing — at least, not to a useable standard. For instance, Acrylonitrile Butadiene Styrene (ABS), a thermoplastic filament which is regularly used for Fused Deposition Modelling (FDM), does not provide adequate properties for the manufacture of steering system parts.

The material provides good levels of strength and is lightweight but is simply not strong or durable enough to be used in a steering application. Instead, ABS modelled parts are only suitable for rapid prototyping.

An alternative material would be the option of Metal Matrix Composites (MMC), a composite with at least two constituent

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materials. When three or more materials are combined, this is known as a hybrid composite. This option provides much higher levels of strength, as several elements can be combined to improve the materials properties and ensure the part meets its requirements.

For niche steering systems, such as those used in HGVs, construction and military vehicles, MMC can provide designers with an opportunity to expertly engineer the metal their part will be made from, while also reaping the advantages of 3D printing. This includes the potential to topologically optimise parts to maximise their strength-to-weight ratio. This is particularly advantageous when used in combination with other design tools, such as Finite Element Analysis (FEA).

MMC printing could be used to manufacture safety critical parts, like the ones used in a steering system. However, MMCs require the use of Selective Laser Sintering (SLS), the process required to print components from metal powder. Currently, this method can be costly and time consuming for manufacturers to implement, deeming it unsuitable for large production volumes.

Looking into the future, when SLS 3D printers become widely available and more cost effective to use, this may change.

As in every optimised steering system, whether that be an entire unit or individual components, any work outside the conventional manufacturing processes will be more expensive. An exception to this rule would be very low production volumes.

However, these cases are usually undertaken with the intention of larger volume production in the future.

When considering whether to implement 3D printing into parts production, manufacturers must understand that the advantages of that process might not outweigh the initial cost. This is certainly the current case for 3D printing for safety critical parts. However, the method is valuable in other areas of production.

3D printing is successfully used in the design phase of safety critical components.

For example, Pailton Engineering uses a HP DesignJet to create prototype steering system components from ABS, including ball pins, drop arms, steering wheels, suspension joints and forgings.

In these cases, the 3D printed part is not used for production, but is replaced with a production equivalent once the design is finalised.

3D printing is certainly present in vehicle manufacturing. However, it is not necessarily suitable for production of safety critical parts.

Instead, Original Equipment Manufacturers (OEMs) should prioritise using safety critical part suppliers, like manufacturers of steering systems, that use the benefits of 3D printing for prototyping and testing.

At Pailton Engineering, this process provides our highly skilled design and production engineers with a visual representation of steering parts and assemblies.

This helps us to identify issues and improvements before production begins to provide customers with a right first-time solution, every time.

For more information on Pailton Engineering’s steering systems, contact the team directly on +44 (0) 24 7668 0445 or e-mail mailbox@pailton.com.

EDITOR’S CHOICE

DS-OCT12-BLACKFAST_Layout 1 20/09/2012 16:28 Page 1

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Fax: 0208 339 7371 Unit 5 Russell House, Molesey Road Email: sales@blackfast.com Walton-on-Thames, Surrey KT12 3PE www.blackfast.com

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Blackfast’s room temperature blacking process is both safe. easy and convenient to use. The process has been developed for safe and reliable use in metal working facilities, so it is no longer necessary for parts to leave the production site for finishing by an outside contractor.

Unlike conventional methods of blacking it is non-hazardous.

Blacking of iron and steel provides a corrosion resistant finish without dimensional change.

This is attractive for machined parts manufactured to tight tolerances. where plating or painting would not be acceptable.

As it is very important that the components are clean and free from grease before using the blacking process, Blackfast also offers a range of degreasers from solvents to water based and rust removers.

020 8339 7370 www.blackfast.com

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.

 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.

www.gfps.com/uk @gfps_uk

Issue 40 PECM

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EDITOR’S CHOICE

STRONGER TOGETHER TROY

TROY MANUFACTURING GROUP ANNOUNCE NEW STATE OF THE ART MANUFACTURING FACILITY

Troy Manufacturing Group are pleased to announce the new Troy Manufacturing Facility is now open and fully functioning. The facility itself boast 26,583 sq. ft of state of the art workshop and office space. The site is situated in Baglan, Near Port Talbot; South Wales, with close links to the M4 for easy access and delivery to their customers. The facility has been fully refurbished, with the latest resin workshop floor, LED lighting throughout, shop floor welfare facility and locker room, optimised office layouts along with a visitor centre and board room.

Troy Manufacturing Group have over 105 machines across various CNC milling & 5 Axis, CNC turning, high spec grinding, wire and spark erosion, high accuracy custom tool grinding and many types of manual machines.

The team has a wealth of combined knowledge across the 47 staff members, which includes 25 highly skilled toolmakers, design engineers, mechanical installation fitters and project managers. They offer a wide range of services including detailed specification of concepts, with design and manufacture of special purpose machinery.

The site runs on twin shift basis with the scope to increase capacity as required, enabling the flexibility to fulfil orders based on any

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individual customer’s needs. The team’s industry knowledge; combined with the facilities state of the art machinery enables them to produce almost any component which has given the them the opportunity of working across a variety of engineering sectors including coin, medical, automotive, oil & gas, food & packaging, aerospace, rail and general machining.

They currently work under ISO 9001:2015 accreditation. The company prides itself on a quality product delivered on time. Over the years they have built up strong working partnerships designing and producing components for some of the top names in manufacturing. Their commitment to producing the best possible product and to helping their customer’s engineering visions

be brought to life can be demonstrated with many previous customers testimonials.

If you would like any more information, please contact Andrew Snell; Head of Troy Manufacturing Group.

Tel: 01792 862141 Andrew.Snell@bawengineering.co.uk

Manufacturing Group

EDITOR’S CHOICE

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Eliminate the need for expensive data acquisition systems and highly trained reliability engineers with a cost effective ATEX and IECEx certified condition monitoring system.

www.machinesentry.com

Issue 40 PECM

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EDITOR’S CHOICE

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

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PECM Issue 40

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

EDITOR’S CHOICE

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Our understanding and collective experience means we can create bespoke solutions for the most complicated industry issues.

If you’re looking for advice or need an issue solving, give us a call or email us!

Tel (+44) 1332 835001 28

PECM Issue 40

admin@mwpolymers.co.uk

www.mwpolymers.co.uk

EDITOR’S CHOICE

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.

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 40 PECM

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EDITOR’S CHOICE

UV CURE-IN-PLACE TECHNOLOGY HERNON MANUFACTURING

HOW TO USE CURE-IN-PLACE GASKET TECHNOLOGY TO IMPROVE OIL SHAFT SEAL PRODUCTION UV Cure-in-Place (CIP) gasketing technology was created to replace an inferior sealing process for automotive oil shaft seals or rotary seals. Direct contact with the shaft is secured using a rubber gasket while the exterior of the seal, where it meets the housing, has traditionally been sealed using a solvent based sealant. Solvents have well-known problems with toxic fumes and material loss due to evaporation.

By contrast, UV CIP does not use any solvents. Instead, it is designed to be cured by UV LED curing lights, built by Hernon®.

These lights are optimized to a specific wavelength for the sealant.

Once cured, the bead for this application is soft and tack free, allowing the seal to adjust its form to fill the gap between gasket and housing.

The dispensing and curing system for this sophisticated application was developed by Hernon Manufacturing as part of their Total Solutions approach. Hernon® experts coordinate mechanical engineering capabilities with precision chemistry to ensure a copacetic application process.

The journey of components through the machine starts with an inbound conveyor where intelligent sensors track part locations.

The sensors communicate to robotic arms when parts are ready to enter active stages. The steel components are picked up using simple permanent magnets. This method reduces the complexity of moving parts from stage to stage when compared to pneumatics or electromagnets and keeps energy usage to a minimum. The seals are first moved to a dispensing station where a robotic spindle arm rotates the seal under Hernon’s proprietary SureShot® 3000 valve.

The valve dispenses sealant onto the spinning seal creating a controlled bead. With the bead in place, parts are moved to a UV curing station. To protect users, the parts are inserted into a protective housing before four high intensity UV LED lights cure the bead for specified exposure times. The final stage is a laser inspection where the bead location and width are analyzed. The bead is also checked to be smooth and contiguous. If the finished part meets all specifications it is transferred to a conveyor out of the machine.

When oil shaft seals come off the outbound conveyor, they can be instantly used or packaged. Parts are processed at speeds of 12-15 parts per minute, depending on the size of the seal. The larger the size, the longer dispensing and curing times needed.

With no solvents used in the new CIP sealant, production is more environmentally friendly, sustainable and much less messy.

Enquiries about UV CIP materials or application processes can be submitted at Hernon.com, emailed to sales@hernon. com or placed via phone at (888) 473-0217.

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EDITOR’S CHOICE

CONTROLLING HUMIDITY HUMIDITY SOLUTIONS

KEEPING RH IN ITS PLACE

Effective humidity control is a necessity for all work environments and is particularly important in many industrial environments, says John Barker of Humidity Solutions In any indoor environment, controlling humidity is essential for protecting the health of occupants and the building fabric.

In an industrial environment, poor humidity control may also impact on productivity and profitability, so there are strong commercial reasons for taking control.

In terms of measuring humidity, we use the term ‘relative humidity’ – or RH - to describe the relationship between the temperature of air and the amount of moisture it can hold. In most industrial environments the RH should be maintained between 40% and 60%.

Humidity Solutions is the UK’s leading independent specialist in humidity control, designing, installing and maintaining humidification and dehumidification systems for a wide variety of industrial and commercial applications. The company is a distributor for humidifiers and dehumidifiers from some of the world’s leading manufacturers and, since April 2019, has been the exclusive UK distributor for the

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PECM Issue 40

West Midland manufactured Vapac range of electrode boiler steam humidifiers.

The strength of this range is reliability and return on investment, with user friendly accessibility and flexibility of installation. Inroom and in-duct options allow the humidifier to be installed into almost every industrial and commercial application.

Rob Luddington, Humidity Solutions’ After Sales Director stated ‘The number of Vapac units installed across the country is testament to the quality and to the ease of maintenance of the humidifier. Vapac is the industry word for electrode boilers and we have certainly found them to be reliable and a great unit for HVAC applications.’

Humidity Solutions provide their own service solution, or are happy to support contractors with technical advice, spares and new units. One of these is Independent Humidity Services, whose director Mick Lillywhite looks after and maintains many Vapac humidifiers on sites including Cumbria Constabulary and The Dean Gallery in Edinburgh.

Mick stated ‘reliability is essential for my customers to ensure that the air that

they are conditioning is kept within the specified parameters. For me the most important thing is the ease of maintenance and the Vapac units certainly tick both of these boxes.’

Humidity Solutions add the reliability of supply with a large stock of spares and units held in our warehouse in Leatherhead, plus technical support either for the design of a new system or assistance when advice may be required post sales. www.humiditysolutions.co.uk info@humiditysolutions.co.uk

EDITOR’S CHOICE

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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• Exclusive distributor • The only British made steam humidifier • UK stocked spares & units with fast delivery • Design, supply & installation services • Full after sales backup, support & maintenance 01372 571200 www.humiditysolutions.co.uk Issue 40 PECM

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EDITOR’S CHOICE

PROMOTING UPTIME ROTAMEC

ROTAMEC REWIND SERVICE HELPS A LEADING BREWERY TO KEEP ITS FIZZ

Compressors are utilised in the production process to carbonate beverages with this gas, performing a vital role in the plant.

[Source: istock - Portra ID:641999556]

Ensuring redundancy in large scale manufacturing operations is key to any plant manager’s peace of mind. In the beverage industry, where processing speeds are high and profit margins per unit low, securing redundancy is especially important towards promoting uptime.

One world famous brewery has turned to Rotamec, an electro-mechanical service provider to industry, who secured its production line by carrying out a specialist motor rewind and refurbishment within seven weeks.

CO2 is what makes drinks fizzy, and is all important in providing a desirable ‘head’ on a glass of beer. Compressors are utilised in the production process to carbonate beverages with this gas, performing a vital role in the plant. Without a running back up compressor to step in seamlessly during issues with the primary compressor, production uptime is at greater risk.

So, when a leading brewery found that the 500kW motor powering its on-site compressor back up had failed, the business required an urgent motor repair and refurbishment to minimise the chances of downtime. With reference to pre-existing maintenance schedules, while balancing adequate time for a quality repair with ensuring manufacturing security, a timeframe of seven weeks was settled on by the brewery.

After contacting several motor specialists that could not fulfil the project requirements, Rotamec was selected. The business was not only able to service the motor within the seven week timeframe, but also provide a cost advantage.

Rotamec has been providing high quality motor rewinds and repairs to industry since 2000, operating state-of-the-art workshop facilities in Cheddar, South Wales and Exeter to ensure a responsive UK service. In fact, the business operates 24/7, 365 days a year to support the needs of its customers.

Engineers undertake in-house training provided by leading motor manufacturers, so can quickly familiarise with customers’ motors for a speedier repair.

Alan Brooks, Branch Manager for Cheddar at Rotamec, remembers the project well:

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PECM Issue 40

When a leading brewery found that the 500kW motor powering its on-site compressor back up had failed, the business required an urgent motor repair and refurbishment to minimise the chances of downtime.

“In terms of this customer, we were required to rewind the motor and carry out a general overhaul. The challenge was that the motor featured pre-formed coils, which are not the most common type. We therefore had to source these coils quickly before we could begin the rewind. Luckily, we have a wideranging capability with regards to specialist motors, which meant we could solve the issue. Ultimately, we were able to return the now refurbished motor within the sevenweek deadline, which was a challenge that our breadth of expertise ensured we could meet.”

Once the motor was re-installed, the beverage manufacturer again had access to a compressor redundancy. As a result,

production uptime was effectively safeguarded to ensure productivity and profitability. Backed by the highly responsive 24/7 Rotamec service, the manufacturer also has access to the support required for continued high speed, large scale manufacturing in the long term.

Alan concludes: “I am very proud that the team could conduct this specialist motor rewind to schedule, despite the challenging coils. Not every supplier can achieve this, but thanks to our capability with regards to motors of all types, it was a challenge we could meet effectively and efficiently.” www.rotamec.com

EDITOR’S CHOICE

Engineering Services Fabrication Welding Machining Painting Assembly NDE

Marine Loading Arms Precision Engineering Swivels Spare Parts Global Life Cycle Support

Installation Inspection

For more information contact:

sales@woodfieldsystemsltd.com

www.woodfieldsystemsltd.com Woodfield Systems Ltd, Tyler Way, Whitstable, Kent CT5 2RS United Kingdom Issue 40 PECM

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EDITOR’S CHOICE

ENERGY SOLUTION AGGREKO

AGGREKO LAUNCHES BRIDGING GAP DECENTRALISED ENERGY SERVICE

Manufacturers can now start the process of implementing a decentralised energy solution to their facilities, after Aggreko officially launched its bridging gap service.

Following the recent growth in UK manufacturing, companies need to ensure that their energy supply is reliable to fulfil increasing orders. The UK’s demand for mains grid power is expected to outstrip supply by 2026, meaning manufacturers need to start looking at generating their own energy.

One option, which is particularly relevant for industry, is combined heat and power (CHP), allowing manufacturers to make significant savings by harnessing the waste heat that is generated, resulting in reliable, cost-effective energy.

Aggreko’s offering, which is a first in the rental market, comprises of three main products: gas generators; CHP packages; and battery storage. All available to hire, the solutions enable companies to adjust power needs to suit current demand, delivering greater efficiency and cost savings.

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PECM Issue 40

The new service means UK industry can immediately reap the benefits of decentralised energy, breaking down the barriers put in place by the significant capital investment required for a reliable source of energy. Avoiding the high up-front costs, companies utilising the new service can start work on building a permanent off grid solution for the future.

One of the key benefits of the Aggreko decentralised energy solution is that it enables organisations to keep pace with the latest technology, therefore mitigating the risk against technical obsolescence. The hire solution can also save manufacturers up to 80 per cent of the lifecycle cost, as there is no need to pay for any running costs.

The new proposition follows Aggreko’s recent report, which found that cost, technical resource and impact on production were key barriers to implementing a decentralised energy solution. Based on a survey of 200 UK energy decision-makers across industry, many respondents remain reluctant to actively consider alternative methods of generating electricity.

Chris Rason, Managing Director of Aggreko UK, said: “We truly understand the dilemma facing UK industry when it comes to decentralised energy. Our recent survey showed us, and the UK, that there is appetite to implement the technology but there are clear barriers in the way.

“Our unique service allows UK industry to end their reliance on the grid, while provides an opportunity to save and prepare for a full decentralised energy model. One of the key benefits is that you keep up-to-date with the latest technology advancements, meaning your energy won’t be outdated.

All of this can be implemented without the heavy installation costs and CAPEX restraints, as the rental includes operation, set-up and management of the service.”

The decentralised energy solution is available now, with Aggreko’s customer service team available to discuss tailored applications.

For more information, please visit www.aggreko.com/energy.

EDITOR’S CHOICE

UVC Sterilisation - Clean, Dry & Effective Sanitising

Hultafors NEW Range of ‘Snap-Off’ Knives

The New Desoutter Transducerised Nano Driver

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, chemicalfree 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 and fully submersible immersion systems ideal for sterilising water tanks and cooling towers.

Precision, quality and long-lasting sharpness are the hallmarks of these superb new products.

Hultafors Tools has launched a new range of ‘Snap-Off’ Knives for professional craftsmen and women. With 13 different knives and 4 long-lasting precision blades, these all-round, ergonomic knives are designed and built to suit a wide range of jobs on site. From industrial and warehouse applications to specialist work on site – from like cutting boxes open and shaping plasterboard, to trimming flooring and paring cables. Symmetrically designed so that the blades can turned over, they’re adaptable for both left and right hand use so that left handed craftsmen and women can adapt the knife rather than their own usage.

What’s more, the blades are available in three widths of 9, 18, and 25mm, with different blends of sharpness and long life built in to suit regular hard work on site.

This innovative transducerised electric screwdriver can deliver torque between 2.82 N•cm and 80 N•cm across three models.

The Nano Driver is equipped with a newly developed seating detection function ensuring each fastener is applied perfectly, without causing damage to the host material. This is particularly useful when working with delicate or brittle materials.

Since accurate repeatability is safety critical, the Nano Driver is second to none with its internal transducer. It measures and controls the torque and allows for production communications protocols, such as, Fieldbus, Profinet, and Modbus. Information from the Nano Driver is integrated into existing data capture systems; ensuring all production parameters are fully traceable.

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

www.hultafors.co.uk 01484 854788

Corporate Courses – RRC RRC have over 90 years experience of delivering health, safety and environmental training worldwide. We have extensive experience delivering corporate training for an impressive portfolio of clients from differentiating industries including: Diageo, Kinross, Petrogas and Tetrapak. Contributing positively to a business’ ability to work safely is something we pride ourselves on.

We tailor our courses and consultancy according to our clients specific needs.

We have offices and partners in over 20 countries – so we can support your HSE training needs no matter the location. RRC has developed over 50 health, safety and environmental management courses. Many of these have been accredited by all of the leading UK awarding bodies - NEBOSH, IOSH, City & Guilds, CIEH, CITB and IEMA. With many courses already provided in a range of languages including English, Arabic, French, Spanish, Turkish, Georgian and Russian and other languages able to be accommodated, we are your ideal global HSE corporate training provider. www.rrc.co.uk

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PECM Issue 40

Major expansion delivers biggest facility in Yorkshire A leading galvanizing business has completed a major expansion that increases capacity by 50 per cent. Humber Galvanizing Ltd has installed a new bath to create the biggest facility of its kind in Yorkshire.

It has also extended its yard, installed new ‘triple acid’ tanks and made a string of changes to improve health and safety in a multi-million pound project. The new galvanizing bath is 7.5m long, 1.2m wide and 2.7m deep.

General manager Richard Speake said: “This is a major investment that will increase the number and size of jobs we’re able to do. It will ensure we’re ‘Fit for the Future’ and provides the platform from which to grow even stronger.”

Contact Richard Speake Humber Galvanizing Ltd Tel: (01482) 322466 Email: Richard.speake@wedge-galv.co.uk

Tel No – 01442 838999 website www.desouttertools.com /www.desouttertools com/?s=nano+screwdriver

A new sales brochure presents the Cistermiser infrared urinal control valve Cistermiser’s market-leading IRC® infrared urinal flushing control valve is fully detailed in an informative new sales brochure, designed for ease of use by specifiers, installers and merchant counter staff. Fitted together with a robust and proven brass-bodied solenoid valve assembly, the IRC® sensor now features a compact body shape, an economy mode option to provide even greater water savings, a new-style mounting bracket for recessed installations and an improved design which allows clients to replace batteries in convenient fashion by simply removing the front fascia to access the battery compartment. The IRC® employs motion-sensing infrared to automatically control the flushing of cistern-fed urinals, minimise water wastage and ensure compliance with Water Regulations. When the PIR sensor detects movement, the solenoid valve is activated, allowing water into the cistern. ourworldiswater.co.uk

hygienic furniture & equipment

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ADVANCED ENGINEERING SHOW PREVIEW

MANAGING UNCERTAINTY ADVANCED ENGINEERING

WHAT COMPANIES ARE DOING TO DRIVE POSITIVE CHANGE The current economic climate in the UK has created some uncertainty. Despite this, UK businesses have been resilient in the face of adversity and many are creatively leading innovation in the engineering sector. Here, Jeremy Whittingham, Head of Marketing at Advanced Engineering, the UK’s leading industrial trade show, explains five ways businesses are managing uncertainty.

1. SPEED UP INNOVATION

The speed at which businesses innovate can take a hit during uncertain times.

Capital investment is likely to fall, decision making on new projects can stagnate and new product lifecycles can elongate.

However, for forward-thinking organisations, the need to innovate and invest in research and development (R&D) becomes even more crucial during tough times. For Xi Engineering, a digital twinning expert who helps its customers speed up innovation, this is exactly the case.

“We work with businesses across the globe to solve engineering problems, in sectors such as high-end audio, automotive, renewable energy and transport” explains Mark-Paul Buckingham, Managing Director of Xi Engineering.

“We offer services like simulation and accurate modelling to help our customers trial innovations that would take longer if done manually. Our customers benefit from reduced development time, a reduction in product cost and a decrease in the number of product changes required during manufacturing. This gives our clients the ability to launch products more quickly to market without the roadblock typically associated with engineering product development.”

2. DIVERSIFY YOUR SECTOR OFFERING

In the battle to compete against their rivals, many businesses can become highly specialised in their product and sector offering. During times of uncertainty, it can be wise to step back and consider sectors where your products and specialisms could offer transferrable benefits.

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As global engineering company Renishaw has found, this strategy can yield surprisingly good results and has helped the business double its employee numbers to 5000 people in just eight years.

“Our success lies in the fact that we have diversified in so many sectors,” explains Jonathan Archer, General Manager for UK sales at Renishaw. “For example, in the medical sector, we’ve used our additive manufacturing expertise to produce some truly ground-breaking implants that would otherwise be impossible to make.

“What we learnt was that, ironically, the challenges that engineers face in the high-precision industrial sector are not too dissimilar to those faced by dentists and surgeons in the medical sector. So, being able to think laterally and applying your expertise in non-traditional sectors is key.”

3. INSPIRE CUSTOMER LOYALTY

It’s not just business strategy that can be affected during times of uncertainty; relationships can also take a negative hit.

That’s why it’s important that businesses build closer ties with their customers and

their own supply chains to mitigate risk.

That’s what Kawasaki Robotics UK did when its customers were uncertain about investing in automation technologies. The company, which forms the UK division of Kawasaki Heavy Industries Japan, turned to education to help strengthen its customer relationships.

“Market uncertainty has led many customers to be cautious about investing in new digital technologies,” explains Ian Hensman, Sales Manager for Kawasaki Robotics UK. “This stems from a wider uncertainty about the benefits of automation technology and how they’ll work alongside the human workforce.

“This is an ongoing issue and one that we really have to help our customers overcome. We’re doing this by educating and supporting our customers more closely on how they can integrate digital technologies in a variety of applications such as welding, material handling, painting and small parts assembly. In particular we’ve used our latest collaborative robot product to demonstrate how automation can work alongside human workers.”

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4. JOIN FORCES

As the saying goes, “if you can’t beat them join them”. This can prove to be a powerful move to overcome uncertainty and is exactly what Atlas Copco did when its Motor Vehicle Industry business division faced the challenge of rising demand in the electric car sector.

“Atlas Copco’s Industrial Technique division has merged its Tools and Industrial Assembly Solutions business areas together, to create an innovative joining partner for manufacturers,” explains Clive Sharp, Business Line Manager for Atlas Copco’s Motor Vehicle Industry business division. “With products and expertise for all assembly applications, including adhesive dispensing, riveting, flow drill fastening, battery joining, sealing and quality inspection, we can meet future market demand, in particular within electric vehicle assembly.”

5. EXPLORE NEW GEOGRAPHIC MARKETS Where some may see uncertainty, others see opportunity. Export markets can inject a fresh lease of life to your existing product offering, with demand from new customers and new industry sectors.

At a time when many businesses were considering leaving the UK, Swedish automation specialist Novotek decided to enter the UK market. Acquiring Glasgowbased Kerrco Automation Ltd, it created Novotek UK and Ireland, and became the

sole distributor of GE Digital products in the region.

“In the UK, Novotek saw the potential to develop this market from an automation perspective,” explains George Walker, Managing Director of Novotek UK & Ireland. “Our goal is to modernise British manufacturing, using edge-computing hardware to help manufacturers gain better insights, improve productivity, and ultimately become more profitable.”

To read the full interviews with the

companies we’ve mentioned above, download Advanced Engineering’s Voice of Industry report – a look at overcoming uncertainty. To find out what’s being demonstrated at this year’s Advanced Engineering exhibition, which takes place at the National Exhibition Centre in Birmingham between 30–31 October, 2019, visit the website today.

www.advancedengineeringuk.com Issue 40 PECM

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30 & 31 October 2019 | NEC, Birmingham

The UK’s largest annual gathering of engineering supply chain professionals 15,000 engineering professionals in attendance

"I found the event a great networking opportunity to meet industrial professionals from different backgrounds with different products."

Kat Clarke, Wing Manufacturing Engineer, Airbus

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ADVANCED ENGINEERING SHOW PREVIEW

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.

Small Production Runs

EMBEDDED SOFTWARE TO POWER THE FUTURE Software is the life blood of the future. Artificial Intelligence, Industry 4.0, the Internet of Things, smart cities and robotics all require safe and secure software.

Harmonic Software Systems have been providing software development services and consultancy to our customers for over 20 years, giving them the edge they need when developing embedded systems. From securing IoT devices, developing bespoke

software, implementing AI and machine learning, to certifying and testing avionic systems, our engineers apply the latest agile software development processes and cutting edge development tools to help you cut costs and deliver on time, every time.

If your company is looking to the future then contact to us to find out how we can help you.

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.

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There is sure To be MAKA Know-how on boArd AgAin. MAKA – your technology partner for 5-axis CNC cutting systems from wood across composites to aluminium.

Sophisticated, individual manufacturing systems have been our core competence for more than 60 years.

Regardless of the industry you are active in – on the basis of our globally tried-and-tested machine portfolio, we develop a solution together with you. Perfectly customised to your requirements, innovative and reliable. Turn our creativity into your success. Talk to us.

MAKA Machinery uK Ltd. C5 Horton Park IE., Hortonwood 7, Telford Shropshire TF1 7GX Tel: 019 52 - 60 77 00, Email: iy@makauk.com

come and see us at stand K118 www.maka.com

CNC Spezialmaschinen

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ADVANCED ENGINEERING SHOW PREVIEW

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 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.

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 Exhibiting at Advanced Engineering Stand K90

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ADVANCED ENGINEERING SHOW PREVIEW

MECMESIN SET TO SHOWCASE OMNITEST™ MATERIALS TESTER AND VECTORPRO MT MATERIALS TESTING SOFTWARE AT ADVANCED ENGINEERING 2019 Mecmesin, a British company specialising in force, materials and torque testing equipment, will demonstrate their OmniTest materials tester driven by their state-of-theart VectorPro MT materials testing software at the Advanced Engineering Exhibition in October 2019.

Designed to meet the diverse needs of both R&D laboratories and quality assurance environments, this new generation of material testers offers enhanced performance and excellent value for money.

On show will be the OmniTest 5 kN single-column tester, which is designed to accommodate tall specimens and has enough travel to measure the tensile strength of the most elastic of materials.

Mecmesin will also be demoing a dualcolumn benchtop OmniTest 25 kN system, designed for testing larger, higher strength samples.

The OmniTest is the ideal solution for performing static tensile and compressive tests to measure the mechanical properties of a wide range of materials, including plastics, rubbers and elastomers, metals, composites,

fabrics, glass and ceramics. Quantitative results for tests such as tensile strength and compression forces on materials are generated with a high degree of repeatability - essential aspects for effective quality control.

The OmniTest has a simple-to-use front panel for selection of test parameters, live load and length readings and precise manual crosshead positioning using the multifunction controller. Coloured LEDs indicate machine status during testing.

The OmniTest incorporates state of the art electronics and a range of high-resolution precision Enhanced Load Sensors (ELS). Load accuracy is 0.5% rdg with a resolution of 1:50000, allowing a wider range of tests to be performed without the need to select a different load sensor.

The system can be supplied with or without an extensometer depending on the customer’s actual testing requirement.

Event information Date: 30 - 31 October 2019 Location: Hall 3 at the NEC, Birmingham Mecmesin’s stand: J56

Mecmesin Limited Tel: +44 (0) 1403 799 979 Email: info@mecmesin.com Web: www.mecmesin.com

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ADVANCED ENGINEERING SHOW PREVIEW

THE FINAL PROCESS FRONTIER ZEEKO

AUTOMATED PRECISION POLISHING ON YOUR CNC MACHINE – THE ZEEKO ZEPHYR PROGRAMME

Zeeko may not be the most famous name in manufacturing engineering – 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 polishing is particularly difficult. So the news that Zeeko has developed a high removal

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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

NORTHERN MANUFACTURING SHOW PREVIEW

PROCESS INDUSTRIES NORTHERN MANUFACTURING & ELECTRONICS 2019

THE NORTH’S FOREMOST MANUFACTURING TECHNOLOGY AND ELECTRONICS SHOW Northern Manufacturing & Electronics, the North’s foremost manufacturing technology and electronics show, returns to EventCity, Manchester on October 2nd and 3rd. With around 250 companies expected to take part this year, an anticipated 3,000 visitors can expect to see a good number of familiar faces, plus some exciting new companies taking part for the first time.

Process industries are a hugely important component of the North’s substantial manufacturing activity, supporting a thriving regional eco-system of specialist vendors of both components and engineering services. Located bang in the centre of this most productive of the UK’s manufacturing regions, Northern Manufacturing & Electronics provides a unique marketplace for engineers, industrial management and procurement professionals to do business. Since the first event six years ago, Northern Manufacturing & Electronics has become well-rooted amongst the region’s engineering community. And, as the most important industrial exhibition in the North West, it also appeals to plenty of the world’s best-known machinery producers.

Live demonstrations of all the most recent solutions from 5-axis machining to laser cutting and advanced manufacturing technologies such as 3D printing give visitors a great opportunity to see the hottest new products from companies such as Haas Automation, XYZ Machine Tools, Stratasys and many others.

Nearly half of visitors typically have components at the top of their procurement shopping lists, and anyone travelling to Northern with these intentions this year won’t be let down. Examples of the products and solutions on display for 2019 include membrane keyboards from Calman Technology, TFT LCD displays from Crystal-Tech Electronics, pressure sensors and transducers from ESI Technology.

Luso Electronics will present a range of power supply solutions from its global portfolio of manufacturers. Highlights include the newest modular configurable units from Excelsys, including the leading edge fanless design CoolX range. Other popular products being showcased include the complete range of Efore and Delta Electronics industrial and medical PSU’s, a range of medical and rail-specific models

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from P-Duke, the 1U high-efficiency range from N2Power and high voltage models from HVM. There’s also custom enclosures from CDT and rugged connectors and cable assemblies from Fischer Connectors, intended for applications, where signals, high speed data and power need to be delivered with 100% reliability even in extreme conditions.

Regular exhibitor igus UK returns for 2019, with its well-known energy chains, bearings, linear guides, flexible cables, stock bar and stock plate materials. Igus’ maintenanceand lubrication-free products are designed to cut costs and increase the service life of modern machinery by offering enhanced corrosion, wear, environmental and debris resistance over traditional materials.

Optimas Components will highlight its vast range of C-class components, including plastic and metal fasteners, caps and plugs, PCB accessories and cable management products. The company now also provides a range of personal protective equipment (PPE), work wear, tools and safety products within its maintenance, repair and overhaul (MRO) product offering.

The exhibition is supported by the two main regional aerospace and automotive business bodies, the North West Aerospace Alliance (NWAA) and the Northern Automotive Alliance (NAA), alongside a number of other

important national bodies, for example Composites UK, the SMMT, the GTMA, the BGA and the CBM. Each will bring a great deal of specialised knowledge and expertise to the show, providing both a highly-approachable industry resource and the knowledge-sharing opportunities of the show’s popular free technical seminar programme. Spanning a busy two-day programme, a roster of high-calibre speakers including award-winning authors and academic authorities as well as experts from industry and trade associations, will tackle a wide range of technical and business topics.

As with the event itself, admittance to the seminar sessions is free of charge of charge, which makes this an excellent chance to hear world-class speakers discuss the most topical ideas in manufacturing, engineering and industrial management. A full list of sessions can be found on the show’s website www. industrynorth.co.uk

Admittance to Northern Manufacturing & Electronics 2019 is free of charge and EventCity offers 3000 free on-site car parking spaces, with easy access by road or public transport. To register online for tickets, simply visit www.industrynorth.co.uk

EventCity | Manchester | M17 8AS

2nd | 3rd OCTOBER 9.30am – 4pm (3.30pm close Thurs)

Northern Innovation and Technology in Action

FREE SEMINARS & PARKING

OIL & GAS

Over 300+ national and international suppliers will gather in Manchester this October for Northern Manufacturing & Electronics 2019 together with the RoadRailAir event. The exhibition will feature live demonstrations and new product launches of machine tools & tooling, electronics, factory & process automation, packaging & handling, labelling & marking, 3D printing, test & measurement, materials & adhesives, rapid prototyping, ICT, drives & controls and laboratory equipment.

Free industry seminar programme online @ www.industrynorth.co.uk The exhibition is free to attend, free to park and easy to get to. Doors open at 9.30am on Wednesday 2nd October.

Pre-register online now for your free entry badge and show preview at

www.industrynorth.co.uk

DEFENCE FOOD & DRINK A U T O S P O RT MARINE A E R O S PA C E PA C K A G I N G LOGISTICS ELECTRONICS A U T O M AT I O N ROBOTICS MEDICAL COMPOSITES S PA C E E N G I N E E R I N G RAIL T R A N S P O RTAT I O N

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

Supported by:

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NORTHERN MANUFACTURING SHOW PREVIEW

INDUSTRIAL FASTENERS TR FASTENINGS

TR TO SHOWCASE EXPERTISE AND PRODUCTS AT NORTHERN MANUFACTURING AND ELECTRONICS 2019

TR Fastenings, the global specialist in the design, engineering, manufacture and distribution of industrial fasteners and Cat C fastenings, will be exhibiting at Northern Manufacturing & Electronics 2019, which takes place from the 2nd-3rd October 2019 at EventCity in Manchester.

Northern Manufacturing and Electronics is ‘one of the key marketplaces for industrial technology, components and engineering services in the North, and an un-missable event for the region’s manufacturers and their associated supply chains.’

TR engineers, manufactures and distributes industrial fasteners to OEMs and Tier 1 suppliers in sectors ranging from automotive, electronics and domestic appliances, and has 32 global locations including 8 manufacturing sites. The continued investment in equipment, resources and skills in these facilities enables the development of innovative fastening solutions, such as the newly launched TR patented EPW screw, a self-extruding thread-forming screw designed for use in thin sheet metal. TR also supports emerging sectors such as Electric Vehicle (EV) charging and EV battery (EVB) technology

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with its combination of fastener product ranges and industry expertise.

At Northern Manufacturing, TR will be exhibiting a full range of industrial fasteners, including its own branded fasteners for sheet metal, enclosure hardware, fasteners for plastic, security fasteners, and plastic hardware, as well as special fasteners designed and manufactured to customer drawings. The EPW screw will also be on display at the show, with TR engineers on hand to talk through its applications and benefits.

Kevin de Stadler, Sales Director of TR Fastenings, comments: “The chance to discuss our products and services with potential customers is always valuable and Northern Manufacturing will give us a great opportunity to share our expertise and demonstrate the breadth of our product range.

“The fact that the show covers such a large variety of sectors, disciplines and specialities means we can not only reach a wider audience but also partake in conversations

about the issues and market conditions affecting each aspect of the manufacturing industry.” www.trfastenings.com

Global specialist in the design, engineering, manufacture and distribution of high quality industrial and Cat C fastenings

Come and visit us on stand G51 Manufacturing 8 manufacturing facilities with an annual output of approximately 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 over 5,000 companies globally across a wide range of industries.

Now working with organisations involved in the design, manufacture and development of Electric Vehicles (EVs), Battery Pack Modules (EVB) and Electric Vehicle Charging Units.

Contact us: +44 (0) 8454 811 800 sales@trfastenings.com www.trfastenings.com

PPMA SHOW PREVIEW

SMART MANUFACTURING PPMA TOTAL SHOW 2019

PPMA TOTAL SHOW 2019 TO HOST THE LATEST SUSTAINABLE DEVELOPMENTS AND INDUSTRY INSIGHTS IN PACKAGING AND PROCESSING

PPMA Total Show 2019 will open its doors at the NEC, Birmingham, from 1 – 3 October for what will be the most comprehensive production line event in the UK.

and innovative solutions. Other areas of interest include artificial intelligence and the integration of vision equipment and robotics into existing production lines.

During the three days, visitors will have access to 450 exhibitors and approximately 2,500 brands, showcasing the latest innovations in smart manufacturing, processing equipment and packaging solutions for the following sectors: food and beverage, pharmaceutical, household products and toiletries, building materials and supplies, pet care, micro-brewery and distilleries, FMCG and contract packing.

Renowned by the industry as a platform for launching new products, the 2019 show will be no exception, with multiple exhibitors announcing plans ahead of the show:

Leading players exhibiting at PPMA Total Show 2019 include: Hewlett Packard, KUKA, Mettler Toledo, Cama, Bizerba, Ishida, Ulma, Schneider Electric, Barry-Wehmiller, Bosch Packaging and Pester – to name a few.

This gathering of industry leading manufacturers will deliver the latest solutions in processing equipment and packaging machinery, with real-time demonstrations of advanced technologies

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• Detectamet Detectable Products will unveil their new innovative detectable temperature digital probe (stand D01). An industry-first, this detectable thermometer minimises the risk of foreign body contamination • IBIS Packaging Solutions (stand C92), UK distributor for the Robotize GoPal mobile robot, is launching the new GoPal 800 – a self-driving mobile robot designed for the automated transport of pallets • Endoline Machinery (stand H120) is launching a brand new, high speed, fully automated, three-in-one erecting, packaging and sealing system • Fortress Technology (stand B01), having already announced its recent acquisition

• •

•

•

•

of long-term partner Sparc Systems, will debut the Interceptor DF, its latest metal detector, which is designed to inspect high-value, low profile foods vertically and horizontally concurrently Smart cable manufacturer icotek (stand A36) will be showing its latest cable entry plate Interroll (stand G12) is introducing a modular platform, based on its Modular Conveyor Platform, for driven pallet conveyance, offering reliable and efficient pallet handling Multipix Imaging Components, recipient of the prestigious Vision Award, is showcasing its latest revolutionary 3D camera technology, the Photoneo MotionCam 3D (stand A85) Leuze Electronics (stand J70) is launching several new products, including the LCAM 408i industrial IP camera, and a new safety laser scanner, the RSL 400 PROFIsafe with PROFINET interface UK packaging solutions provider, Hazel 4D, has added a new void fill system to its range to help businesses use less plastic (stand C54)

ENTERPRISE ZONE

The Enterprise Zone at PPMA Total Show 2019 will offer visitors a focal point for knowledge and expertise to educate and inform visitors with a free to attend, issuesled conference programme set to support business growth and development.

Featuring high-profile and respected experts from IKEA, DS Smith, The British Plastics Federation and The Sunday Times, this year’s first-class, industry-responsive conference programme will focus on some of the key issues facing modern manufacturing, including Brexit, serialisation, artificial intelligence, plastic packaging, food waste, and sustainability and the circular economy.

Case studies and presentations will also give visitors real examples of best practice manufacturing and excellence in processing and packaging production, aiming to motivate and inspire visitors to improve their businesses.

Richard Little, Show Director for the PPMA Group of Associations, said: “This year’s PPMA Total Show is topical for a number of reasons.

Not only will it be the biggest PPMA show in the Association’s history, it’s only taking place in the same month that the UK is scheduled to leave the European Union. As a result, it’s encouraging more businesses to think laterally about investing in new machinery and equipment to ensure they maintain a competitive edge.

“New technology, working machinery and live demonstrations are always a big draw for visitors to our shows, and this year’s Total Show will be no exception. Pre-registration is again up year-on-year, which proves that, despite the global economic slowdown, demand remains high for PPMA shows and there’s a real appetite for companies wanting to exhibit to grow their customer-base.

“The environmental agenda is also continuing to push the boundaries of our industry; particularly waste reduction and the use of plastic, so sustainability and waste reduction are topical themes for PPMA Total Show 2019. This is supported by a first-class speaker programme, with two prominent keynote presenters, who will look to impart their knowledge on the circular economy and political climate across Europe respectively.

“It’s an important time for the processing and packaging industry. We’re entering a phase where political changes are set to impact our business dealings internationally. I’m very confident, though, that this year’s PPMA Total Show will again provide visitors and exhibitors alike with new ideas, solutions and networking opportunities to help drive their businesses forward,” he added.

In addition to a rich seminar programme and thriving Enterprise Zone, PPMA Total Show will also house a full-scale model of the 135,000 bhp, rocket powered supersonic car, Bloodhound, which is aiming to break the land speed record in the next two years.

Visitors will have the opportunity to learn

more about one of the most advanced aerodynamic and advanced engineering projects of the 21st century and how Bloodhound Education is inspiring a generation to study science, technology, engineering and mathematics (STEM).

In a bid to inspire more young people to take up a career in engineering, this year’s event will again house an education hub that will offer guidance about apprenticeships and how companies and visiting students can potentially gain access to funding through the PPMA’s charitable arm, BEST (Business, Education, Skills and Training).

PPMA GROUP INDUSTRY AWARDS 2019

The PPMA Group Industry Awards 2019 will be held at the National Conference Centre in Birmingham on the evening of the first

day of the Show. Now in its eighth year, the Awards ceremony brings together more than 300 industry professionals from the world of processing and packaging machinery and recognises the finest examples of innovation, smart manufacturing and entrepreneurship.

For further information on the Awards, visit: https://www.ppmatotalshow.co.uk/awards/ ppma-group-industry-awards.

FREE VISITOR REGISTRATION

Registration for the PPMA Total Show 2019 is now open.

To register for your FREE visitor badge, visit the PPMA Total Show website at: www.ppmatotalshow. co.uk/ Issue 40 PECM

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PPMA SHOW PREVIEW

OEM AUTOMATIC TO RETURN TO PPMA OEM Automatic, a leading supplier of components for industrial automation, are set to return to PPMA and will be showcasing the latest and most comprehensive range of cable management solutions from three of Europe’s leading manufacturers.

Conta-Clip produces a revolutionary range of cable entry systems; AGRO, manufacture an extensive selection of high quality cable glands; German market leader Flexa, OEM’s newest partner and producer of flexible cable conduits.

“Cable management is an area where we’re seeing sustained growth. The continued automation of industrial processes means components require more connections than ever before. With more automation often comes the required management of hoses, air pipes and conduits.

We’re very excited about showcasing all three of our partnerships at once. What sets OEM apart from other component suppliers is our industry expertise and ability to provide complete solutions. By adding AGRO and Flexa to our product range, I feel like we’re now in a position to offer a

complete cable management solution, no matter the application,” Anthony Wrighton, Business Area Manager, Panel.

www.oem.co.uk/

All your industrial automation components from one trusted supplier

Offering technical expertise and application solutions

Panel

Pressure & Flow

Sensors & Safety

www.oem.co.uk 54

PECM Issue 40

Machine Vision

0116 214 5264

Motors

PPMA SHOW PREVIEW

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

Find us on Stand J100 at PPMA 2019

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

uk.rs-online.com

What did you want to be when you were young?

Your ambition has led you to the fast-changing world of engineering.

And your ideas are shaping its future.

But to do what you do best, you need the time to focus on what really matters.

For 80 years we’ve been helping customers achieve their goals through our extensive range of industrial maintenance and electronics products, and world-class service.

We’re here

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

Issue 40 PECM

55

PPMA SHOW PREVIEW

Bulk Materials Handling Equipment

SPIROFLOW TO SHOWCASE REMOTE MONITORING SYSTEM AT PPMA Bulk materials handling specialist, Spiroflow, will be using the PPMA Total Show to promote their new innovative monitoring system that remotely provides real time information on the performance of their complete machinery range. The system is known as SAM – Spiroflow Active Monitoring.

The aim of the initiative is to automatically monitor customers’ equipment through sensor-based technology, thereby providing key performance related, safety and operational data. As an ‘upgrade’, SAM is built into the standard electrical panel on Spiroflow’s machinery by an in-house team of skilled electrical engineers and

PPMA 2019 VISIT US ON STAND

B64

connected remotely via 4G/5G or Wi-Fi. Commenting on the new system, Spiroflow’s James Podevyn, said: “As an industry leader, it is important for us to embrace not only IIoT in all that we do, but also to support the private sector’s move towards industry 4.0. As an industry first, SAM will allow our customers to have unbiased facts at their fingertips allowing for an enhanced overview of equipment performance, together with the ability to quickly identify issues and rectify them.”

To learn more, see Spiroflow on stand B64 or visit spiroflow.com/samsaves

Flexible Screw Conveyors

Bulk Bag Fillers

Aeromechanical Conveyors

Bag Conditioners

Tubular Drag Conveyors

Fully Integrated Systems

Bulk Bag Unloaders

Electrical Controls

01200 422525 www.spiroflow.com sales@spiroflow.com

UNATTENDED PRODUCTION FOR RUTLAND Rutland Plastics, is a private company based in Oakham Rutland with a 66000 ft sq factory and a turnover in excess of £10 million, operating moulding machines ranging from 150 tonne to 1700 tonne.

Looking to achieve unattended production on a Krauss Maffei KM150, Rutland Plastics selected UPM Conveyors to provide a turnkey solution requiring 8 belt conveyors to allow automatic product divert for QC inspection; ferrous/non-ferrous metal detection; product cooling; parts separation and box filling with a capacity of 8 full; 8 empty and 1 filling.

Product divert is achieved with a small reversing conveyor located onto a swan neck conveyor in the well of the machine and at any stage in production an operator can energise to reverse and transfer a shot to an integral sample drawer for QC inspection.

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PECM Issue 40

Metal detection is based on UPM inserting a search coil under the inclined section of the Swan Neck in the well of the machine and on detecting a foreign body will energise an audible / visual alarm and stop the belt conveyor so an operator can check and remove the contamination.

This does not affect the moulding machine cycle as product continues to be produced and accumulated on the conveyor until the operator has reset to start again.

The central control is a PLC controlling all aspects of the system interfacing with the variable speed drives on each conveyor and connecting to the weigh scale.

Rutland expressed their total satisfaction with the UPM project team who installed and commissioned the system which is operating 24/7 trouble free.

www.upmconveyors.co.uk

CONTAMINATION EXPO SERIES PREVIEW

ENVIRONMENTAL INNOVATION CONTAMINATION EXPO SERIES

THE EXPO AT THE CENTRE OF AN EVER CHANGING LANDSCAPE There is less than one month to go until the Contamination Expo Series gets underway at the NEC, Birmingham.

The highly successful environmental event will be running on the 11th and 12th of September at the National Exhibition Centre in Birmingham, bringing over 6,000 visitors from across the globe to Europe’s leading event for contamination and geotechnical professionals.

The Contamination Expo plays host to seven separate shows, covering a selection of topics from across the field. The shows on offer include: Land Remediation, Hazardous Materials, Geotechnical and Geoenvironmental, Clean Air Technology, Spill Response, Waste Water, and Nuclear Decommissioning. By combining seven different sectors from across the contamination and geotechnical industry, we have created a comprehensive event that truly positions itself in the centre of the environmental field.

There are a number of reasons why you will want to attend the Contamination Expo, with the CPD accredited seminar programme being a particular highlight.

Within the seminar programme, the Keynote Speaker lineup is particularly impressive this year - with speakers from organisations such as The City of London Corporation, Jacobs, and Highways England. The seminars at the Contamination Expo are designed to offer you and your colleagues the chance to expand your knowledge on developments surrounding your sector - this newly gained knowledge creates value by being applicable to your every day work.

Over 200 market-leading businesses throughout the environmental sector are coming to the Contamination Expo Series to showcase their new and innovative products and services to the wide audience. There are a number of amazing businesses you will want to visit at the event including: 3M Scott, Grundon, Olympus, and In-Situ Europe Ltd. There are other businesses promoting their services as well. These include: the British Society of Soil Science, and the sponsors of the Keynote Theatre, Neal Soil Suppliers.

Because of the success of previous years, the Contamination Expo Series is again colocated alongside RWM, Future Resource, Flood Expo, and the Fasteners Expo, which is set to attract over 22,000 professionals for two unique days for the environmental sector. This all proves that the 11th and 12th of September are going to be two vital days in the calendar for environmental professionals around the continent.

Tickets for the Contamination Series Expo are completely free, so make sure you come along on the 11th and 12th of September at the NEC Birmingham for two unmissable days of action. Registering for your ticket is easy, just head over to contaminationexpo.com and click on free tickets to get started.

Issue 40 PECM

57

11 & 12

120 CPD Speakers

sept 2019

200+ Leading Exhibitors

nec, birmingham

Industry Awards

CONTAMINATION EXPO SERIES

SUPPORTED BY

Europe’s leading event for contamination and geotechnical professionals Register for free tickets contaminationexpo.com @ContaminationEx #Contam19

58

RUNNING

PECM IssueALONGSIDE 40

FLOOD EXPO

CONTAMINATION EXPO SERIES SHOW PREVIEW

WE’LL HELP IDENTIFY EVERY R&D OPPORTUNITY As an independent consultancy, we help businesses and institutions to access the government grants and incentives they’re entitled to.

liaising with HMRC, we’ve helped hundreds of SMEs and large corporates to get the funds they need to support innovation and improve cash flow.

Could your company qualify for widely available funding?

A STRESS-FREE EXPERIENCE FROM START TO FINISH

From R&D claims, Patent Box to Land Remediation and Creative Industry tax relief, publicly funded incentives and grants are a valuable resource for businesses – yet so many fail to claim.

Is your company one of the 97% of businesses that incorrectly assume they can’t apply for funding to support their innovative work? Don’t miss out on the potential of this valuable financial support simply because you didn’t choose to make a quick call!

We’re here to help you…

We know that perceived barriers such as complicated reporting requirements and a lack of awareness or difficulty in identifying eligible activity can stop businesses from accessing this crucial funding. But we can do all that for you…

With our proven track record of successful client claims and extensive experience

At MCS Corporate, we take care of the full process, ensuring that it’s smooth and hassle free at every step – to reduce the impact on you and your team.

Speak to one of our friendly experts today and let us: • Find grants and incentives in your sector.

• Evaluate your eligibility.

• Identify the criteria you need to meet to get funding and assistance.

• Prepare and submit full applications and documentation on your behalf.

• Liaise with the awarding body, including HMRC, on your behalf.

WHY CHOOSE TO PARTNER WITH MCS?

MCS Corporate has years of experience working in the Research & Development cost recovery sector. We’re specialists in identifying and submitting eligible claims for R&D Tax Credits/ Allowance, Patents, Creative Industries and Grants on behalf of our clients.

We have a proud track record of success and proven capabilities in securing larger-thanexpected claims returns. Better still, we work on a success fee only basis – meaning there’s no risk to you. We’ll do all the work and charge a fee only when your claim is successful.

GIVE US A QUICK CALL TODAY – THAT’S ALL IT TAKES!

Research, innovation, new products, process design and business development are driven by the range of valuable funding schemes that are readily available for companies of all sizes and in all sectors.

We partner with ambitious companies to extend the global, domestic, technological and economic effects of their work. You can read a selection of case studies and view additional resources on our website.

Take 10 minutes to get in touch and we’ll be able to quickly and efficiently assess your funding eligibility.

Give us a call today: 01926 512 475 Visit: www.mcs-corporate.com

COME AND VISIT US AT STAND NUMBER: K43

MCS Corporate Strategies Ltd For all R&D Tax Claims / Land Remediation / Patents / General Cost Recovery

MCS Corporate Strategies Ltd For all R&D Tax Claims/Land Remediation/ Patents/General Cost Recovery

www.mcs-corporate.com

01926 512475

gjw@mcs-corporate.com Issue 40 PECM

59

SENSORS AND INSTRUMENTATION SHOW PREVIEW

CUTTING-EDGE TECHNOLOGY SENSORS & INSTRUMENTATION LIVE

CELEBRATING A CONNECTED WORLD AT SENSORS & INSTRUMENTATION LIVE When: 25 & 26 September 2019 Where: Hall 2, NEC Birmingham Sensors and the myriad of instruments that measure and collect data provide the backbone for the Internet of Things (IoT) and our increasingly connected world, and for the last ten years Sensors & Instrumentation Live has served as an annual hub for the cutting-edge technology that has been driving this connectivity.

This year’s special anniversary event, sponsored by Mouser Electronics, will be no different - with sensors among the many technologies from industry titans on display in Hall 2 at the NEC Birmingham from Wednesday 25 to Thursday 26 September 2019.

A LIVELY EXHIBITION FLOOR

The Sensors & Instrumentation Live exhibitor line up continues to grow as the event approaches and Bronkhorst, Charcroft Electronics, Keller, Kistler and Rheintacho are just a few of the market-leading companies that will be present on the show’s aisles.

In addition to the unique opportunity to source an array of products and solutions under one roof, visitors will be able to explore the latest technological innovations and gain insight from top organisations on how to grow businesses or streamline productivity in a number of the event’s newly introduced feature areas.

THE ENTERPRISE HUB

The new Enterprise Hub is a prime opportunity to discover the variety of options available to visitors that are looking to grow their business. Representatives from key engineering institutions and organisations will give a series of invaluable presentations, covering topics from funding, training and apprenticeships through to making the most of supply chains.

The Defence and Security Accelerator (DASA), The Institute of Engineering & Technology (The IET), Make UK, the University of Birmingham’s Centre for Innovation in Advanced Measurement in Manufacturing, the British Measurement & Test Association (BMTA) and GAMBICA are

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PECM Issue 40

among the organisations that have already been confirmed to speak in The Enterprise Hub in September.

WATCH LIVE DEMONSTRATIONS

Innovation in Action, sponsored by PCB Piezotronics, is another new feature for the 10 year anniversary of Sensors & Instrumentation Live. Free-to-attend, Innovation in Action will see live demonstrations of some of the best products on the market - giving visitors the opportunity to see how these products work in real life and have their questions answered by the experts in person.

Companies already confirmed to give live demonstrations of their products in Innovation in Action include sponsor PCB Piezotronics, Devtank, Kistler, SIKA and Bronkhorst.

INNOVATION SHOWCASE

The popular Innovation Showcase, sponsored by Bronkhorst, makes its return to Sensors & Instrumentation Live in 2019. Serving as an assembly of the most cutting-edge products and solutions available from exhibitors at the show, the Innovation Showcase gives visitors a chance to get hands on with devices from companies including Charcroft Electronics, Mantracourt, Broadband Technology 2000, Rheintacho and Bronkhorst and make sure they do not miss out on a single thing.

ENGINEERING SYMPOSIUM: SENSING INNOVATION

The Engineering Symposium is an exciting new partnership between DJB Instruments and Sensors & Instrumentation Live, presenting CPD-accredited training that is driven by sensor innovation and the very latest in engineering.

DJB will bring together a team of speakers from some of the UK’s leading technology and engineering companies for a two day programme of technical training sessions, exploring topics from the basics of signal processing and analysis and control of noise sources in data to accelerometer technology and more.

REGISTER ONLINE NOW - FOR FREE!

Registering for Sensors & Instrumentation Live’s 10th anniversary spectacular is quick, easy and completely free of charge. Not only will a free ticket provide visitors with access to these great feature areas and the best sensors and instruments on the market, but it will also provide entry to the co-located TCT Show.

To find out more about Sensors & Instrumentation Live 2019 or to register for a free entry badge, visit sensorsandinstrumentationlive.co.uk.

SENSORS TEST MEASUREMENT CONTROL ALL UNDER ONE ROOF

25 & 26 September 2019 | Hall 2, NEC Birmingham

REGISTER ONLINE NOW www.sensorsandinstrumentationlive.co.uk

SENSORS & INSTRUMENTATION LIVE SHOW PREVIEW

THE JOURNEY CONTINUES RHEINTACHO UK

100 YEARS OF TRADITION AND INNOVATION

RHEINTACHO UK, is now celebrating 100 years of business including many turbulent years of differing ownership, management buyouts and since the last acquisition by Rheintacho Messtechnik from Freiburg, Germany in 1990, a period of growth and stability has dominated the last 20 years.

Rheintacho is not only growing in terms of staff, but also technologically. The Leeds based company is not the Rheintacho Group’s competence center for intrinsically safe products (ATEX certified) and is now enlarging this ATEX portfolio constantly.

Latest additions are the complete family of eddy current tachometers for use in printing, paper production, refuelling operations, paint and coating productions and more. We are developing new products in ATEX versions to further serve the core markets in hazardous areas with instruments, tachometers and stroboscopes which are ATEX certified.

In addition, Rheintacho is the specialist in the production of sensors for detecting, recording, measuring and controlling rotational speed and linear movement are

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the benchmark for the industry in quality and reliability. The newest trend in our development of sensors is moving us toward multi-functionality, i.e. introducing sensors which not only measure rotational speed, but also detect temperature; one sensor for 2 functions. The advantages of such multi-functional sensors help our customers save money and reduce complexity of their own systems. Our M8, for example, is a small multi-functional sensor for both speed and temperature.

And its compact size and intelligent design make it easier for engineers to include in their product developments as well.

On top of sensors, RHEINTACHO is a leading manufacturer of both portable and stationary industrial stroboscopes.

The newest development is another high-performance handheld device with an auto-synchronisation function to the speed of the moving object called the PocketStrobe LED Laser. Rheintacho stroboscopes are among the brightest and most reliable on the market.

They are frequently used in our family of tachometers, including eddy current tachometers and handheld mechanical, optical and digital tachometers is quite extensive offering many different options.

Call us for more information.

Unit 17, Enterprise Court, Pit Lane, Micklefield, Leeds, LS254BU, UK Tel: +44 (0)113 287 4411 Email: sales@rheintacho.co.uk www.rheintacho.co.uk

Come see us at Stand Number 9 at the Sensors & Instrumentation live show

www.rheintacho.com Issue 40 PECM

63

AIR, GAS & ODOUR CONTROL

MAXIMUM EFFICIENCY ATLAS COPCO

IMPROVING QUALITY AND EFFICIENCY WHILST CUTTING COSTS WITH SMART CONNECTED ASSEMBLY In the fast-paced world of manufacturing, ensuring maximum efficiency and profitability by striking the right balance between quality and costs is certainly one of the biggest challenges facing producers, even more so with Brexit looming.

For Atlas Copco Tools & Industrial Assembly Solutions, supporting manufacturers through collaborative partnership is the bedrock of its business, which saw its centenary in the UK in 2019.

A leader in assembly tools and data driven services designed to add value to any production environment, from batch of one to high volume manufacturing, Atlas Copco continually takes the pulse of its core markets, through ongoing customer engagement.

The company has recently published a whitepaper, which identified that errorproofing in the production process remains a key issue for manufacturers. Based on field research from across Atlas Copco’s diverse and global customer base, it was found that manufacturers employing the company’s Smart Connected Assembly technology and process were tackling their challenges successfully.

One customer reported a reduction in rework of 15% by utilising Atlas Copco’s ‘Pick-to-Light’ system, which ensures operators pick the right parts at the right time in the assembly process, in order to mitigate production errors and costly line shutdowns.

Titled ‘Error-Proofing the Production Process’, Atlas Copco’s whitepaper introduces a range of measures to improve quality, efficiency and profitability, based around current and future production needs. The publication provides insights on how organisations can implement strategies to boost performance in relation to different levels of complexity in the assembly process. These are based around the principle of ‘Basic Needs’, ‘Complex Needs’ and ‘Very Complex Needs.’

Detailing Atlas Copco’s Seven Steps to Securing Product Quality as part of its Smart Connected Assembly philosophy, its report also illustrates a scalable and flexible

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roadmap to delivering the best achievable product quality. The sequential process integrates tooling and systems, which deliver both full traceability, as well as errorproofing protection, so that manufacturers have a complete understanding of the effectiveness of every stage of production.

Atlas Copco’s Seven Steps to Securing Product Quality:

Step 1: Classify Joints Step 2: Introduce Torque Control Step 3: Introduce Joint Control and Angle Monitoring Step 4: Introduce Process Error-Proofing Step 5: Introduce Reject Management and Part Control Step 6: Secure Process Reliability Step 7: Use of data for continuous improvement

Commenting on its research and whitepaper, Paul Clark, Business Line Manager for Atlas Copco Tools & Industrial Assembly Solutions, said: “Maintaining quality is an essential aspect of the assembly process, as both the direct and indirect cost for product quality issues can be immense. The demand for error proofing is high. When it comes to brand reputation, all the big manufacturers want to get it right first time, so error-proofing is now a core focus for manufacturers, regardless of their scale or the complexity of products. Our new whitepaper gives them an informative guide to the value of error-proofing that fits their current and future assembly needs.”

ADDING VALUE WITH SMART CONNECTED ASSEMBLY Whilst a clear leader in supporting automotive manufacturing, Atlas Copco’s Smart Connected Assembly approach is being adopted by an increasingly diverse number of industries, from white goods and aerospace, to wind energy and agricultural applications.

Customers are seeing increasing complexity in their product mix and demands for higher quality, so the Smart Connected Assembly concept was designed to provide a clear return on investment by blending advanced tooling with data driven services and total customer back-up. This partnership approach towards zero defect assembly with full traceability enables companies to be more agile in dealing with international competition, globalization and new technologies.

From a product perspective, fully data integrated Low Reaction Tools are a key part of the company’s proposition to maximise assembly line productivity and efficiency, whilst reducing human error and ensuring operator safety.

By bringing together its Tools and Industrial Assembly Solutions divisions, Atlas Copco is now best placed to continue its journey as the manufacturing industry’s preferred joining partner.

To download Atlas Copco’s whitepaper, click here: go.atlascopco.com/201903-UK-LP-SCA_03-SQS-White-paperRequest.html Issue 40 PECM

65

Boilers & &Maintenance BOILERS MAINTENANCE

Editors Choice

Imax Xtra EL top of the class on NOx emissions

Battery Powered Universal RTU & IoT Terminal

Filterse leading distribu

Gas Process Burners From within its compact & robust case the NanoULTRA™ packs a big punch!  Huge connectivity [Analogue, Digital, Serial, Modbus, CANbus, I2c, SPI, etc]

We offer a va aerospace, e

 Autonomous Operation [ Low power for battery use and Lanemark gas burner systems offer users reliable, high efficiency, GSM connectivity]

We have ou filter silencer

process heating solutions.

 On Board SD card “flight recorder” for granular data

Additionally filter rolls or

FD Series Oven/Dryer Burners  Instant SmartHub accessPackaged for Internet of Things!

•Specifically designed for process air heating applications in convection

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 Over 4 years battery life possible due to its world beating low power consumption. 

•High turndown/short flame lengths providing accurate process PDF data sheet •

temperature control

Caption Data staff will High helpeffi atciency everygas stage theonly selection andand testing + airthroughout modulation, gas modulation simpleprocess to ensure the best outcome for your trials. Why not give us a call to discuss your high/low control options application?

•Heat Input Range: 9 kW – 1550 kW

TX Series Gas Fired Process Tank Heating Systems Email: Sales@captiondata.com www.captiondata.com

FD-C high turndown oven/ dryer air heating burners.

FD-E low cost high turndown

oven/dryer air heating burners.

•High efficiency (80%+) heating of all types of spray and dip process tanks •Compact high efficiency small diameter immersion tube heat exchangers occupying minimum tank space

•Accurate performance modelling using Lanemark TxCalc design software •Heat Input Range: 15 kW (1½") – 1150 kW (8")

Midcoleader HMA Series Air Replacement or “Make-Up” Air Heating Burners Datalogic is a global in Automatic FD-GA modulating gas + air Leading British manufacturer,process Ideal Commercial Boilers is Data Capture and•Industrial Direct fired, high efficiency burner systems, for high volume air heating air heating burners.

Automation applications such as paint spray committed to ensuring that every condensing boiler in its range markets. As a world-class producer of booths, ovens and dryers. eithercomputers, as Midco burner heads for OEM system integration or outperforms current regulations in terms of output, efficiency and bar code readers, •Supplied mobile Lanemark DBand or FDBlaser complete packaged systems including modulating systems energy use. In keeping with this undertaking, the latest addition sensors, vision as gas valve trains and controls to its �oor standing condensing �oiler range, t�e �ma� �tra �� marking systems, Datalogic offers innovative solutions for a vast range range of firingofrates to suit alternative temperature rise and including air •Wideall types manufacturing environments launc�ed in �anuary ����, is t�e only �� �oiler to �a�e �een of applications within velocity system requirements automotive, Midco HMA high efficiency, TX high efficiency small diameter food & beverage, electronics and healthcare. From inventory a�arded a �lass � ��� rating from t�e �uropean �tandard �� software •DbCalc and real system time design tracking of work in progress across the high turndown, air replacement immersion tube management tank heating ���� ���� relating to gas �red central �eating �oilers� �e�eral production line, to facilitating quality assurance inspections that ensure or “make-up” air heating burners. systems. have already been installed into the educational, religious and product safety is upheld at all times; manufacturing organisations across manufacturing market sectors. the globe rely on Datalogic solutions to improve traceability and enhance Lanemark Combustion Engineering Limited

operational efficiency.

Lanemark House, Whitacre Road, Nuneaton, Warwickshire CV11 6BW United Kingdom Tel: +44 (0) 24 7635 2000 Fax: +44 (0) 24 7634 1166 E-mail: info@lanemark.com www.datalogic.com C O M B U S T I O N E N G I N E E R I N G Ideal Commercial Boilers www.lanemark.com Tel: 01482 492 251 � (PDLO FRPPHUFLDO#LGHDOERLOHUV FRP +44 (0)1582 790020 Datalogic House, Dunstable Road, Redbourn, Herts, AL3 7PR ZZZ LGHDOFRPPHUFLDOERLOHUV FRP X4620 Lanemark Ad SDAW.indd 1

CERTUSS

A New SeaShi Protec

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The new webs available to cu world case stu questionnaire receive tailore available in an

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�uel types o�ered are �as, �ig�t �il, ��� and �io �uel, �it� com�ination �urners o�ered on all units from ����g��r up�ards� Also available are a range of Electrical Steam Generators from ��� to ������ ������� also o�er a ne� ��� �odel� �it� touc� screen control and full modulation from ������� �ring� ��e �� o�ers output ranges from 500-2000kg/hr and is compatible with many BMS interface pro�isions suc� as �ro��us and �od�us etc�

ͻ ďƌĂ ͻ ^ƉƌĂLJ ͻ ƌLJ & ͻ dŚĞƌ ͻ ŝŶĐ ͻ ZĞĨƵ ͻ /ŶƐƉĞ ͻ DĂƐŬ ͻ ƐƐĞ

Brown McFarlane is one of the world’s leading specialist steel plate Distributors, Processors and Profilers. Dealing primarily with Western European mills we supply industry leading customers across the world.

Our focus is on the supply of High Grade Carbon and Stainless Steel products with one of the most diverse stock ranges available anywhere in the world running from carbon Manganese through to Super Duplex Stainless Steels.

Within our 100,000 sq.ft processing facility we possess a wide range of plate profiling equipment which has recently been complemented by the most sophisticated Messer machine yet, the Infinity Contour Plasma Beveller, capable of producing virtually all weld-prep configurations imaginable. Allied to our numerous accreditations including ISO 9901, 14001 and 18001 and Rolls Royce Nuclear approved, our ability to offer precision cut complex shapes in all thicknesses and grades is unrivalled.

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Email: PECM@brownmac.com T: +44 (0) 1782 289 909 www.brownmac.com

66 PECM Issue 40 48 PECM Issue 22

Tel: 01922 www.filte

31/08/2016 09:04

All CERTUSS Steam Generators are type tested according to European Pressure Equipment Guideline DGRL 97/23/EG. ������� o�er se�en construction groups �it�in t�eir range of fossil fuel Generators with outputs ranging from 80kg/ hr to 2000kg/hr and operating pressures of up to 32 Bar G. �o accompany t�e �enerator, ������� also o�er t�eir ��� Package Plant Module, where all of the associated ancillary items are pre-piped, pre-wired and factory tested.

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

We distribut filters. Whet our technica service.

Tel: 0121 327 5362 � Fax: 0121 328 2934 sales@certuss.co.uk � www.certuss.co.uk

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PECM Issue 23

erve are the UK’s g independent utor of Industrial Filtration.

CABLES

MITIGATING RISK

ast range of filters catering for all applications within oil & gas, engineering, power generation, food & beverage industries.

ur own manufacturing facility producing basket strainers and ers. Other bespoke filters can be manufactured.

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HOW TO IDENTIFY A SUBSTANDARD OR NON-COMPLIANT CABLE Email: salessupport@filterserve.com

If you’re looking for a list of things that as a specifier or electrical engineer you can quickly cross off against then you’re going to be disappointed. The truth is, you’re lucky if you can spot substandard cable just by looking at it – and it probably it’s a to pretty major defect. But don’t ales International means are pleased e launch of a newly redesigned let that stop you reading as there are their SeaShield marine protection measures you can take to mitigate the risk. ch can now be found at www.seashield.com.

w Website for ield Marine ction Systems

site features a modern, streamlined design that showcases the solutions a cable toproduct be substandard cableand or real ustomers, details For for each of the systems available udies highlighting SeaShield’s protective capabilities.

A comprehensive non-compliant cable it can have a wide allows enquirers to outline their own unique requirements in order to range with of problems, allenquiries, of which have ed advice or make contact more general all can of which are n easily navigable, mobile optimised format. potentially damaging effects on both the

tems provide protection to structures are vulnerable to corrosion in short-term andthat long-term operational nments. Offering long-term corrosion prevention to jetty piles, offshore viability of your project.

The cable d sheet piles, multiple grades of defense can be employed to achieve cost conductor maydesign. have a reduced copper ection irrespective of section structure

content; the minimum or mean thickness ail@denso.net www.denso.net of the insulation may not meet the required measurement; the braid coverage may be reduced – and that’s before you start to think about whether it meets the requirements of the RoHS Directive, the Low Voltage Directive, CE marking, CPR compliance… There’s any number of issues to consider.

So what can you do? If you can’t be sure you can see it just by looking, we recommend considering the following:

ƵƐƚƌLJ ůĞĂĚĞƌƐ ŝŶ ƌĞĨƵƌďŝƐŚŵĞŶƚ ƐƉĞĐŝĂůŝƐĞĚ ƐƵƌĨĂĐĞ ĐŽĂƟŶŐƐ Where are you buying the cable from?

It sounds obvious, but are you buying Ś ŽǀĞƌ ϱϬ LJĞĂƌƐ ĞdžƉĞƌŝĞŶĐĞ from a legitimate source? A trusted cable

ĂƐŝǀĞ ůĂƐƟŶŐ supplier who can provide the evidence ĂLJ ƉĂŝŶƟŶŐ of batch traceability and compliance &ŝůŵ ŽĂƟŶŐƐcertification. Whilst next-day delivery and stock availability are vital parts of the ƌŵĂů DĞƚĂů ^ƉƌĂLJ WŚŽƐƉŚĂƟŶŐ service, so is having a knowledgeable and ƵƌďŝƐŚŵĞŶƚ trusted point of contact and a set of QA protocols they follow that you can rely on. ĞĐƟŽŶ ŬŝŶŐ Θ ^ƚĞŶĐŝůůŝŶŐ Has it been independently tested? ĞŵďůLJ Θ <ŝƫŶŐ

Choosing a supplier you trust means also putting your trust in their supply chain.

Manufacturers conduct their own predespatch testing but with high quality cables manufactured throughout Europe, Ŷ ƚŽƵĐŚ ǁŝƚŚ ƵƐ ƚŽĚĂLJ͙ the Middle East, India and China that may feel like a leap of faith even if they ϭϭϯ ϮϱϬ ϮϮ ϱϱ are reliably ĞŶƋƵŝƌŝĞƐΛĂƵƐƟŶŚĂLJĞƐ͘ĐŽŵ compliant. What provides the added assurance is independent testing.

Does your chosen supplier offer that?

Look out for ISO 170205 accreditation – it’s ǁǁǁ͘ĂƵƐƟŶŚĂLJĞƐ͘ĐŽŵ the highest standard for laboratories and certifies the impartiality and accuracy of the results they produce.

Does it hold a third-party accreditation?

There are a number of well-respected third-party accreditations for cables, including BASEC, LPCB, and the BSI Kitemark. It’s worth remembering that no one body accredits all types of cable and their testing protocols will differ, but a cable holding a third-party mark can provide valuable additional assurances. As a business, our portfolio includes cables holding BASEC and LPCB approval but we also hold the BSI Cable Testing Verification Kitemark, an intensive and rigorous

programme of testing that quality marks specific reels and drums rather than across product ranges.

So really, procuring and installing quality, compliant cable (and avoiding the risk of substandard cable) is straightforward enough – it’s all about making sure someone else is doing the checking!

To find out more, visit www.elandcables.com Issue 40 PECM

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CABLES

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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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 owner of the world-renowned INTEMP trademark

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

CALIBRATION SOLUTIONS

PERSONALIZED INSTRUCTION BEAMEX

BEAMEX ANNOUNCES THE OPENING OF ATTENDEE REGISTRATION FOR ANNUAL CALIBRATION EXCHANGE

Beamex have announced the opening of attendee registration for Annual Calibration Exchange (ACE 2019), which will be held Wednesday and Thursday, September 18th & 19th at the University of New Orleans in New Orleans, Louisiana, USA. The event will explore the latest insights, trends and best practices for process plant managers, engineers and technicians seeking to improve calibration quality, safety, accuracy and efficiency.

The two days of personalized instruction includes:

Instructors will discuss day-to-day challenges and how best to solve them through new and innovative strategies and advances in calibration technology—all designed to save time while achieving quality metrics and improving safety.

• Calibration competitions with prizes

Participants will benefit from a highly interactive learning approach, providing the practical skills and know-how needed to improve daily maintenance processes and tasks.

• Open discussions of the best calibration strategies and how to perform complex calibrations • Strategies for eliminating calibration paperwork and ensuring data integrity • Hands-on multivariable calibration workshop

Access to this event is limited, so interested persons are encouraged to register soon.

The registration includes access to all presentations, breakfast and lunch.

Each attendee is responsible for his or her travel arrangements and expenses.

To reserve your spot, view details on the program, review a list of recommended hotels and more, visit the ACE website.

Register now as space is limited.

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About Beamex BEAMEX is a leading worldwide provider of calibration solutions with the sole purpose to create better ways to calibrate for the global process industry. Beamex offers a comprehensive range of products and services — from portable calibrators to workstations, calibration accessories, calibration software, industry-specific solutions and professional services. Through Beamex’s subsidiaries, branch offices and an extensive network of independent distributors, their products and services are available in more than 80 countries. Beamex has more than 12,000 customers worldwide. www.beamex.com/

CALIBRATION SOLUTIONS Project4_Layout 1 13/10/2014 12:19 Page 1

&

CALIBRATION SERVICES

INSTRUMENT HIRE:

ONE OF THE UK’S LEADING SPECIALIST INSTRUMENT HIRE COMPANIES Supplying the UK’s leading organisations with calibration equipment

CALIBRATION & REPAIR:

Aughton Hire offer a wide range of the latest test equipment, fully calibrated and tested before despatch complete with full certification and a price match guarantee.

We offer a full traceable calibration service of all types of electrical, electronic and pneumatic test equipment.

EQUIPMENT FOR SALE:

A full range of testing and measurement instrumentation is available from all leading manufacturers offering a quotation for new and ex-rental items.

Project4_Layout 1 13/10/2014 12:19 Page 1

& 115 Evans Road CALIBRATION SERVICES Venture Point Business Park Liverpool L24 9PB

Aughton Hire provide full technical support for our products, next day delivery and same day for those urgent requirements.

Contact kathy@aughtonuk.com or Roy@aughtonuk.com.

Telephone 01928 589600 www.aughtonhire.co.uk

Issue 40 PECM

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CONNECTIONS & FITTINGS

PRESS FITINGS & TUBES NERO

NERO NOW STOCK STAINLESS STEEL PRESS FITTINGS & TUBES

Nero’s brand new range of press fittings & Tubes are made of stainless steel 316 / 1.4404, WRAS/DVGW approved, Size range 15mm up to 108mm. The fittings are fitted with an EPDM seal as standard with optional FPM seals available.

The fittings utilize the widely standard M-shape form and are also supplied with a blue ‘press check’ sleeve to ensure a ready to test system after a quick visual inspection.

Covering a wide range of Industries • • • • • • • • • •

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Potable water Heating Gas Sprinklers Industry Cooling and refrigeration Offshore Shipbuilding Solar systems Saturated steam PECM Issue 40

Press fittings are quickly becoming the connection method of choice for a wide range of industries, this is due to the clean, heat free jointing method which requires no naked flame or hotwork permits.

Our Stainless Press fittings can be crimped with any standard M-contour tool such as the REMS range which will also be available for purchase through ourselves.

The fittings are system-independent and can be used with any DVGW-tested pipe that we offer from stock.

This range is available online at nero.co.uk or email your requirements to sales@nero.co.uk.

If you would like further information about NERO’s new range of Stainless Steel Press Fittings, please contact our sales team either by email sales@nero.co.uk or telephone 0121 665 3900.. they will be happy to assist.

Issue 40 PECM

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CONTROL & AUTOMATION

ZEEKO MACHINE FANUC

HIGHLY POLISHED PERFORMANCE

The UK was once one of the major players in the tool-making world, but the number of British OEMs still in operation has rapidly diminished over time. Yet, in a quiet corner of the East Midlands, Zeeko Ltd has bucked the trend and established itself as the go-to global supplier for ultra-precision polishing and metrology machines.

“It all started in 2000,” begins Zeeko’s Managing Director, Dr Christopher King, who joined the company in 2010 as Metrology R&D Manager. “The initial concept spun out of a post-doctoral research project at University College London, which looked at ways to produce mirrors used as part of astronomical research. What ultimately emerged was a tool which provided ultraprecise control over a polishing process. It was only a short step for company founders, Professor David Walker and Richard Freeman, to commercialise the concept, which ultimately led to Zeeko being formed.”

Fast-forward 18 years and Zeeko is now a 35-strong company, with a burgeoning apprentice scheme. As well as its Coalville head office, the company has R&D facilities at Glyndwr University in North Wales, and Kyoto University in Japan.

The technology centres on the highly precise control of spinning tools covered with a rubber polishing pad, which use state-ofthe-art software to position and orientate the tool, adjusting the position, speed and pressure of the polishing head as required

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to achieve the desired finish. This enables the machines to produce ultra-smooth and nanometre-accurate surfaces on a variety of materials, from glass and stainless steel through to tungsten carbide and silicon carbide.

Notable projects that have used optics, processed using a Zeeko machine, include the NASA Lunar Reconnaissance Orbiter mission in 2009; while the company was also part of a consortium to develop manufacturing technologies for the fabrication of the primary mirror segments for the European Extremely Large Telescope.

As well as being used for the polishing of high precision optics, Zeeko machines can also process orthopaedic joints, semi-conductor applications, camera lenses, along with various parts for consumer electronics, and even turbine blades.

Zeeko currently offers eight different polishing machines in its Intelligent Robotic Polishers (IRP) series, which are able to process parts from 50mm x 50mm, through to 1600mm x 1600mm. All machines in the IRP series can be used for pre-polishing and fine figuring work, as well as hybrid ‘grolishing’ applications, which can significantly reduce process time when tackling mid-spacialfrequency errors in subaperture polishing technologies. The multi-use nature of the IRP series can therefore remove the need for endusers to purchase multiple machines for each part of the polishing process.

Chris continues: “We build all of our machines to order, with the lead time very much dependant on the size of machine.

Some of our smaller machines can be ready in as little as two months, while our larger machines can take up to eight months to manufacture.”

Despite being a 100% export business, with Zeeko having sold machines into 18 different countries, including China, Japan, and the USA, the company has remained true to its British roots by cultivating a predominantly UK-based supply chain. Chris continues: “Where possible, we source the majority of raw parts from local suppliers, many of whom are located within a 50 mile radius.

However, there are some elements in which we need to work with partners with a wealth of global experience. When you need to control the surface finish to within a few wavelengths of light, one critical element is the CNC.”

To fully realise the potential of the technology, and to take it to the level of precision which would enable Zeeko truly stand-out above its competitors, the company needed a CNC partner with a vast amount of experience across a variety of different market sectors. Fortunately the UK headquarters of the world’s leading CNC systems provider, FANUC, was a mere 26 miles away from Zeeko’s Coalville site, in Coventry.

Zeeko first trialled FANUC CNC in 2003, and now uses FANUC’s 30iB control across its entire portfolio of polishing machines.

The 30iB CNC series has been specifically developed by FANUC for use across complex, high-speed and ultra-precise machinery operating multiple axes and multiple tool paths, all within an intuitive user interface.

When integrated with Zeeko’s state-of-theart software solutions, users are able to polish concave, freeform and other complex geometries to within 2-3 Angstrom (the equivalent of 0.1nm).

While Zeeko leads the field of ultra-precision polishing machines, one of the main challenges of holding such a position in a highly niche industry is the pipeline for work.

“Given a Zeeko machine is a high-capital purchase, it is not unusual for customers to undertake extensive R&D testing with us to prove that the machine is able to meet their polishing requirements,” says Chris.

“For example, we worked with a customer for nine months on a prototype optic for a land satellite survey system. Once they were satisfied, the machine was installed at their facility, and produced the next optic in just four weeks.

However, this approach can result in a somewhat spikey cashflow, so in order to grow the business sustainably, we knew we needed to find other avenues with less intensive R&D requirements.” With a view to leveraging the knowledge housed within the business, the management team took the decision to expand Zeeko’s position from solely being an OEM to include systems integration.

Chris continues: “We realised that the machines we were manufacturing could also be put to use in applications where the polishing requirements were less demanding, such as making tools for injection mould parts.

To break into that market, we looked at what other companies were using and came across the FANUC RoboDrill. Given our own polishing machines were controlled

by FANUC CNC, we were confident we could create an integrated machine tool and polishing machine offering that could operate using a common control.”

The first step was for Zeeko to purchase a FANUC D21 MiB5 RoboDrill, to develop the software element which would allow the two machines to work in unison.

While that offering has been available to customers for five years – and represents a significant growth opportunity for the business – Zeeko has retained its original RoboDrill, which it now uses to manufacture the tools used on its own range of polishing machines.

Now the company is not only able to offer integrated cells direct to new customers, but

it can also provide upgrade kits to existing FANUC RoboDrill users looking to integrate polishing in their finishing process.

With one eye on the future, the company once again turned to FANUC to drive productivity internally, through the integration of two robotic arms. “The RoboDrill is now supported by two FANUC robots as part of a fully-automated machine tending and measurement cell. One robot takes blanks from a rack, loads them onto the chuck, before the RoboDrill then machines them to the desired specification,” continues Chris.

“A second robot then unloads the finished part, and transfers it to a measurement and calibration system to ensure it has been processed to the exact specification required.

Once measured, the second robot will then transfer it to another rack where the completed parts can be processed.”

As well as machine tending pick and place applications, the robotic arms can also be used to provide initial polishing to the freshly-machined parts made by the RoboDrill.

While the fully-integrated cell is still being fine-tuned at Zeeko’s Coalville factory, it won’t be long until robots are added to its turnkey cell integration offering for customers. Once complete, however, it will mark the latest in a long line or remarkable steps which has seen the company evolve from a dynamic university start-up into one of the country’s last-remaining British manufacturers of precision tooling equipment.

Unlike a number of those left who are looking over their shoulder at the threat posed by cheap imports from low-cost economies, Zeeko has its eyes firmly set on continuing its sparkling upward trajectory.

www.fanuc.eu

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CONTROL & AUTOMATION

NEW APPOINTMENTS QUANTUM CONTROLS

NORTH EAST BORN QUANTUM CONTROLS WELCOMES NEW TEAM MEMBERS AS THE NEXT PART OF SCOTLAND EXPANSION

Quantum’s sales team at Oulton Hall, Leeds for their quarterly Sales meeting “UK Drive and Motor Supplier of Year” 3 years running; Quantum Controls has appointed Karolina Mickevica and Kevin Dick as their new Technical Sales Engineers for Scotland, South and North respectively.

Commenting on the appointment, Manging Director and Owner Kevin Brown said: “We are delighted to welcome Karolina and Kevin to the team to support the amazing growth we are experiencing in Scotland.”

Karolina brings 11 years of experience to her new role, having worked with brands including Sage Plc and Newcastle Building Society delivering sales and after sales services to a wide customer base.

“They are both focused, highly skilled and have excellent experience of Scottish Industrial Sectors. The most important thing is they also really get what we do.”

In addition, Karolina is known in the region for her work with the NewcastleGateshead Initiative, as well as her time as Chief Executive of The Entrepreneurs’ Forum. She is also a non-executive director of Tyne & Wear Archives & Museums.

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Karolina, who received her MBA from Durham University Business School earlier this year, added: “I’m overjoyed to be a part of such a fast-paced market leading company here in the Scotland. The culture is infectious and one of energy - this is a business with a real can-do attitude.”

Kevin Dick says “Having worked with Quantum in my previous role at Aggreko, I recognised immediately the potential for even greater successes here. Kevin and the team have built the foundations for growth and I am very much looking forward to being part of the next chapter here in Scotland.”

Quantum Controls are a North East born company, with Service Centres around the UK. The Glasgow Service Centre being the first part of the Scottish expansion, with further plans to expand in to the Southern Area in late 2019.

Offering unique Maintenance Partnerships have led to our exceptional growth in Scotland.

Drive Service contract partners throughout the UK. The new facility opened in December 2018 which houses the following: • Local Base for Drive Service Engineers in Scotland • Office and Admin Function • Drive Spares Stock • Drives Stock • Hire Drive Stock • ABB Motors Stock • Drive Test and Repair Facility

Our Weatherproof Hire Drives helping emergency services at Whaley Bridge Scottish Engineering’s review of the manufacturing engineering sector shows overall a continuing positive quarter for the third time in 2018, albeit with some declining indicators also evident. Order intake, exports and optimism all remain positive at less than 5% above even, whilst staffing numbers and capital investment show double digit positive indicators.

“With all these factors considered we have decided make this investment in

our business in Scotland. The New Drive Service Centre near Glasgow creates local 24/7 support for all of our clients based throughout Scotland and creates new jobs locally” say Kevin Brown, Owner and Managing Director.

Quantum Controls UK Drive Service Centre Network is a network of bespoke premises that allows our growing team of currently 18 Drive Service Engineers to operate from a local facility to service all of our 200+

One

If you would like to discuss our products and services with Karolina or Kevin, you can contact them on: Karolina Mickevica - k.mickevica@ quantum-controls.co.uk 07970 630 846 Kevin Dick - k.dick@quantumcontrols.co.uk | 07779 786 216

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visit: www.onecall-quantum.co.uk for full information and to sign up today For £2.59* per day, only £947 net per 12 month contract

“At 2am, we had a VSD breakdown. One phone call to Quantum and their on-call engineer was with us within hours and had our plant back up and running. Very happy customer and very relieved that we had a contract with Quantum which enabled the quickest response time possible”. Jim Tait, Principle Site Engineer.

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Issue 40 PECM

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CONTROL & AUTOMATION

PACKING LINES BRILLOPAK

MORRISONS CHOOSES BRILLOPAK TO AUTOMATE MULTIPLE FRESH PRODUCE PACKING LINES In the last 18-months, Brillopak has installed a range of fully automated pick and place packing lines at three of Morrisons fresh produce and fruit manufacturing sites.

Aligned to Morrisons’ strategy to provide the retailer’s 11 million weekly shoppers with the best quality fresh produce, Jason Kelly, Head of Operations for Morrisons Manufacturing has led the automation strategy across their fresh produce business, which includes the recent Brillopak systems installed at Rushden, Thrapston and Gadbrook.

All three sites are delivering improved in-store presentation for apples, potatoes and other root vegetables. What’s more, the turnkey systems can be easily adapted to handle reusable and renewable packaging formats reports Rushden’s site manager Andy Day. Commenting on how automating fresh produce lines can lead to a higher quality product and efficiency improvements, Jason says: “The characteristics fresh produce means that gentle handling is essential to prevent damage and costly waste. Equally important is the need to retain product freshness.”

Jason continues: “Rushden was the third multi-line implementation where Morrisons worked with Brillopak. Rather than creating individual autonomous operating units, we sought an integrated, comprehensive, more labour efficient system that covered everything from packing produce to palletising. Brillopak’s modular automated concepts have proven to be extremely flexible and reliable, accommodating variations in speeds and packaging formats. The true measure though has been the almost immediate improvements to operational efficiency effectiveness (OEE).

Historically, the Rushden packhouse, which cleans, stores, packs and distributes thousands of tonnes of potatoes every year, loaded bags of flow wrapped potatoes manually into crates. Now, thanks to two fully-automated and two semi-automated pick, pack and palletising lines, the Northamptonshire site has enhanced its potato packing precision and transformed its operation from an unergonomic roundtable manual crate separation and case loading method, to a safer, high speed, optimised

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potato packing process. Similar turnkey lines were installed at Gadbrook.

Forming part of a company-wide investment in front and back end manufacturing improvements, Rushden has significantly boosted its OEE within 12 months, reports Andy. Yet, most importantly for the site manager, the way potatoes are presented in crates has dramatically improved.

Additionally, waste is down, bottlenecks have been virtually eliminated, reliance on agency staff has reduced and workforce wellbeing and satisfaction is the best it has ever been.

Andy explains: “Designing a system that would accommodate our facilities tight footprint was the biggest challenge. Yet, having worked with Brillopak on Thrapston’s apple packing line, I felt confident that they could prove their concept and invent a modular automated system that we could introduce in phases causing minimal disruption to our seven-day-a-week processing and warehouse operation.”

Because of the efficiency of the already automated back end section of the warehouse, the Brillopak packing systems needed to boost the pick and place line speed. Rather than commission a readymade robotic system, the Rushden team worked collaboratively with Brillopak to engineer a new pick and pack concept.

Comprising two long stretches of conveyor feeding bagged potatoes from the manufacturing and bagging operations, each automated line features eight Brillopak elements. At the start of the line a crate destacker unit lifts and feeds Morrisons’ retail trays at a consistent speed and continuous stream on conveyors to the dexterous P180 spider arm robotic cell. Snaking alongside are the product conveyors. Rumble technology is fitted to a small section on each conveyor to help settle the packs as the feed single file into each P180 Spider Arm Unipick Dual Robot Cell.

Unlike other depots that wash, grade, pack, palletise and send out in the same day, Rushden has a separate wash, store, pack and case loading area. Because there’s more fresh produce being processed and stored, space at Rushden is at a premium.

Rather than using gripper end effectors that would pierce the potato bags, Brillopak designed a glove-like end effector that wraps around each potato pack robot arm lowering rapidly yet gently into trays at very high speeds.

A FITTING PARTNERSHIP

Filled trays then pass over a vibration panel to settle the potato packs in the crates. This ensures packs don’t get caught when the bale arms close. If the bale arm is damaged, the crate is rejected and the potatoes are returned to the start of the packing process for reprocessing.

The filled crates of potatoes then pass to a double crate stacker, which places one loaded crate on top of the other. From here the double stack is presented to the integrated yet compact palletiser.

For maximum efficiency, Brillopak’s compact palletiser accommodates two pallet stacks side-by-side.

When one stack is full the cell door slides open and the full pallet is removed. To protect workforce Health & Safety, only when the cell door closes, does palletising on the remaining empty pallet resume.

OVERCOMING ORIENTATION The difference having an automated packing line has made to the presentation of fresh produce packs cannot be underplayed reports Andy.

“Product accumulations and the speed in which potato packs were delivered onto the rotary turntable previously resulted in irregular orientations,” he recalls.

On the manual packing stations, Andy had an equally clear objective - to get rid of the unergonomic turntable packing system. Citing that it wasn’t the right solution for the potato packs or people, Rushden implemented an inline system. Andy describes as a hybrid design as it borrows elements from the five Brillopak Packstations installed at Thrapston’s apple packing depot.

Andy explains: “Physically fitting more people around the turntable to pack faster was unfeasible. Space just wouldn’t allow it. When creating our two Brillopak C130 Semi-Automated Packstations we combined the best of Thrapston’s design and integrated several bespoke specifications. Our site’s modified design guarantees pack orientation to our colleagues on the manual line. Rather than clusters, packs come through in single file. This helps to guarantee consistent presentation of packs within the trays.”

In addition, the design of the C130 lines helps to mitigate repetitive strain injuries and makes the whole manual packing process seamless. “Our colleagues find it much more ergonomic,” states Andy. “They’re not bending over or moving around the turntable or lifting trays for lengthy durations. This rotation around different tasks, combined with less reliance on agency staff, has created a much stronger team ethic,” he highlights.

To minimise production disruption, Brillopak built, tested and installed Rushden’s machines in phases. Most of the really disruptive work was done at night, out-ofhours. “The teams’ responsiveness was a real value-add,” says Andy.

“Brillopak clearly understands the manufacturing environment and how critical production schedules are to getting fresh produce packed and looking good on the retail shelves,” ends Jason

OPTIMISING OEE

To resolve this, the company installed two four-axis Delta type robots side-by-side within the two P180 Unipick pick and place systems.

With one multi-skilled person managing both automated P180 lines, as well as pulling away the pallets, Rushden has reduced its packing headcount. An increased packing speed, fewer rejections and less front to back end bottlenecks means that OEE is constantly improving. “All lines are now running consistently at high speed, which means we don’t have a product build up or backlog.

We are pushing our vertical form fill and seal limits,” comments Andy.

Capable of orientating packs quicker than any human being, the robot arms don’t miss a beat exclaims Andy. “They just keep going, loading with dexterity, tilting and placing potato packs individually at speeds that even a layer packing robot couldn’t contend with.

It’s an extremely clever piece of kit,” he says.

Brillopak’s modular design also means that Morrisons has a future proof investment.

“Rushden currently has four packing lines handling between 13 and 14 SKUs. If volume of products or capacity demands it, we can converge all four lines and run through the robotic cells.

The consequence was frequent production stops and starts, and messy trays with packs being placed into trays in different angles and patterns. “Regaining control over the orientation without stopping the line was near impossible once the packing pattern was lost,” adds Andy.

The ability to swap, chop and change or drop in new kit knowing that with one supplier it will work seamlessly alleviates a lot of pressure,” adds Andy. This benefit also extends to sourcing critical spares, which in turn reduces stock holding.“It becomes much easier to manage an automation project when you know exactly who to go to when a problem needs to be fixed,” says Andy. Currently, Brillopak is assisting Rushden with a rumble conveyor to stress test the pack seals before they enter the packing warehouse. The end goal is to keep as much rework as possible in the room where it can be repacked, rather than downstream.

www.brillopak.co.uk

Issue 40 PECM

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CONTROL & AUTOMATION

NEW Network-Capable Absolute Encoder from BEPc For EtherCAT communication in a precision absolute encoder, we’ve got your solution.

BEPc’s Model A58 features networking capability and is EtherCAT ready. With its minimal setup, you can install these encoders quickly and easily. The model A58 offers :• • • • • • •

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Call BEPc today to learn how an EtherCAT absolute encoder can fit your application.

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PECM Issue 40

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TF Automation design, engineer and manufacture process automation solutions, ranging from full manufacturing units to specialist components all engineered to integrate fully with existing production lines.

With over 40 years’ experience, we support a wide range of manufacturing industries, providing special purpose machinery designed to clients’ bespoke requirements.

Our engineering and design expertise is extensive and we offer the latest technology across a wide range of disciplines, with all projects carried out in-house, from concept design created in Solidworks 3D CAD to commissioning and installation.

Services • In-house design • In-house manufacture • Testing & commissioning • Programming Expertise • Assembly & testing • Process automation • Robotics & product handling • Product identification • Manual workstations Industries

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DESIGN | ENGINEER | MANUFACTURE Tel: 01274 308005 | Email: info@tfautomation.co.uk | Web: www.tfautomation.co.uk Issue 40 PECM 81

CONTROL & AUTOMATION

WAREHOUSE ROBOTS INSPEKTO

IMPROVING OPERATIONAL EFFICIENCY

Traditional machine vision solutions wreak havoc on operational efficiency and the industry is ready for change. As the late Japanese industrial engineer Shigeo Shingo once said, â&#x20AC;&#x153;Improvement usually means doing something that we have never done before." Here Miki Gotlieb, VP of Operations at Inspekto, explains how Autonomous Machine Vision impacts operational efficiency in a way that has never been seen before.

Traditional machine vision solutions, which have been around since the 1980s, are implemented in a project-based approach.

The process requires the selection and acquisition of numerous components, including cameras, lenses, lighting, filters, computing platform and software from a range of suppliers. The QA manager is therefore subject to the lead times of the vendor of each piece of equipment â&#x20AC;&#x201D; while the resulting overall lead time is governed by the long lead item (LLI).

Once the integrator receives the components, they can then integrate them with one another, alongside the tedious task of preparing the software selected and then

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building a hard-engineered solution on the shop floor, before beginning the software training process.

For a simple application, implementation can take several weeks to a few months. For a more complex solution, typical time frames are several months and, in some cases, go up to an entire year.

In addition to these lengthy waits, since traditional machine vision solutions are specifically designed for a location on the production line, it is nearly impossible to move the solution from one location to another. Alongside this, the diagnostic tools for a traditional machine vision solution are often unique too, which means they are an expensive investment.

In most cases the manufacturer is unable to diagnose a fault themselves, due to a lack of machine-vision specific knowledge and must instead rely on the integrator for assistance.

This inability to address the issue immediately in-house delays manufacturing, which may have to be halted while the fault is addressed.

One way to reduce the downtime should a machine vision solution become faulty is to stockpile spare components.

A factory with several system configurations will keep spares of all unique system parts in order to achieve a decent mean time to repair (MTTR) and minimise the downtime in case of a malfunction.

This increases costs and effort for the parts which must be maintained and managed.

A new way of working Since the launch of Autonomous Machine Vision (AMV) first product entries in VISION 2018 in Stuttgart, these challenges can be completely overcome. While AMV systems can be purchased for 1/10th of the cost of a traditional solution and installed without the help of an integrator 1,000 times faster, they also bring about a vast array of operational benefits to the manufacturer.

The Inspekto S70 is the world’s first Autonomous Machine Vision system.

Designed with the manufacturer in mind, the system is suitable for any quality assurance, gating or sorting application. The system’s arm is flexible enough to be installed on any machine, at any angle and position to get the required field of view (FOV). The system’s visual sensor, comprising all camera, lenses and lighting components, has a wide range of capabilities to suit different applications.

In addition, the fact that AMV systems are an off the shelf product – and not a lengthy integrator project – removes the lead time of ordering the components for traditional machine vision solutions. The Inspekto S70 can be delivered as soon as the purchase order is received, and it can then be implemented upon arrival in the plant. In addition, as Inspekto, as a vendor, represents the cost structure of one company. This means purchasing a system from Inspekto is unlike purchasing components from the many vendors involved in a traditional integrated solution, which generates savings

that are passed on to the customer in the form of the very affordable prices.

Finally, thanks to the several artificial intelligence (AI) engines underlying the S70’s ‘brains’, very minimal configuration is required of the manufacturer’s employees and the system will self-adapt and selfadjust to its environment. For example, no proof of concept (POC) creation nor any solution development is required from an external integrator to set up the system.

Once installed the system will self-adjust to any changes on the line or the lighting environment.

Furthermore, once the manufacturer has set up an Inspekto S70 system, it is not fixed forever to that point on the production line, unlike a traditional solution would be. If at any time in the future the QA manager identifies another point on the line that would benefit more from visual QA, the system can be moved from its original location to the new one. Additionally, if the system is not required for a period of time, it can be stored and then re-installed as necessary in a couple of hours.

This state of affairs is drastically different from that of machine vision solutions of the past, where moving a solution from location to another would in most cases be either impossible, due the new location’s specific physical and components requirements, or require a very notable bill of waiting time and cost for an integrator to make the necessary change.

Complete autonomy If any adjustment is required with an installed Autonomous Machine Vision system, it will perform self-diagnosis to identify the issue, significantly reducing the MTTR. It can set up its own parameters and use its intelligent capabilities to test itself and report back to the QA manager. The QA manager requires no specific training to achieve this, all is built into the system and it is easy to use.

AMV offers very fast MTTR. For example, if the system’s visual sensor apparatus is faulty it can be efficiently fixed or replaced by a member of the factory QA team. This is in stark contrast to traditional solutions, which would require the return of the integrator to suggest tests, figure out the problems and attend the site to correct it —a timeconsuming and costly process.

The improvement in operational efficiency offered by AMV represents, as Shigeo Shingo said, something we have never done before.

Advancements in machine learning, artificial intelligence and optics have made AMV possible, paving the way for the Inspekto S70. Manufacturers can now finally benefit from powerful visual QA systems with no downtime, very short implementation lead times, rapid diagnostics and far less testing, training and spare parts. www.inspekto.com

Issue 40 PECM

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ELECTRICAL & ELECTRONICS

SWITCHTEC’S ENCLOSED FUSED SWITCH DISCONNECTORS OFFER A COMPACT SOLUTION WITHOUT COMPROMISING ON QUALITY Now available with Rotary Isolator and separate Fuse Holder, Switchtec’s NTFS enclosed fused switch disconnectors offer improved performance at a more competitive price.

The NTFS Fused Switches use the industry standard combination of Rotary Isolator linked to a DIN rail mounted fuse holder fitted into an IP65 metal enclosure.

This enables Switchtec to offer a cheaper solution whilst maintaining the use of high quality components ensuring there is no compromise on quality.

As a result of Switchtec’s experience and knowledge of the marketplace, its vast supplier network and buying power, it is able to source the components at a more competitive price and passing this on to its customers. Fitted with high quality Telergon switches & Mersen Fuse Holders, the packaged enclosures are available in ratings 32A, 63A, 80A and 125Amp ex-stock.

All of the NTFS enclosed fused switch disconnectors are supplied in a high quality IP65, RAL 7035, pale grey painted, mild steel enclosure and for versatility, they have removable top and bottom gland plates.

The switches offer an IP20 level of internal protection with their touch proof terminals. They have a door interlocked, padlockable facility deployable in the operating handle ‘off’ position and are supplied with a door earth lead. All products conform to IEC60947-3, are certified by UL, EAC, CCC, and are CE approved.

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PECM Issue 40

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Aimed at electrical contractors, equipment manufacturers and machine builders, the fused switch disconnectors provide a solution where general switching duties are required.

They are suitable for control switches for multiple circuits and for use in resistive load applications as main circuits for machines, heating equipment, lighting, ventilation and air-conditioning.

Switchtec’s knowledgeable field sales engineers are available to provide application advice and product choice assistance as are the company’s in-house sales and design team.

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ELECTRICAL & ELECTRONICS

CRITICAL POWER SOLUTIONS POWER CONTINUITY

100% TOTAL NO BREAK POWER UNINTERRUPTIBLE POWER PROTECTION SOLUTIONS, 24 HOURS A DAY Power Continuity provides Critical Power Solutions for all mission critical business operations that require absolutely 100% Total NO Break Power uninterruptible power protection solutions, 24 hours a day. All Power Continuity installations are automatically activated in the event of a GRID failure providing seamless emergency power to ensure your operations continue without any power disruption. 100% No Break in power.

PowerContinuity also prevents damage to your equipment caused by sudden voltage drop and power outages. These can totally screw up up production lines when power surge spikes ‘knock’ out software and robotics lines. Critical Power Solutions Installations from Power Continuity Ltd. gives peace of mind.

Do you really need Critical Power Protection Solutions from PowerContinuity?

More than ever! Today we are plagued with the risk of lost production, crashed servers, corrupted data, burnt out inverters, transformer failure, GRID overload, harmonic distortion, vandalism & terrorist actions. We need Power!

Power Continuity Engineers will prevent power outage disruption forever.

How do we do that? By Installing a Power Continuity fully automatic NO Break power supply system. Firstly, we carry out a detailed power survey to identify your power risks, then secondly, we design from the ground up your bespoke automatic fully installed Power Continuity System to ensure that after installation, external power outages will never again cause your site operational issues. Total Power Continuity 24 hours / 365 days of the year Power Continuity Ltd. is our name and Power Continuity are our solutions.

True NO BREAK Power Protection ‘kicks in’ automatically to prevent any loss of production, as well as this, Power Continuity will also eliminate ALL and EVERY disruption caused by random power dips, spasmodic brown outs, over voltages as well as undervoltages. We design, build and install UPS systems backed up by rapid start diesel generators = Power Continuity.

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PECM Issue 40

With Power Continuity NO Break Critical Power Protection Solutions installed, you get instant pain relief from:Power Continuity Eliminate Power Dips - Yes these do happen regularly. Power Continuity can stamp these out forevertotal power protection Power Continuity Eliminate Brown outs too – Yes, they do happen too, especially during the coming winter months These have the same impact as Power Dips. We at Power Continuity will prevent them, once and for all.

We service and maintain all our UPS systems and Diesel Generators with our own nationwide trained engineers. On call 24 hours a day.

Power Continuity Ltd can ensure True NO Break Power for your production facility, data centre, laboratory, aerospace facility, by designing a bespoke PowerContinuity System always consist of Uninterruptible Power Systems supporting by our own build diesel generators with fuel tanks & fuel filtration.

100% Automatic Power Protection Systems for TRUE 24/7 Power Continuity. That’s

why we are Power Continuity Ltd. Bespoke trademarked Power Continuity Generators & UPS systems that work every time, 365 days a year.

100% NO BREAK Critical Power Protection Solutions call Power Continuity WE DESIGN. WE BUILD. WE INSTALL. NO IF’S OR BUTS. NO BREAK POWER CONTINUITY = SEAMLESS POWER WE ARE POWER CONTINUITY

Call us on 0845 055 8455 We’re here to help 24/7 www.powercontinuity.co.uk

ELECTRICAL & ELECTRONICS

OPEN SOURCE OS INSYS

LINUX IS NOT DEAD Windows operating system (OS) has over 79.46 per cent market share of the desktop computer sector. However, in every other computing sector, the complete opposite is true with Linux OS holding the majority of the market share. Here Florian Froschermeier, technical sales manager of industrial router manufacturer INSYS icom, explains why Linux is in such a dominant position.

Technology giants like Cern, Amazon and Google and the majority of server-side and embedded technology all use Linux OS for their systems and applications. There are many reasons for OS’s popularity because Linux is a licence-free open-source OS that is highly flexible, customizable, portable and of course at no cost to the user.

Free is great unless the product is not. As Linux is open-source, it means that the source code is available to be redistributed and modified freely and with ease. With over 80 per cent of industrial applications using Linux systems, the OS is constantly being patched and upgraded by a legion of highly technical users, ensuring it remains secure and reliable, without costing you a penny.

The large variety of applications that use Linux mean that the people updating the software are from a diverse range of different industrial backgrounds. Linux OS has, therefore, been and can be customised to work in many varied applications. This has allowed the OS to become incredibly flexible due to its constantly growing range of use cases.

The main reasons for Linux’s popularity is its reliability and the lightweight nature of the OS. However, equally as critical is its portability. Many operating systems are not compatible with different versions of themselves and require modifications to the system or the software before they can work.

The different types of Linux OS are manufacturer neutral by design, meaning that it has been programmed, following portable operating system interface standards, to reduce or remove issues of porting software between different Linux environments.

Why businesses choose Linux Another major benefit for businesses that use Linux is that they can create their own version

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of the Linux for specific use cases. For example, most major technology businesses have their own version of Linux such as Amazon Linux, gLinux and at INSYS we have our icom OS.

allows for industrial data to be analysed before it is sent off-site, reducing the amount of bandwidth required.

We designed icom OS due to our need for a router specific OS. This has allowed us to create a secure, portable and lightweight OS, specifically made for use with routers. Other industrial routers use off-the-shelf OS that, while still functionable, can become saddled with extra parts that slow down operations and leave it vulnerable to attack.

Linux into the future The current and future potential for Linux based systems is limitless. The system's flexibility allows for the hardware that uses it to be endlessly updated. Functionality can, therefore, be maintained even as the technology around the devices change. This flexibility also means that the function of the hardware can be modified to suit an everchanging workplace.

One of the major benefits that we have seen from implementing our own version of Linux is that our router can now support Linux containers (LXC). LXCs are self-contained programs that carry out operating-systemlevel virtualization methods for running multiple isolated Linux systems.

For example, because the INSYS icom OS has been specifically designed for use in routers, this has allowed it to be optimised to be lightweight and hardened to increase its security.

Containers are becoming a key tool in modern programming and application development.

Containers allow companies, if they have the capabilities in house, to write their own code and run it without the need for OEM support.

This means that developers and IT teams are not waiting on updates from the OEM to enable new functions but can go ahead and generate their own specific application.

This has become increasingly easy because, due to technological progress, modern hardware has a large amount of excess computing power. Hardware can, therefore, incorporate extra functionality beside their main duties elevating the system.

For example, INSYS routers have more than enough computing power to route data from industrial applications. By taking advantage of this excess capacity and using icom OS and LXC’s, end-users can implement extra functionality such as edge computing, which

Multipurpose OS have large libraries of applications for a diverse range of purposes.

Great for designing new uses, but these libraries can also be exploited by actors with malicious intent. Stripping down these libraries to just what is necessary through a hardening process can drastically improve security by reducing the attackable surfaces.

Overall, Windows may have won the desktop OS battle with only a minority of them using Linux OS. However, desktops are only a minute part of the computing world. Servers, mobile systems and embedded technology that make up the majority are predominately running Linux. Linux has gained this position by being more adaptable, lightweight and portable than its competitors. For more information on the benefits of Linux OS and industrial routers read more on the INSYS website.

www.insys-icom.com

ELECTRICAL & ELECTRONICS

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www.kaizentechnology.co.uk Middlesex Aerospace engineers substantial energy savings with Goodlight LED lighting

Award winning brand, Goodlight, have announced that Middlesex Aerospace, a leader and strategic manufacturer of aerospace engineering components has made between 50-80% energy savings following the replacement of their old fluorescent lighting with energy efficient, low maintenance LED tube lighting from the Goodlight range. Payback on the installation is on target and expected to be achieved within 18 months. The company adopted Goodlight LED lighting to meet their commitment towards ISO14001.

Installation of the LED lights was carried out over the weekends to limit the impact on production times and reduce disruption for staff.

Middlesex Aerospace specified Goodlight GX1 Plus (150W) LED High Bays, G5 LED Battens, T8 LED Tubes and LED Ceiling Panels for their main production factory and inspection area at the 50,000 sq ft manufacturing site in Hampshire, replacing energy hungry fluorescent lighting.

Goodlight LED lighting technology offers more efficient light at lower cost and reaches full brightness instantly with no warm-up required. The lights are specifically designed for retrofit applications and can be quickly and easily installed into existing fixtures. They provide immediate energy savings and are virtually maintenance free. Goodlight LED products are guaranteed for five years and rated at 50,000 hours.

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Issue 40 PECM

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ELECTRICAL & ELECTRONICS

MAKING POWER EASY TO CONNECT Famatel UK Ltd is part of Famatel Spain www.famatel.com We are one of five subsidiaries in Europe and the USA, we have established our self in the Southwest of England supplying Industrial Plugs and socket 24v range and full 16a to 125a Plugs sockets and switch gear and distribution equipment.

We have grown up in a challenging market and have achieved good penetration into the UK market and have product specified via consultants and specifiers, with a keen eye on quality and competitive pricing, however we do not sacrifice quality.

We produce our range to our highest quality possible, Famatel UK Ltd distributes its products via the Electrical wholesale channel in the UK. Our customers then focus on Electrical contractors small to large involved in turn with blue chip clients within in the general Electrical contractor sector and within commercial and industrial specifiers.

RCD Switched sockets with changes in the UK Electrical regulations Famatel have been a keen driver of producing our products like the RCD switched socket and customer

build units to the highest standard always using quality products from the Cable (Tri Rated) to Devices supplied by well know manufactures, having confidence knowing the devices we fit have been tested and ready for use and minimise down time on sites to device failures.

Custom Build with a compact design we can offer an Electrical distribution system that is design for your needs and meets your commercial requirements, with quality made parts and assembled into a power distribution system that gives you the edge.

Nano, having an eye of new products like the Nano light a first to the UK a LED high quality 240v pendant light source in mains

and Emergency, and also is available in 24v, 110v, 240v, with a 50,000 hr life it has to be a product to take notice of with gland fitted and the ability to cable through and to hang up and link together into a string, combining standard and emergency units together making them easy to see in orange for Emergency and black for standard.

It is always our goal to make a transaction or projects with Famatel UK run smoothly and have a positive feel. Feel free to send you enquiry to sales@famatel.co.uk. www.famatel.co.uk sales@famatel.co.uk

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PECM Issue 40

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Hilsonic ultrasonic cleaning tanks are built to customer specifications

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Manufactured in the UK

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Hilsonic is a specialist in the supply of ultrasonic cleaning equipment for the power7HO generation and ZZZ KLOVRQLF FR XN marine industries Issue 40 9515 IssuePECM 16 PECM

CASE STUDY CASE STUDY

CASE STUDY CASE STUDY

Johnston Logistics UK Johnston Logistics UK Environment: Logistics Environment: Logistics

BayLED Eco BayLED BayLED Eco Eco

TLT TLT GET GET FIT

FIT

Tomorrow's Tomorrow's Tomorrow's Lighting Lighting Lighting Today!

Today!

Today!

Financed Financed Financed Installation Installation Installation Today!

Today!

Today!

UPGRADE NOW! UPGRADE NOW!

Jason Pullen Warehouse Manager Jason Pullen Manager “The lights thatWarehouse have been installed are very good, they are instant, no delays and the energy savings of

“The “Thewe lights lights that have have been been installed installedbill are areare very very good, good, they they are are instant, instant,isno no delays delays and the thethan energy energy savings savings of of 75% will that make on our electricity very good.

The visibility 100 timesand better it was”.

75% 75% we we will will make make on on our our electricity electricity bill bill are are very very good. good. The The visibility visibility is is 100 100 times times better better than than it it was”. was”.

Johnston Logistics UK, a specialist provider of third-party logistics has just completed a new LED lighting installation Johnston Johnston Logistics Logistics UK, UK, aa specialist specialist provider provider of of third-party third-party logistics has just just completed completed aa new new LED LED lighting installation installation using GG Lighting’s BayLED Eco Philips component poweredlogistics high bayhas luminaires.

Johnston’s remit to lighting GG Lighting was to using using GG GGlight Lighting’s Lighting’s BayLED BayLED Eco Eco Philips Philips component powered powered high high bay bay luminaires. luminaires.

Johnston’s Johnston’s remit remit to to GG GG Lighting Lighting was was to to improve levels for health and safetycomponent reasons and to significantly reduce energy and maintenance costs. improve improve light light levels levels for for health health and and safety safety reasons reasons and and to to significantly significantly reduce reduce energy energy and and maintenance maintenance costs. costs.

The original installation consisted of 400W metal halide luminaires which were in use in excess of 7,500 hours per annum The The original original installation installation consisted consisted of 400W 400W metal metal halide halide luminaires which which were were in in use use in in excess excess of of Eco 7,500 7,500 hours hours per annum annum (8.5 months).

The new GG Lightingof installation consists ofluminaires one-for-one replacement 200w BayLED high bayper luminaires (8.5 (8.5 months). months).

The The new new GG GG Lighting Lighting installation installation consists consists of one-for-one one-for-one replacement replacement 200w 200w BayLED BayLED Eco Eco high high bay luminaires fitted with passive infrared detection (PIR). On paper of the energy saving is 50%; however in real terms duebay to luminaires the use of fitted fitted with with passive passive infrared infrared detection detection (PIR).

(PIR).

On On paper paper the energy energy saving saving is is 50%; 50%; however however in in real real terms terms due due to to the the use use of of lighting controls energy savings will be in excess of 75%the with a short 24 month payback period. lighting lighting controls controls energy energy savings savings will will be be in in excess excess of of 75% 75% with with aa short short 24 24 month month payback payback period. period.

The use of lighting controls also positively impacts service life which at an already impressive 100,000 hours (11 years) The The yield use use of of lighting lighting controls controls also also positively positively impacts service service life life which which at at an an already already impressive impressive 100,000 hours hours (11 (11 years) years) will huge maintenance savings.

Due toimpacts the success of the first installation GG Lighting has100,000 now been requested to will will yield yield huge maintenance maintenance savings. savings.

Due Dueand to to the the success success of of the the first first installation installation GG GG Lighting Lighting has has now now been been bill requested requested to to carry out huge a second.

The resulting energy carbon footprint saving was a massive 75% off of their energy excluding carry carry out out aa second. second.

The The resulting resulting energy energy and carbon carbon footprint footprint saving was was aa massive massive 75% 75% off off of of their their energy energy bill bill excluding excluding maintenance costs to purchase and installand replacement lamps. saving maintenance maintenance costs costs to to purchase purchase and and install install replacement replacement lamps. lamps.

200W 200W

PERFORMANCE THAT MATTERS PERFORMANCE THAT MATTERS

Energy Efficient Energy Efficient Energy Efficient

Environment Environment

Storage area Storage Storage area area Energy load Energy Energy load load Operating hours Operating Operating hours hours Annual running cost (£0.09 per kWh) Annual Annual running running cost cost (£0.09 (£0.09 per per kWh) kWh) Annual energy saving of 75% Annual Annual energy energy saving saving of of 75% 75%

£8,289 £8,289

Annual Savings Annual Savings Annual Savings

Current installation Current installation 41 x 400w Metal Halide 41 41 xx 400w 400w Metal Metal Halide Halide 16.4kW 16.4kW 16.4kW 7,488 7,488 7,488 £11,052 £11,052 £11,052

50,000 50,000

Up to 100,000 lifetime (hrs) Up to 100,000 lifetime (hrs) Up to 100,000 lifetime (hrs)

GG Lighting Solution GG Lighting Solution

41 x 200w BayLED Eco PIR 41 41 xx 200w 200w BayLED BayLED Eco Eco PIR PIR 8.2kw 8.2kw 8.2kw *3,744 *3,744 *3,744 £2,763 £2,763 £2,763 £8,289 £8,289 £8,289

LIGHTING LIGHTING

SOLUTIONS SOLUTIONS

MADE SIMPLE! SIMPLE! MADE

TLT TLT

GG Lighting’s Light as a Service makes it easy for your business to GG Lighting’s Light as a Service makes it easywith for no your business to upgrade to a new turnkey LED lighting solution upfront costs! upgrade to a new turnkey LED lighting solution with no upfront costs!

GG Lighting use best in class components that deliver energy and GG Lighting savings use best in will class components that deliver energy and maintenance that finance your new lighting. maintenance savings that will finance your new lighting.

We design, install and maintain. WE MAKE IT EASY! We design, install and maintain. WE MAKE IT EASY!

LIGHT AS A SERVICE LIGHT ASyour Abusiness SERVICE Using GG Lighting’s ‘Light as a Service’, can benefit from a ‘zero’ upfront

Usingcost GG Lighting’s ‘Light fully as a Service’, your business can benefit from a ‘zero’ upfront state-of-the-art maintained lighting solution.

GG LIGHTING WILL: cost state-of-the-art fully maintained lighting solution. GG LIGHTING WILL:

DESIGN

Survey your existing lighting installation DESIGN and propose a low energy, low Survey Survey your your existing existing lighting lighting installation installation solution. and and maintenance propose propose aa low low energy, energy, low low maintenance maintenance solution. solution.

Certificate Number 1979-QMS-001 ISO 9001 Certificate CertificateNumber Number1979-QMS-001 1979-QMS-001 ISO ISO9001 9001

INSTALL

Arrange and organise installation INSTALL around yourand requirements with minimal Arrange Arrange and organise organise installation installation disruption to your business. around around your your requirements requirements with with minimal minimal disruption disruption to to your your business. business.

MAINTAIN

As part of our full service offer, we will MAINTAIN maintain your new lighting solution As As part part of of our our full full service service offer, offer, we we will will throughout the lifelighting of the contract. maintain maintain your your new new lighting solution solution throughout throughout the the life life of of the the contract. contract.

gglightingsolutions.co.uk gglightingsolutions.co.uk +44 (0) 1842 763 752 | upgradenow@ggls.co.uk

+44 +44 (0) (0) 1842 1842 763 763 752 752 || upgradenow@ggls.co.uk upgradenow@ggls.co.uk

FACILITIES MANAGEMENT

WAREHOUSE ROBOTS EMS

PICK IT, PLACE IT, SHIP IT, ALL AUTOMATIC Warehousing is becoming an increasingly automated system, with robots storing, retrieving and delivering packages day in, day out. In fact, some warehouses use aircraft control style systems to organise and control their robots, due to the complexity of the system. As such, precision is fundamental for the successful running of automated warehouses.

Here Stewart Goulding, managing director at precision drive system supplier EMS Ltd, explains why it is imperative that warehouse robots are installed with high precision actuation.

Warehousing is one of the key industries that is embracing automation, with robots firmly at the centre.

Robots can drastically improve many warehouse processes including streamlining and enhancing production efficiency. In fact, Amazon anticipates such potential that it recently unveiled its new warehouse robot, which are purpose built to replace conveyor belt systems.

However, efficiency isnâ&#x20AC;&#x2122;t the only benefit of incorporating workplace robots. General workplace accidents, including slips, trips and falls, are a considerable threat to worker safety in the warehouse, which accounts for 3.9 million lost workdays in the UK alone in 2018. Incorporating workplace robots and facilitating safer working environments will not only prevent workplace injuries, but also streamline processes.

These benefits, and the return on investment that these products can create, shows how important robotic developments are becoming to the warehousing industry. Additionally, the progress being made in developing these systems means that there are ever more ways to implement warehouse robots.

For example, some warehouses are using centralised systems â&#x20AC;&#x201D; similar to those used by air traffic control. These central systems give exact instructions to the robots, which makes sure that they use the most efficient path available. Using this system is advantageous because it allows the robots to be more lightweight as they are not carrying heavy and intricate sensor systems.

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On the other hand, some warehouses are implementing dispersed and autonomous robots that can plan their own paths while communicating directly with other robots around them. This creates a network where the robots are continuously communicating and updating each other on their location and movements. Using this decentralised system can prevent the risk of information bottlenecks.

Regardless of how warehouse robots are deployed, their actions must be precise. If a robot movement calibration is not exact, then the impact could be disastrous. The speed and proximity with which the robots work means that small deviations could cause significant damage to the robots, their surroundings and the products.

Ensuring that robots have precision actuators that control movement is vital whether it be for propulsion, lifting or gripping.

Gripping is especially important, because regardless of how fast you manage to get a product to a customer, it is no use if it is damaged.

For this reason, actuation in grippers must be strong and precise to ensure that the robot has the strength to pick up products and to place them with accuracy.

Selecting drives and motors that can deal with these requirements is vital.

For example, FAULHABER BX4 drive in just 32mm diameter have been used successfully in warehouse robot grippers, they have 62 watts of power and can deliver rated torques of up to 72 mNm in continuous operation and peak torques of 96mNm. The high power-density results in a dynamic lightweight motor able to handle packages firmly but with care.

Effective grippers mean that operation managers can be sure that their robots will be able to carry out their duties without dropping, damaging or losing packages.

The use of autonomously and intelligently acting logistics robots in warehouses are becoming more prominent, with their obvious advantages but it remains essential to ensure that care is taken to select the most appropriate drive system for precise reliable actuation to allow them to reach their full potential.

www.ems-limited.co.uk

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.

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.

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

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.

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 applications. Durable, reliable and low in

C&P Engineering Services Ltd

Fraser Technologies

For over 45 years C&P Engineering Services Ltd has been supporting customers and delivering Electrical, Control & Instrumentation engineering solutions to local, national and global industry within the oil & gas, chemical, nuclear, pharmaceutical, steel, process manufacturing, renewable energy and industrial markets. C&P’s services can be combined to provide the total EC&I engineering solution or divided into the following design & build, operation and maintenance, consultancy and training services: • EC&I Turnkey Project Engineering Solutions • Instrumentation, Control & Automation • Safety Instrumented System Engineering • Functional Safety Consultancy Management – IEC 61508 / 61511 • ATEX Inspection & Consultancy Services • CompEx Training Services • Commissioning & Maintenance • High Voltage Services - 11kV 33kV 132kV

A sunset date has now been set for nPB (normal Propyl Bromide) of the 4th July 2020.

After this date, its use is banned, unless an authorisation has been granted for a specific use and no alternative is available. nPB is a solvent commonly used in the cleaning and degreasing process for the aerospace, precision engineering, medical, optical and electronic industries. If you’re still using nPB, now is the time to act and look into alternative solvents.

Fraser Technologies supply a range of new generation solvents which are safe, very economically friendly and meet the new F Gas regulations making them the idea replacement solutions for nPB. Contact us today!

+44(0)1792 897002 email: info@cpengineering.co.uk www.cpengineering.co.uk

Tel: 01506 443058 Email: sales@frasertech.co.uk www.frasertech.co.uk

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.

Come and visit us at Stand L156 www.sdproducts.co.uk

Major expansion delivers biggest facility in Yorkshire A leading galvanizing business has completed a major expansion that increases capacity by 50 per cent. Humber Galvanizing Ltd has installed a new bath to create the biggest facility of its kind in Yorkshire.

It has also extended its yard, installed new ‘triple acid’ tanks and made a string of changes to improve health and safety in a multi-million pound project. The new galvanizing bath is 7.5m long, 1.2m wide and 2.7m deep.

General manager Richard Speake said: “This is a major investment that will increase the number and size of jobs we’re able to do. It will ensure we’re ‘Fit for the Future’ and provides the platform from which to grow even stronger.”

Contact Richard Speake Humber Galvanizing Ltd Tel: (01482) 322466 Email: Richard.speake@wedge-galv.co.uk

Issue 40 PECM

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FAST LIVE SHOW PREVIEW

FREE TO ATTEND! FAST LIVE

LOOKING FOR LIGHTWEIGHTING SOLUTIONS? The FAST Live exhibition is still the UK’s only specialist fastening, bonding and assembly event for design engineers, production professionals, manufacturers and fastener buyers - and it is all FREE to attend!

Whatever you’re designing or producing we guarantee there will almost always be a better way to put it together. Need to reduce costs? Keen to speed up production? Want your joints to resist vibration? Seeking a way to join dissimilar materials? Looking for lightweighting solutions? Then visit FAST Live.

Book now: www.fastenerexhibition.co.uk/ book-now FAST Live The National Conference Centre, Solihull 19th September 2019

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PECM Issue 40

ASSOCIATED AND COLOCATED WITH

www.em-live.co.uk

@eng_materials

www.fast-live.co.uk

LIGHTWEIGHTING

BONDING

SURFACE TREATMENT

@fasteninguk

ALTERNATIVE MATERIALS

Transform your designs with the latest materials, products and processes

19 SEPTEMBER 2019

D

EN T T A O T FR E E

The National Conference Centre, Solihull

REGISTER AT WWW.EMLIVE.CO.UK Issue 40 PECM

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FASTENERS & FIXINGS

SPOTLIGHT STAR FASTENERS

THE HUCK® MAGNA-LOK® STRUCTURAL FASTENER The Huck Magna-Lok is a versatile, hole filling fastener that can be installed with conventional installation tools. It has a unique circle-lock feature, which means a simple visual inspection ensures it is installed properly, 100% of the time.

Unlike competitive blind structural rivets, the Magna-Lok doesn’t require a special nose-piece insert in order to be properly installed; the locking mechanism has been engineered into the fastener ensuring the mandrel does not pull through or drop out.

With a large grip range, the Magna-Lok is the best gap-pulling fastener available.

Like all Huck fasteners, it provides a secure joint and is vibration resistant.

• Unique circle-lock feature means simple visual inspection can ensure proper installation.

• Available in steel, stainless steel, 316 Stainless Steel, or aluminium.

• The hole is completely filled through a radial expansion of the fastener. This can help compensate for uneven, misaligned, or irregular prepared holes • Excellent gap closure ensures strong, secure joint • Flush pin break removes the safety issue associated with a protruding pin • Outstanding hole filling on the blind side adds to joint security and the fasteners resistance to moisture.

Available Sizes: 3/16”, 1/4”, 3/8”, 1/2” Materials: Steel, Aluminium, Stainless Steel, 316 Stainless Steel (ideal for saline environments).

Head styles: Protruding, Truss, 100° Flush POTENTIAL APPLICATIONS Agricultural machinery Air Conditioning Commercial manufacture Electrical appliances Electrical boxes and enclosures Metal construction and structures Solar panels As a well-established leader in the global Huck® fastener distribution network Star Fasteners (UK) Ltd, are committed to supplying customers with the most innovative fastening solutions on the market.

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For further information email sales@starfasteners.co.uk or call us on +44 (0) 115 9324 939

FLUID HANDLING

SUBTLE OR DISRUPTIVE – WHICH TACTIC IS MOST INNOVATIVE? As experts in progressive cavity (PC) pumps, innovation is at the heart of SEEPEX’s culture. Lesley Eaton, Marketing Executive, explains why fostering a supportive climate is more valuable than a single great idea when it comes to encouraging innovation.

We have a joined-up approach to innovation, with a dedicated technology and innovation department comprising R&D, innovation strategy, engineered solutions, and product and industry management. After all, where’s the value in a good idea if there isn’t a framework to enable development beyond the idea phase?

However, the framework only pays dividends if a company also fosters a supportive culture. In real terms, this means: • Having an open mind; • Being patient; • Learning from your experiences; • Promoting collective ownership; • Collaborating.

Once a supportive culture and a framework to support the development of any new ideas have been established, it’s time to consider how your company can truly innovate. This doesn’t necessarily mean a breakthrough invention – think instead

about your customers’ problems and how you can help to solve them.

and investigate other options to find the solution your customers need.

For example: • The same but different Innovation can sometimes be as simple as using the same product in a different application.

• Doing things better Make your existing product range even better by listening to your customers and the wider industry.

• Exploring alternative solutions If your existing range has limitations, stretch

Rather than trying to hit upon the next big thing, companies should consider focusing on the cornerstones of innovation: listening to customers, collaborating with industry and fostering a supportive staff environment. Big or small, any company can enjoy the benefits that come with being an innovator.

Smart Stator

INCREASED EFFICIENCY SMART CONVEYING TECHNOLOGY

www.seepex.com

Smart Rotor

Smart Rotor Technology Smart Seal Housing

Smart Conveying Technology (SCT) provides quick maintenance, significantly reduced life cycle costs and the shortest downtime. Smart Seal Housing, the newest innovation for SCT pumps, removes the need to dismantle the suction or discharge pipework for inspection and replacement of the mechanical seal.  Adjustable stator restores pump efficiency  Reduced maintenance time by up to 85%  Up to 200% longer stator life  Increased energy savings compared to conventional progressive cavity pumps

 Rapid removal and reassembly of mechanical seal  Easy retrofit onto your existing SEEPEX pumps

SEEPEX UK Ltd. sales.uk@seepex.com www.seepex.com

Issue 40 PECM

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FLUID HANDLING

STEAM GENERATION CYCLE MAGNETROL

ARE SUBTLE INEFFICIENCIES CONDENSING YOUR BOTTOM LINE? In many process industries, as much as 60% of total energy consumption goes to the production of steam. Our newly updated white paper on the steam generation cycle shows how better level instrumentation can improve efficiency, reduce fuel consumption, lower costs, and prevent production downtime.

To identify key areas in the steam generation cycle, condensate recovery system and waste heat recovery process where cost-effective instrumentation solutions offer a tangible return on investment over the short-term. The goal is to reduce heat rate, environmental impact, fuel and water consumption, water treatment and maintenance costs in commercial and heavy industries where steam generation is essential to the production processes.

Although plausible, it is rare to identify a single source of inefficiency related to poor-quality level controls that impact a company’s bottom line in the doubledigit percentile. More so than not, it is these small incremental opportunities for improvement across various aspects of the steam generation cycle, condensate recovery system and waste heat recovery process that ultimately equate to substantial savings.

respectively. Additionally, better level control technology at the boiler side eliminates energy losses resulting from unnecessary blowdown to prevent carryover conditions.

• Reduced water consumption, treatment, discharge and inventory management • Improved boiler/steam drum control – energy savings and steam quality • Reduced fuel consumption – waste heat recovery • Energy management – fuel gas, combustion air and compressed air flow • Hardware protection & maintenance – pumps and pump seals Oftentimes, the hidden maintenance costs and inefficiencies associated with a technology’s vulnerabilities (sustained operation in high pressure and temperature steam environments; chemical exposure; errors due to the complexity of the measurement itself and subsequent calibration requirements) are overshadowed by the day-to-day operation of these processes.

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Regardless of the scale of an operation –commercial power generation or small scale boiler system, leveraging the inherent attributes of an instrument’s fundamental technology in both the shortterm (engineering, upfront cost, installation and commissioning) and long- term (maintenance, day-to-day practicality and energy management) present simple and cost-effective approaches to maximizing the return on investment in the system itself.

Estimates of up to 49 percent of the energy can be recovered through the use of flash steam routed to heat exchangers or the deaerator to preheat boiler makeup water or support the deaeration process,

Optimizing boiler, deaerator, heat exchanger/condenser and blowdown usage relative to level control primarily affects fuel economy by better managing the amount of energy required to produce high quality steam for any given task.

Seamless response to changes in demand and reducing maintenance associated with the instrumentation or damage to hardware are residual benefits that have their own financial ramifications; hence, should also be considered when implementing any technology. The return on investment time frame can vary depending on the scale of the operation as well as the time spent maintaining aging instrumentation.

Download the white paper today. www.steamgen.magnetrol.com

Efficiency matters.

Reliability matters.

Safety matters.

In your world, it all matters.

This is why

level matters.

Rag layers, foam and mud tanks. Scrubbers, shakers and steam.

There are no excuses when you need the toughest level measurements.

That’s why Magnetrol® matters. We have the deepest experience in your applications and the broadest portfolio of level instruments for your industry. Our experts will help you identif y ef ficiencies, lower costs, improve production and reduce downtime. It all mat ters.

Because in your world, level matters.

©2019 ©2019 Magnetrol Magnetrol International International

Connect with the level measurement experts at magnetrol.com

FLUID HANDLING

ROTAFLOW THANK ALL INVOLVED IN SAVING WHALEY BRIDGE

Fluid Carrying

Rotaflow is based in the Derbyshire town of Whaley Bridge. The town was evacuated by emergency services due to the Toddbrook Reservoir overflowing, which caused significant structural damage to the retaining wall of the dam.

Flexibility

The wall repairs ran alongside a multi-service operation to reduce the water levels in the dam by 8 metres. Teams of specialists worked around the clock to complete the operation.

A combined effort between the Police, Fire crews, Mountain Rescue, Canal & Rivers Trust, the Environment Agency, the Army and the RAF ensured the area was safely evacuated and the public were well informed.

Local companies supplied aggregate and built makeshift roads providing access to the dam. Residents filled sandbags and local groups provided survival equipment and cooking facilities. Schools and the council made sure all were catered for.

The reservoir had to be drained to half of its capacity, reducing flood

Articulated Torsion Pipework In Hoses Rotating Cylinders

Swivel joints allow pipework to pressure 1/4” to 40” and beyond.

Vacuum to over 20,000psi.

Stock and bespoke production.

Unique bearing/seal design for longer life.

risk to the town. Access to Whaley Bridge was restricted, forcing Rotaflow staff to work remotely.

ISO 9001 CE marked where applicable.

Normal service has since resumed and Rotaflow have been working overtime to catch up. We’d like to sincerely thank the people involved for their hard work in repairing the dam and saving the town. rotaflow.com

Swivel Joints

Tel: +44(0)1663

Bingswood Trading Estate Whaley Bridge | High Peak | SK23 7LY | UK

E-mail:

735003

LABTEX 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.

We also work with LLG Germany, the 3rd largest lab supplies distributor in Europe and have a catalogue of 20,000 items from over 200 respected brands.

We are now distributing the advanced metering pump range developed by the highly regarded and innovative Heidelberg based company, ProMinent. This exciting new specialism will further enhance our ability to offer solutions for an increasingly wide range of scale-up processes.

The foundation of ProMinent’s global success story is highquality products based on decades of engineering expertise, an in-depth understanding of applications and continuous innovation.

The modular ProMinent range, integrated into carefully designed solutions, will enable customers in a wide range of industries to achieve maximum safety and efficiency in their production processes.

We share Prominent’s commitment to environmentally

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sound, sustainable and cost-effective solutions for metering technology in the pharmaceutical, chemical and manufacturing sectors.

Greg Smith, Managing Director at Labtex, said “ProMinent group’s position as a global market leader means a continuous commitment to excellent products and services and an obligation to think and act responsibly. It is a real privilege to be working with such a great company, with an innovative culture and commitment to excellence, very similar to ours.

I look forward to the journey ahead.”

Sales & Service 01484 600 200 info@labtex.co.uk

GEARS, DRIVES & MOTORS

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

NEW NSK DEEP-GROOVE BALL BEARINGS FOR ELECTRIC MOTORS BOOST ENERGY EFFICIENCY The low energy consumption of electric drives is an important target in many industrial applications, and rolling bearings can play a role in delivering this ambition. NSK demonstrates this effect with a new series of deep groove ball bearings that generates up to 80% less energy loss, a factor that has a positive effect on the energy efficiency of electric motors.

Before this development, NSK conducted an intensive investigation into the parameters influencing the energy loss of bearings, drawing a number of interesting conclusions. As a result, the

new bearing series uses new grease that has been specially developed for friction reduction, while the grease filling level has also been optimised.

In comparison with a conventional deep groove ball bearing, the new NSK highefficiency bearings demonstrate 60% less friction when using a steel cage. If a plastic cage is used, internal friction is reduced even further, by almost 80%. As a further benefit, service life with the new grease is increased by a factor of 2.7. www.nsk.com

NoTap

quick – clean - positive

A method for working on pressurised pipes Traditionally, modifications to pipe systems or repairs to leaking pipes or valves cause major inconvenience or high cost. Often these works involve draining down whole buildings and lengthy refill with attendant venting & de-aeration. Often the process can take many days to complete and re-commission.

NO TAP engineering goes to the heart of the problem on pressurised pipe-work by being effective in the right spot. It eliminates drain downs, refilling and venting. It accomplishes your solution in an interval of time which other methods fail to achieve.

It offers great advantages to the Contractor and client alike – economy – no nuisance, inconvenience or lengthy shut downs.

NO TAP – is quick – clean - positive. Work is confined to where it is required.

Further information contact our sales dept: C. A. Baldwin & Co, Valan House, 146-154 Wells Way, Camberwell, London SE5 7SY 020 7703 2138 info@cabaldwin.com www.cabaldwin.com

Issue 40 PECM

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HEALTH & SAFETY

SAFETY LASER SCANNER SICK

SICK VENTURES OUTDOORS WITH WORLD’S FIRST SAFETY LASER SCANNER CERTIFIED TO IEC TS 62998 SICK UK has announced the launch of the outdoorScan3, the first laser scanner in the world to be safety-certified for use outdoors.

The outdoorScan3 Safety Laser Scanner safely and reliably monitors hazardous areas around machines and industrial vehicles outdoors with a high level of availability.

The SICK outdoorScan3 Safety Laser Scanner answers the need for a high-performance safety scanner certified for outdoor use in industrial automation and intralogistics environments, as well as for integration into autonomous and semi-autonomous vehicles used in sectors such as airports, agriculture, and mining.

The outdoorScan3 can be used in safety applications requiring certification to PLd (EN ISO 13849)/SIL2 (EN 62061) and is additionally a class D device according to IEC TS 62998, the new technical specification governing outdoor use.

Equipped with SICK’s safeHDDMTM time-of flight infra-red scanning technology, already used in SICK’s microScan3 family, the SICK outdoorScan3 uses intelligent algorithms to filter out the influences of bright sunlight, rain, snow and fog.

With the outdoorScan3 onboard, automated guided vehicles (AGVs) can be certified for travel between indoor and outdoor industrial environments and thereby enable the continuous workflow of materials between production halls or warehouses.

Says Dr Martin Kidman, SICK’s UK product manager for machinery safety: “The outdoorScan3 ably masters a delicate balance between performance and resilience to outdoor influences. It has the sensitivity needed to detect people or objects in its monitoring area reliably.

At the same time, it is more resilient to the pitfalls of frequent error stops as a result of harsh weather, dirt or dusty environments.

“Until, now there has been no opportunity for outdoor applications to be safety-certified.

IEC TS 62998 provides a new technical specification for compliant devices, and the outdoorScan3 is the first to meet the requirements for a Class D device.”

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With a wide scanning angle of 275° and a protective field range of 4 metres, the outdoorScan3 achieves a total safe scanning area of 38.40m2 with a minimum response time 90 ms. The outdoorScan3 can monitor up to 128 individual and freely-definable protective fields, and up to eight fields simultaneously, giving it ability to respond highly dynamically to the changing environment around it.

The SICK outdoorScan3 offers options for easy and versatile integration using SICK’s Flexi Soft safety controller and SICK Flexi Soft EFIpro gateway. Up to six outdoorScan3 devices can be networked into a safety system, with the option to integrate safety encoders for safe motion control. Configuration and field set up is easy using SICK’s intuitive SafetyDesignerTM software tool.

Resilient to ambient light with an intensity of up to 40,000 lux, the outdoorScan3’s intelligent software algorithms filter out the influences of snow (light to moderate) and rain to a precipitation intensity of 10 mm/h (moderate rain). Safety is ensured in foggy conditions by the fogSight function, which detects when meteorological visual range (MOR) values eclipse 50 m and turns off the safe outputs (OSSDs).

The outdoorScan3 can be used in temperatures from -25 to +50 °C. The new safe contour detection fields provide additional versatility for mobile vehicle applications, such as safe AGV docking and protecting workers at narrow access points.

With a ‘non-safe’ warning field range of 40m, the outdoorScan3 also can also output raw measurement data via Ethernet for navigation purposes, so safety and navigation duties can be achieved with a single device, without the need to use a separate scanner for navigation.

This new IEC TS 62998 Technical Specification details requirements for the development and integration of safety related sensors (SRS) and safety related sensor systems (SRSS) used for protection of persons with special attention to systematic capabilities. IEC TS 62998 defines environmental influences and tests for outdoor use which can influence the sensing function and dependability of the detection capability.

It is likely new applications for the outdoorScan3 will be developed as users explore the potential of a new technology to operate in outdoor environments.

To support its customers, SICK has opened an outdoor development and testing centre at its headquarters in Waldkirch, southern Germany, to explore and develop best practice in outdoor safety sensing and systems.

For more information please contact Andrea Hornby on 01727 831121 or email andrea.hornby@sick.co.uk. www.sick.co.uk

HEALTH & SAFETY

SUCCEEDING IN THE LONG RUN ROSPA

HIT THE GROUND RUNNING WITH IOSH At some point or other we’ve all heard the phrase ’hit the ground running’. For most of us however, the dream of being instantly successful at a new activity is just that: a dream. It’s hardly surprising. Imagine strapping on a set of skis before hurling yourself down the Alps. The results would not be pretty. That’s because the secret to success usually involves hours of hard work and dedication in order to make your exertions look effortless later on.

In many ways the same applies to a career in safety. Only by putting in the time and effort will you be able to arm yourself with the skills you need to succeed in the long run. That’s where IOSH comes in….

WHAT IS IOSH? The Institution of Occupational Safety and Health (IOSH) is a world-leading professional body for people responsible for safety and health in the workplace, providing training courses and practical tools so that individuals and organisations can create safer and healthier working environments. In particular, the IOSH Managing Safely training course is a practical solution to managing health and safety risks.

WHAT IS IOSH MANAGING SAFELY? IOSH Managing Safely is designed for managers and supervisors in any organisation or sector. It’s a pragmatic course with a sharp business focus, which is held in high esteem by delegates and delivered at locations throughout the UK as well as incompany, or online for those based overseas or who simply wish to learn at a time and place to suit their needs.

WHAT ARE THE BUSINESS BENEFITS? Above all else, businesses who employ holders of the qualification can expect to cut their costs without cutting corners or compromising on safety. But beyond that, there are a wealth of other key reasons why this occupational safety course is good for business: • Greater productivity from fewer hours lost to sickness and accidents • Improved organisation-wide safety awareness culture and appreciation of safety measures

• Active staff involvement to improve the workplace • Internationally recognised certification for managers and supervisors • Enhanced reputation within the supply chain So, whether you’re a manager who needs to handle health and safety or simply looking to further your career in health and safety,

hitting the ground running with IOSH is a great place to start.

T: 0121 248 2233 E: enquiries@rospa.com W: www.rospa.com/iosh-managingsafely Issue 40 PECM

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HEALTH & SAEETY

HSE ENFORCEMENT EXTRACTABILITY

HSE FOCUS-IN ON THE HAZARDS OF WELDING FUME

Five months after the HSE issued a change in their guidance and enforcement expectations in relation to the control of exposure to welding fume, including fume from mild steel welding, the response and industry activity has not yet died down.

of new, next generation fume extraction torches recently launched by Extractability, a division of Weldability Sif.

The HSE have begun conducting visits to sites where welding is being carried out, along with any other business where fumes, dusts, vapours or small fibres considered detrimental to human health might be present or created. They are very keen on seeing welding fume control systematically enforced and companies who are found not in compliance with the HSE enforcement expectations can expect to be given an improvement notice, enforcement order or fine. There is no window of leniency; businesses are expected to have already tackled this problem.

The SifGUN Evolution fume extraction MIG Torch is more robust than competing models, with a sturdy metal swan neck, available in a range of angles and an ergonomic, easy to manipulate, metal trigger. The brand new fume extraction concept includes improved airflow and greater visibility of the weld pool, so while the gun may look very similar, the internals have been totally upgraded. This kind of on-torch extraction offers a 95% reduction of fumes and the SifGUN in particular features an optimised nozzle, which balances pressures to prevent disruption of the shielding gases. This means you can use the same shielding gas flow rates as with a standard MIG torch.

Compliance with the Health and Safety at Work Act 1974 and the Control of Substances Hazardous to Health Regulations Act 2002 means, in part, accepting that opening a window or relying on general ventilation is inadequate in terms of welding fume control. Similarly, welding outside will require at the very least, suitable respiratory protection equipment (RPE). This has led to a shift towards fume extraction at-source and coincides with the emergence of a range

Businesses with appropriate fume extraction systems could still face fines, however, if their equipment hasn’t been COSHH tested annually or records of upto-date testing cannot be provided. As well as a range of high-spec, low-cost fume control solutions, Extractability provide a comprehensive on-site LEV COSHH testing service on all makes and types of welding fume and dust extraction equipment, working strictly in accordance with HSE guidelines.

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It is the employer’s responsibility to ensure up-to-date fume extraction equipment is being used correctly. The ProtectoScan Edi is an indoor Environmental Detection Instrument (Edi) that measures particulate levels, records real-time data and is capable of switching on your fume extraction equipment once a pre-set level has been detected. Edi has an LED traffic light display, alerting users to any notable issues and providing an instant visual representation of what is going on in the workshop. Edi will also measure noise, temperature and humidity and is the perfect solution for monitoring and recording exposure levels, every second of the day, 365 days a year.

With the recent Industry 4.0 trend seeing a greater integration of automation and data exchange in the manufacturing sector, the ProtectoScan Edi is Extractability’s boldest step yet to help employers remove hazards from the workplace, stay within the regulations and improve health and safety among their workforce, creating a safe and clean workplace environment for everyone.

For more information, an evaluation to determine if you are compliant, or to have your current fume extraction equipment tested, contact Extractability on 0845 862 2620 or email service@extractability.eu

Does welding take your breath away?

The HSE are currently visiting all fabrication companies to ensure adequate, working, certified fume extraction is in use.

They have the power to issue an improvement notice, enforcement order, fine or even shut you down!

The solution is simple. Extractability, a division of Weldability Sif, can evaluate your company to determine if you are compliant, advise what fume extraction solutions are available to you and install or provide the necessary equipment.

Contact us today to discuss.

0845 862 2620 • sales@extractability.eu www.extractability.co.uk

® ®

www.weldability-sif.com

WELD www.learn-to-weld.com

HEALTH & SAFETY

HONEYWELL BW SOLO HONEYWELL SAFETY AND PRODUCTIVITY SOLUTIONS

HONEYWELL INTRODUCES CONNECTED GAS MONITOR TO ENHANCE WORKER SAFETY AND IMPROVE EMERGENCY RESPONSE TIMES Honeywell (NYSE) launched the Honeywell BW Solo, a connected, serviceable, singlegas monitor with Bluetooth Low Energy (BLE) connectivity that provides real-time visibility into the status and safety of hazardous-area workers, helping companies respond faster and more decisively to safety incidents.

Safety threats such as gas leaks can appear suddenly and unexpectedly, and studies indicate that workers often remain silent in the face of danger. A survey by the environmental services company Antea Group reports that almost half of all workers indicate they are uncomfortable about reporting workplace dangers.

BW Solo simplifies and automates the incident reporting process by connecting workers and supervisors in real time to provide near instantaneous updates of gas concentration levels and worker location.

Workers and supervisors can stay in constant communication, even if they are thousands of miles away. In the event of a gas event or other safety incident, this real-time connectedness can aid safety managers in responding faster to mitigate—or even prevent—safety incidents with potentially catastrophic outcomes.

“Our connected worker solutions provide customers with a wireless ecosystem to enable real-time monitoring in the field.

This gives workers confidence that someone has their back, and enables supervisors to gain greater visibility to emerging gas threats,” said Whitney Hornby, Global Product Manager, Single Gas Portables for Honeywell’s Industrial Safety business. “Our new gas detector goes beyond meeting the basic compliance standard typical of most single-gas detectors, and offers the prospect of increased safety and productivity gains on the jobsite. It can generate immediate alerts and create digital reports on the fly, which eliminates hours of tedious paperwork associated with compliance reporting.”

Key features of Honeywell BW Solo include: • Comprehensive gas family: 14 sensors are available to detect both standard and exotic gases

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• Optional Bluetooth-enabled cloud connectivity and downloadable app manages and stores fleet data automatically, enables remote notification and bi-directional communications • Enhanced device management and automated reporting offered by IntelliDoX instrument management system (sold separately) with free Windows-based software, Honeywell Safety Suite Device Configurator; with additional capabilities (e.g. dashboards, email notifications, multi-site management) offered through cloud-based Honeywell Safety Suite Device Manager • IntelliFlash™ pulsing light indicates sensor functionality and compliance status • IntelliDoX docking/charging station (sold separately) automates fleet management, generates compliance records, alarm history and events, calibration certificates and more • Serviceable design reduces ownership costs through longer operating life,

maintenance ease, expanded gas family and automated compliance records Honeywell manufactures the industry’s most comprehensive, advanced gas detection instrumentation and software under the Honeywell, Honeywell BW and Honeywell RAE Systems brands, and provides training and technical support to protect people, assets and environment from toxic and combustible gas hazards around the world. Honeywell’s wireless, connected gas detection solutions in fixed, portable and transportable configurations can be found at millions of points of detection every day in upstream, midstream and downstream oil and gas; semiconductor manufacturing; water treatment; food refrigeration and commercial building applications.

For more information, please visit www.honeywellanalytics. com/en/products/BW-Solo; email detectgas@honeywell.com or call 800-538-0363.

HEALTH & SAFETY

SMARTER PRODUCT USABILITY

GUARDING WAS NEVER THIS GOOD. SAFETY LASER SCANNER RSL 400 With two autonomous protective functions, an operating range of 8.25 m and a scanning angle of 270°, the RSL 400 sets new standards in safety sensor technology.

easy handling.

Rolf Brunner, Head of Product Center – Laser Scanners

www.leuze.co.uk

AZ_191x124_RSL_400_uk.indd 1

19.12.2014 15:51:57

Issue 40 PECM

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HEALTH & SAFETY

PRESSURE RELIEF WITH BREATHER VALVE REMBE

PROTECTING LOW PRESSURE STORAGE TANKS IN THE FOOD INDUSTRY

Edible oils such as palm, soy and coconut oils are frequently used in the manufacturing of processed foods. Cookies, chocolate and icecream are only a few examples in a long list of such foodstuffs.

Almost every processed and packaged food that we eat nowadays contains some form of edible oil.

One of the main challenges for the use of such oil in food production is maintaining quality and shelf-life. Oxidation is a chemical reaction caused by exposing the oil to oxygen and which causes the oil to turn rancid, changing its colour, flavour and aroma.

There are a number of methods to avoid oxidation of edible oils but blanketing storage vessels with an inert gas like nitrogen is a popular choice to prevent the oil being exposed to oxygen and avoiding the use of chemical antioxidants.

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Nitrogen blanketing systems work under a low level of pressure and therefore require pressure protection.

The REMBE ELEVENT is a pressure and vacuum relief valve which provides optimum protection against overpressure and vacuum for storage tanks with low design pressures.

The leak-rate up to 1x10-6 mbar x l/sec guarantees a controlled level of pressure in the tank and prevents both the loss of nitrogen and air getting entering the system.

High quality materials of construction (316 Stainless Steel as a minimum) mean that it is ideal for sanitary and food grade applications.

Modular construction as well as the possible installation of an ELEVENT via tri-clamp connections facilitates easy dismantling for cleaning.

The ELEVENT is used to protect storage tanks of leading global producers of milk products, chocolate and soft drinks as well as in other industries with high product purity and stringent quality requirements such as the pharmaceutical industry.

www.rembe.de

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

HYDRAULICS & PENUMATICS

BENEFITS n

Easy and quick to install

n

Reduced pressure drop

n

n

Corrosion, fire and UV resistance No welding

SicoAIR is the practical and useful solution for compressed air distribution, from small distribution systems to large industrial plants. SicoAIR features a range of calibrated aluminium pipes with nylon junctions, offering good resistance to shock and pressure. For more information contact Tom Parker Ltd.

APPLICATIONS

NEW ONE TOUCH 20 BAR FITTINGS FROM CDC Fluid power specialists Tom Parker Ltd have introduced a new line to their extensive range of CDC one touch fittings: a one touch 20 bar version for high pressure applications. Designed for use with polyurethane and nylon tube, the one touch 20 bar range features a push to connect configuration to permit instant tubing connection. A smaller body size and wider temperature range of -20ยบC to 80ยบC make it a versatile choice.

The main body of the PL and PT versions rotate to provide better accessibility and comprise O-ring or Teflon coated sections. The new lines include: swivel male elbow, swivel branch tee, straight union, union elbow, and union tee.

Available in white with sizes ranging from 4 mm to 12 mm.

CDC Pneumatics is a leading global manufacturer recognised for quality, service and value. CDC one touch 20 bar fittings are available from Tom Parker Ltd.

Sales: 01772 255109 | Online: tom-parker.co.uk

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Visit tom-parker.co.uk

MACHINING & MACHINERY

CRAZYDRILL COOL SST-INOX MIKRON TOOL

WITH THE RIGHT COOLING AND GEOMETRY: DRILLING UP TO 40XD IN ONE STROKE – FOR STAINLESS AND HEAT RESISTANT STEELS Small, deep and fast, these are the characteristics of the small drill CrazyDrill Cool SST-Inox. Due to internal coolant ducts, innovative geometry and coating, the machining of stainless steels, nickel based super alloys and CrCo-alloys has become significantly simpler and process stable. This goes also for small diameters as well as deep holes. The range includes drills in diameters from 1 to 6 mm and working lengths up to 40 x d.

So far nothing special. Drills with spiralized coolant ducts are available already; even in small diameters. However, many get into trouble with toughelastic materials or with the poor heat conductivity of super alloys. Here the cooling through “classic” round ducts is insufficient even with high pressure. A premature edge chipping, packing of chips, buildup of the flutes prevents a process stable drilling. Markus Schnyder, head of Mikron Tool, knows about the problematic: “For many years our customers suffered when drilling stainless steel. The process was instable and slow; thus, machining became extremely expensive.“ Now, a new geometry provides a chipbreaking effect at the front creating short and curved chips. In the back an open flute profile facilitates the evacuation of microchips. For longer drills a polishing of the flutes helps the easy evacuation of chips from the bore.

Performance and process stability is mainly given by the cooling of the tool: two spiralized, internal coolant ducts guarantee a constant and massive coolant flow during the entire drilling process, an important factor to prevent overheating even with high cutting speeds.

The coolant ducts are in an area with little stress and therefore the stability of the tools is not jeopardized. Comparing to the conventional round diameter, this means a 4-time higher coolant flow. The advantage is the increased tool life of the drill because an overheating of the cutting edges is avoided right from the beginning.

Combined with the innovative tip geometry, the cooling helps greatly to break and flush out the chips from the flutes. All these characteristics make permit to work with higher cutting parameters (speed, feed) and to drill in one single stroke, reaching a high drilling quality (cylindricity, diameter, alignment).

Mikron Tool SA Agno Via Campagna 1 6982 Agno / Switzerland Phone: +41 91 610 40 00 Fax: +41 91 610 40 10 www.mikrontool.com

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Drilling up to 40 x d in one single stroke deep hole drilling EASY DRILLING – Stainless steels

– Heat resistant alloys – CrCo-alloys

WITH HIGH PERFORMANCE – Fast and precise machining

– Increased tool life – High process reliability

– Internal coolant ducts – Diameter from 1 to 6 mm – Drilling depths up to 40 x d

Hall 3, Stand H11

MIKRON TOOL SA AGNO 6982 Agno | Switzerland U.K enquiries: lee.wilkinson@mikron.com www.mikrontool.com

MACHINING & MACHINERY

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 40 PECM

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MACHINING & MACHINERY

COUNTERFEIT GOODS TEC TRANSNATIONAL

COUNTERFEIT PARTS AND CONFLICT MINERALS

Counterfeiting has a long and ignoble history, ranging from art and literature to manufactured goods. Unlike other industries, counterfeiting in the aerospace, defence and automotive industries may have life or death consequences. Although it is clear that counterfeit parts do enter the supply chain, the time and place of their entry is unpredictable. Managing this uncertainty has become more important due to the recent rise in the incidence of counterfeit reporting.

What are counterfeit parts?

Counterfeit Part – a fraudulent part that has been confirmed to be a copy, imitation, or substitute that has been represented, identified, or marked as genuine, and/or altered by a source without legal right with intent to mislead, deceive, or defraud

•

raw materials

•

outsourced special processes

•

mechanical components

•

standard and COTs parts

•

IT and communications technology

Most of us are aware of ‘blood diamonds’ (also called conflict diamonds) which are diamonds mined in a war zone and sold to finance an insurgency, an invading army’s war efforts, or a warlord’s activity! What may be less well-known are conflict minerals which share a similar pedigree and may inadvertently enter the supply chain. They include tin, tantalum, tungsten and gold (referred to as ‘3TG’). Recent legislative and regulatory initiatives by the OECD and EU seek to keep such ‘contaminated minerals’ out of the industrial supply chain by requiring organizations to prove that such minerals are either not from conflict-affected areas or that their production and trade have not contributed to conflict financing and human rights abuses.

Fraudulent Part – any suspect part misrepresented to the customer as meeting the customer’s requirements (includes Fraudulent recycled – sold as new “unused”!)

.. .. .. and all types of ‘matériel’ – i.e. the aggregate of ‘things used’ or ‘needed’ by any organization for the production of its products – distinguished from personnel.

Suspect Part – a part in which there is an indication that it may have been misrepresented by the supplier or manufacturer and may meet the generic definition of fraudulent part or counterfeit part.

What are Conflict minerals?

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The following definitions are common to all standards and regulations relating to counterfeit parts –

Examples of a counterfeit part can include, but are not limited to, the false identification of marking or labelling, grade, serial number, date code, documentation, or performance characteristics.

Although most of the focus is on ‘EEE’ (Electrical, Electronic, and Electromechanical) parts, the principles and practices are applicable to other commodity types, including –

In conflict-affected and high-risk areas of the world, organizations involved in mining and trade in minerals have the potential to generate income, growth and prosperity, sustain livelihoods and foster local development. Unfortunately, they may also be at risk of contributing to, or being associated with, significant adverse impacts including serious human rights abuses and conflict.

The minerals that pose the greatest threats are tin, tantalum, tungsten and gold, collectively known as ‘3TG’.

counterfeit parts use and their inclusion in product(s) delivered to the customer. Such processes should consider –

For example, conflict minerals have for some years been a particular problem in minerals sourced from conflict-affected areas of the eastern DRC (Democratic Republic of Congo).

The DRC’s mineral wealth is enormous.

It is estimated that this country contains between 65-80% of the world’s columbitetantalite (coltan) reserves, 49% of its cobalt reserves, and 3% of its copper reserves.

•

training of appropriate persons in the awareness and prevention of counterfeit parts;

•

application of a parts obsolescence monitoring program;

•

controls for acquiring externally provided product

•

requirements for assuring traceability of parts and components to their original or authorized manufacturers;

Organizations can, knowingly or unknowingly, be affected by the risk of supply chain ‘contamination’ with conflict minerals. This can occur at a number of stages, whether mining or trading in the eastern provinces of DRC, in an adjoining country, or further along the chain.

Meeting customer and international requirements At this time the following three standards contain requirements relating to counterfeit parts – •

AS5553:2016 Rev B

•

IEC TS 62668-1:2016

•

AS9100:2016 Rev D

Organizations must plan, implement, and control processes, appropriate to their operations and the product, for the prevention of counterfeit or suspect

•

verification and test methodologies

•

monitoring of counterfeit parts reporting from external sources;

•

quarantine and reporting of suspect or detected counterfeit parts

To minimize the risk of counterfeit matériel the golden rule is to only use authorized suppliers! Preferably use stockists, which are AS9120:2016 certified.

Recent guidance and regulatory initiatives seeking to keep conflict minerals out of the industry supply chain include – •

OECD Due Diligence Guidance (available now!)

•

European Union adopted Regulation (EU) 2017/821 (in force 2021)

The term ‘due diligence’ means acting with reasonable care and investigating an issue

before making a decision on procurement.

In other words, it is an on-going, proactive (and reactive) process through which organizations put in place actions to make sure they are able to identify, manage and report on ‘3TG’ risks in their supply chain.

Organizations are advised to formulate their own supply chain policy to conform to the OECD Due Diligence Guidance outlining the ‘3TG’ risks of significant adverse impacts of conflict minerals.

Once the policy has been documented, the organization must adopt, and clearly communicate to suppliers and interested parties, up-to-date information on the policy.

Next actions Dr Scrimshire (MD of TEC) said: “Counterfeit parts and Conflict minerals pose a clear and present danger to organizations, their customers and the end-user of products – organizations need to be empowered to meet the challenge”.

TEC Transnational (www.tectransnational.com) provide a comprehensive 2-day course focused on Counterfeit parts and Conflict minerals.

They have also created a LinkedIn ‘Group’ specifically focused on Counterfeit parts & Product safety – feel free to join. www.insys-icom.com

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MACHINING & MACHINERY

EPSILON ENGINEERING CAN SIGNIFICANTLY IMPROVE YOUR MANUFACTURING PRODUCTIVITY...

Our core strengths are analysis and creating a design to solve your production or process problems – helping your organisation to become more profitable! Our customers usually need ‘bespoke’ solutions. We study the requirement in detail, and discuss with you the customer the most appropriate way of upgrading a manufacturing, packaging or safety process.

We have been acquiring a wealth of experience since 1989. We have modified existing machinery, built new machinery, re-tooled or reconfiguring production lines and upgraded machinery safety systems to meet current standards. We have also built palletising, and special purpose handling robotic systems using Kawasaki, ABB and Kuka robots.

We fit in as an extension of your engineering department, and without the day to day distractions that they face, we can move forward swiftly with solutions that pay for themselves quickly.

We use Solidworks for our CAD and simulation and we can also provide CAD drafting at competitive rates, either from our offices or on-site.

We have worked with customers at their sites and with their suppliers across Europe … our customers include Cadburys, Knauf UK, Northern Foods, and Lavazza Professional.

WEBSTER TECHNOLOGIES As specialist engineering and design consultants, our family heritage began in the early 1960’s where we began designing, manufacturing and global distribution of mining equipment, being the first to use hydraulics for cutting. The Webster Roadheader quickly became a well- known and respected brand and product range, still used in quarrying and mining applications today.

Being the original inventors, we remain famous for The Rockwheel, now a proven and recognised cutting equipment attachment range, utilised in many industries and applications across the globe, since it was first introduced over 25 years ago.

Our International presence has continued to grow, when in 2013, we were delighted to licence the manufacture, global sales and distribution of the Rockwheel to Strategic Partners, Rokla GmbH. This collaboration has brought together a winning combination of creative technical design capability, quality manufacturing and sales and service focus, resulting in impressive global sales of the Rockwheel range of attachments.

This successful collaboration allows Webster to continue to concentrate and focus on what we do best, the continued development and design of a range of new and exciting products, addressing Industry challenges, and focussing on the growth of the UK’s largest Rockwheel hire fleet and range of complimentary bespoke and Kennametal consumables. www.webstertechnologies.co.uk

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For further information visit our web site epsilon-engineering.uk or call us on 01732 760066 or 07802 204421.

We are ISO9001:2015 registered.

MACHINING & MACHINERY

NEW MEWA OIL-TRAPPING MAT ABSORBS UP TO THREE LITRES OF FLUIDS MEWA, the textile service specialist, is proud to announce the launch of the MEWA MULTITEX® hazardous fluid trapping mat in the UK. This mat is the perfect underlay for repair and maintenance tasks, or in sensitive areas around machinery and equipment. It is so absorbent that it can soak up to three litres of fluids before needing to be replaced.

MEWA’s MULTITEX absorbent mat offers a simple and efficient way to keep the workplace and floor free from contamination and hazardous fluids.

NEW FUME EXTRACTION SYSTEMS MEETING LATEST HSE WELDING REQUIREMENTS New from Wilkinson Star, one the of the UK’s largest independent distributors of Welding and Industrial Equipment, is the F-Tech Fume technology product range of high vacuum fume extraction systems and welding torches.

Welders and operatives can be exposed to welding fumes, grinding dust and oil mist in the working environment. It is therefore obligatory for employers to create safe and healthy working conditions for operatives by reducing these health risks.

The F-Tech Fox is a high vacuum dust extraction system offering a portable solution to extract dust from manual welding and grinding processes.

The F-Tech range is available through Wilkinson Star’s extensive distributor network. For further details please contact Wilkinson Star on 0161 728 7900 or visit wilkinsonstar247.com.

It replaces the need for sand, granules or plastic tubs and is a reusable solution that offers a cost-effective way to manage hazardous waste.

The secret of the mat’s success is that it immediately transports fluid from the outer fabric to the absorbent, inner core, allowing the surface to remain relatively dry. Available in a 60x90cm towel format, the MEWA MULTITEX mat can be used as a standalone item, or as several mats placed side by side for larger areas. www.mewa.co.uk

ALLSPEEDS ANNOUNCES 1000 BAR TANGYE HYDRAPAK PUMP UK-based hydraulic tool specialist, Allspeeds, announces the Tangye Hydrapak pump providing hydraulic pressure up to 1000 bar (14500 psi) for testing hydraulic tools and systems and as a backup system when HPU power packs or other power sources fail.

The Hydrapak hydrostatic pump is designed to proof test 700 bar hydraulic tools, typically 20-25% higher than the rated pressure. Made from lightweight aluminium, the compact pump is highly portable and weighs only 4.5 kg. It offers two speed operation allowing a rapid prefill or no-load approach, and push button changeover to higher pressure.

An optional factory fitted pressure relief valve may be fitted to the pump and set at any specified pressure between 56 and 1000 bar to prevent exceeding maximum safe working pressures.

The Tangye Hydrapak pump range includes seven pumps ranging from 110 bar (1600 psi) to 1000 bar (14,500 psi). The pump is supplied with nitrile seals suitable for use with mineral

The Tangye Hydrapak 1000 bar pump.

oils, water, oil/water emulsions, paraffin and glycerine. Ethylene Propylene (EP) seals are available to order for applications using phosphate ester based hydraulic fluids and vegetable-based brake fluid. EP seals are compatible with Skydrol 500B and LD4.

For more information on the Tangye Hydrapak, call +44 (0)1254 615100, email: info@allspeeds.co.uk or visit www.allspeeds.co.uk

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TRANSPORTATION AND DEFENCE UNISIG

PRODUCTION GUNDRILLING OF TRACK PINS William Cook is a UK manufacturer of track running gear for armored vehicles.

Their relentless drive to engineer, test, and produce the best products in this category has propelled them to their position as a global industry leader. William Cook is the main supplier of vehicle tracks to the British Army, in addition to having their products on the majority of armored fighting vehicles worldwide.

These vehicle tracks include a key component – track pins – which are designed to endure intense wear and tear from large, fast moving vehicles on uneven terrain. Components are produced to be strong, lightweight, and durable – at enormous production volumes. The material used is challenging to machine, and the combination of design and production demands leaves no room for compromise.

Track pins have a deep hole throughout the length of the part, which William Cook had previously been sending out to be gundrilled. A company-wide initiative to further modernize production provided plant systems engineer Brian Birkett with the responsibility of not only bringing the process in-house, but to also educate himself and his team on the foundations of deep hole gun drilling.

CONFIDENCE BEGINS WITH EDUCATION Deep holes exist in the majority of industries, and many manufacturers such as William Cook encounter these applications, typically considered holes with a depth-to-diameter ratio of 20:1 or greater. When manufacturers are inexperienced with the process and equipment, the specific challenges can seem intimidating to go through alone.

However, deep hole drilling uses modern tools, machines, and technology and follows proven methods. With the right partner and experience, in- sourcing the process and planning for long-term gundrilling success is easily manageable.

The team at William Cook initially brought their application to UNISIG for a machine solution, but according to Brian, UNISIG provided more than just a recommendation.

UNISIG’s technical team provided indepth foundation information about the gundrilling process, available tooling, and the right machine to meet their needs.

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“The machines are perfectly paced to keep up with production. The machines do exactly what was promised. UNISIG knows what they are talking about, and our expectations are exceeded.”

Increase your mold manufacturing versatility Brian also praised the ease of operation, with UNISIG’s standard using the power of gundrilling with the PLC interface and a thorough training session, allowing the team to feel completely confident with deep leaders in deep hole drilling, UNISIG. Offering hole drilling. The straightforward operation complete solutions for everything allows them tofrom set up their program Brian and UNISIG discussed a heavy duty, and let the machine do the work, while simple to complex mold components, UNISIG operators monitor the process and look for multi-spindle gundrilling machine, designed machines help moldmakers improve improvements.

“It’s such a benefit. It’s so to maximize the production potential of easy to learn”, he commented. high-feed indexable gundrilling tools. efficiency, throughput and precision with Following this initial proposal, the team Overall, the initial payback from the visited the Wisconsin, USA facility to see the outstanding part-processing versatility at an investment is expected to take place within process and machines first hand, meet with 2 to 3 years, according to the team, and the exceptional the technical team to reviewvalue. the application in detail, and learn what goes into the precision of UNISIG machines.

long-term impact will be substantial.

SUPPORT FEELS CLOSE

YOUR MOLDMAKING OPERATIONS “UNISIG’sTAKE knowledge of how our application TO HOME would benefit from indexable gundrilling FURTHER WITH UNISIG TODAY. was influential in our decision to go with Having close support post-installation them” he stated. “They clearly explained was another priority to William Cook.

Partnering with an international supplier what we needed to know, addressed all the can sometimes create distance, but this questions we had, and brought confidence was not the case with UNISIG. Technical in what ultimately was our solution. ” Find out more at www.UNISIG.com support teams are quickly able to access the Brian went on to explain that the machine and the operating staff to diagnose combination of process, plus procedure, and troubleshoot, even when remote. The plus expertise contributed to their firsttechnical support from early on in the sales class experience with UNISIG, throughout process, to responsiveness after installation the entire process. He praised the team for has set UNISIG apart from others. immediately being able to recognize and “UNISIG’s service team responds quickly to understand the demands of the application, take care of any issues, just as if we were and do a thorough job of presenting next door. Support feels close to home.” a solution – one which has lived up to expectations.

Brian’s confidence with the UNISIG machine and partnership has influenced William INTUITIVE AND POWERFUL Cook’s long-term reliable production, and a modern solution that aligns with the future The UNI-25HD machine at William Cook of their company. is currently running full production with three products, and plans to expand their part lineup. The machine is surpassing William Cook’s expectations for required cycle time, with the high gundrill feed rates and multiple spindles, made possible with matched power and torque requirements on the machine.

Loading automation is seamlessly integrated to maintain a steady production pace with less operator effort. Brian believes that they have a solution that is perfectly aligned to their part and performance requirements.

UNISIG is also exhibiting at the EMO show in Hannover, Germany 16.-21.

09. 2019, Hall 15, D34 Further information on all machines of the UNI series and the complete UNISIG machine program is available at: www.unisig.com or follow the company on LinkedIn and Twitter (@ UNISIG).

UNISIG.COM

UNISIG TAKES YOUR GUNDRILLING PRODUCTION FURTHER

Gundrilling and BTA deep hole drilling for highly productive shops.

Whether your shop needs on-center or off-center holes, specialized job shop work or fully automated production, UNISIG has a deep hole drilling solution with the accuracy and performance you need.

Take your shop’s production further - learn more at UNISIG.COM.

The world of metalworking - UNISIG Hall 15 D34 UNISIG machines, engineered and manufactured in the USA

MEASUREMENT & MONITORING

FLOW MEASUREMENT BELL FLOW SYSTEMS

A GUIDE TO CHOOSING THE RIGHT FLOW METER Flow measurement is a critical aspect of plant and process operation in many industries.

Users choosing equipment to measure the flow of liquid or gas processes must consider a wide range of factors to arrive at an optimal solution. Experience has shown there are significant differences between flow meter technologies, with each type of device having its own advantages and disadvantages. The following article describes the key criteria in flow meter selection. It evaluates the most common instrument designs and offers guidance in implementing the right solution for specific applications.

TYPICAL FLOW APPLICATIONS In modern plants and facilities, personnel need to make faster and better decisions by capturing, managing and analysing the right data at the right time. These facilities rely heavily on flow processes, and thus accurate and reliable measurement technology is vital to the efficiency and safety of their operations.

Typical flow-metering applications in the chemical/petrochemical sector for example include: • • • • • • • • • • • • • • • • •

Chemical Batching Dosing/Blending Catalyst Injection Chemical Recovery Custody Transfer Steam Flow Lube Oil Loading Process Cooling Pressure Regulation Leak Detection Fuel Consumption Monitoring Fiscal Transfer Product Load-out Reactor Feed Safety Shutdown Waste Treatment Emissions Monitoring

Most chemical processing plants have two primary flow measurement challenges: accuracy and cost. The goal is to correctly match the right flow meter to the right application to achieve the best performance for the lowest purchase prices and total cost of ownership.

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COMMON MEASUREMENT TECHNOLOGIES Flow meters are excellent tools to measure, monitor, and control the distribution of a host of process fluids. The question is which technology to use, since a wide variety of meter designs are available. Each type of meter has pros and cons, and must be properly deployed to achieve optimal performance.

Coriolis Coriolis meters contain a vibrating tube in which a fluid flow causes changes in frequency, phase shift or amplitude. The sensor signal is fed into the integrally mounted pc-board. The resulting output signal is strictly proportional to the real mass flow rate, whereas thermal mass flow meters are dependent of the physical properties of the fluid.

One of the most important features of Coriolis flow meters is that they directly measure fluid mass over a wide range of temperatures with a very high degree of accuracy. Their unobstructed, open flow design is suitable for viscous, non-conductive fluids that are difficult to measure with other technologies.

With no internal moving parts, Coriolis meters require a minimum amount of attention once installed. However, they are sometimes considered too sophisticated, expensive or unwieldy for certain applications (See Fig 3).

Differential Pressure Differential Pressure (DP) meters measure the pressure differential across the meter and extract the square root.

They have a primary element that causes a change in kinetic energy, creating differential pressure in the pipe, and a secondary element measuring the differential pressure and providing a signal or read-out converted to the actual flow value.

Differential Pressure meters are versatile instruments, which employ a proven, wellunderstood measuring technology that does not require moving parts in the flow stream. DP meters are not greatly affected by viscosity changes, however, they have a

history of limited accuracy and turndown, as well as complex installation requirements.

Electromagnetic Electromagnetic meters employ Faraday’s law of electromagnetic induction, whereby voltage is induced when a conductor moves through a magnetic field.

The liquid acts as the conductor, with energized coils outside the flow tube creating the magnetic field. The produced voltage is directly proportional to the flow rate.

Electromagnetic meters will measure virtually any conductive fluid or slurry, including process water and wastewater. They provide low pressure drop, high accuracy, high turndown ratio, and excellent repeatability.

The meters have no moving parts or flow obstructions, and are relatively unaffected by viscosity, temperature and pressure when correctly specified. Nevertheless, their propensity to foul can cause maintenance issues. Electromagnetic meters tend to be heavy in larger sizes and may be prohibitively expensive for some purposes.

Positive Displacement Positive Displacement (PD) meters separate liquid into specific increments, and the flow rate is an accumulation of these measured increments over time.

The rotational speed of a PD meter’s impeller is a function of the process flow. An internally coupled counter, either electronic or mechanical, monitors the measuring element’s rotations to provide a volumetric recording of the flow total.

Positive Displacement meters are highly accurate (especially at low flows) and have one of the largest turndown ratios. The devices are easy to maintain as they have only one or two moving parts.

There is no need for straight pipe lengths as with other metering approaches. However, PD meters require clean fluids and can be large and burdensome to install.

Thermal Mass Thermal Mass meters utilize a heated sensing element isolated from the fluid flow path. The flow stream conducts heat from the sensing element, which is directly proportional to the mass flow rate.

The meter’s electronics package includes the flow analyser, temperature compensator, and a signal conditioner providing a linear output directly proportional to mass flow.

Thermal mass meters carry a relatively low purchase price. They are designed to work with clean gases of known heat capacity, as well as some low-pressure gases not dense enough for Coriolis meters to measure. The main disadvantage of thermal technology is low-to- medium accuracy, although suppliers have improved the capabilities of these meters in recent years.

Turbine Turbine meters contain a freely suspended rotor, and the flow against its vanes causes the device to rotate at a rate proportional to flow velocity. A sensor/ transmitter is used to detect the rotational rate of the rotor; when the fluid moves faster, more pulses are generated. The transmitter processes the pulse signal to determine the flow of the fluid in either forward or reverse direction.

Turbine meters incorporate a time-tested measuring principle, and are known for highaccuracy, wide turndown and repeatable measurements.

They produce a high-resolution pulse rate output signal proportional to fluid velocity, and hence, to volumetric flow rate Turbine meters are limited to use with clean fluids only. Bearing wear, a common concern with this type of device, was largely addressed by the development of ceramic journal bearings.

As a mechanical meter, turbines require periodic recalibration and service.

Impeller Impeller meters are frequently used in large diameter water distribution systems. The device consists of a paddle wheel inserted perpendicularly into a process stream. The number of rotations of the paddlewheel is directly proportional to the velocity of the process.

Impeller meter attributes include: direct volumetric flow measurement (often with visual indication), universal mounting, fast response with good repeatability, and relatively low cost.

Note their performance suffers in applications with low fluid velocity. The meters are also sensitive to flow profile. They can only be used in clean, low-viscosity media.

Variable Area Variable Area meters are inferential measurement devices consisting of two main components: a tapered metering tube and a float that rides within the tube. The float position — a balance of upward flow and float weight — is a linear function of flow rate. Operators can take direct readings based on the float position with transparent glass and plastic tubes.

Simple, inexpensive and reliable, Variable Area meters provide practical flow measurement solutions for many applications. Be advised most of these meters must be mounted perfectly vertical. They also need to be calibrated for viscous liquids and compressed Gases. Furthermore, their turndown is limited and accuracy relatively low.

Ultrasonic There are two types of ultrasonic meters: transit time and Doppler. Both designs will detect and measure bi-directional flow rates without invading the flow stream. Ultrasonic meters are ideal for troubleshooting, diagnostics and leak detection. They can be used with all types of corrosive fluids, as well as gases, and are insensitive to changes in temperature, viscosity, density or pressure.

Ultrasonic meters have no moving or wetted parts, suffer no pressure loss, offer a large turndown ratio, and provide maintenancefree operation—important advantages over conventional mechanical meters. Conversely, the precision of these meters becomes much less dependable at low flow rates Unknown internal piping variables can shift the flow signal and create inaccuracies.

Vortex Vortex meters make use of a principle called the von Kármán effect, whereby flow will alternately generate vortices when passing by a bluff body. A bluff body is a piece of material with a broad, flat front that extends vertically into the flow stream.

Flow velocity is proportional to the frequency of the vortices. Flow rate is calculated by multiplying the area of the pipe times the velocity of the flow. Vortex meters have no moving parts that are subject to wear, and thus regular maintenance is not necessary.

Only clean liquids can be measured with this type of instrument. They are particularly well suited for measurement of gas emissions produced by wastewater. Vortex meters may introduce pressure drop due to obstructions in the flow path.

Oval Gear Oval Gear meters utilize a positive displacement meter design, whereby fluid enters the inlet port and then passes through the metering chamber. Inside the chamber, fluid forces the internal gears to rotate before exiting through the outlet port.

Each rotation of the gears displaces a specific volume of fluid. As the gears rotate, a magnet on each end of the gear passes a reed switch, which send pulses to the microprocessor in the register to change the LED display segments. The latest breed of Oval Gear meters directly measures actual volume. It features a wide flow range, minimal pressure drop and extended viscosity range. This design offers easy installation and high accuracy, and measures high temperature, viscous and caustic liquids with simple calibration.

Nutating Disc Nutating Disc meters are most commonly used in watermetering applications. A disc attached to a sphere is mounted inside a spherical chamber. As fluid flows through the chamber, the disc and sphere unit wobble or “nutate ”. This effect causes a pin, mounted on the sphere perpendicular to the disc, to rock.

Each revolution of the pin indicates a fixed volume of liquid has passed. Nutating Disc meters have a reputation for high accuracy and repeatability, but viscosities below their designated threshold adversely affect performance. Meters made with aluminium or bronze discs can be used to meter hot oil and chemicals.

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KEY FACTORS IN FLOW METER SELECTION In a typical chemical production facility, fluid characteristics eg. single or double phase, viscosity, turbidity, flow profile (laminar, transitional, turbulent, etc.), flow range, and accuracy requirements are all important considerations in determining the right flow meter for a particular measurement task.

Additional considerations such as mechanical restrictions and output-connectivity options also impact the userâ&#x20AC;&#x2122;s choice.

For most general industrial applications, the key factors in flow meter selection are: Process Media Different flow meters are designed to operate best in different fluids/gases and under different operating conditions. Thatâ&#x20AC;&#x2122;s why it is important to understand the limitations inherent to each style of instrument. The most important difference between these two types of media lies in their relative compressibility (i.e, gases can be compressed much more easily than liquids). Consequently, any change that involves significant pressure variations is generally accompanied by much larger changes in mass density in the case of a gas than in the case of a liquid.

Type of Measurement Industrial flow measurements fall under one of two categories: mass or volumetric.

Volumetric flow rate is the volume of fluid passing at a given volume per unit time eg. Litres per minute. Mass flow rate is the movement of mass per time unit eg.

Kilograms per minute.

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It can be calculated from the density of the liquid (or gas), its velocity, and the cross sectional area of flow. Volumetric measuring devices, like variable area meters or turbine flow meters, are unable to distinguish temperature or pressure changes.

Mass flow measurement would require additional sensors for these parameters and a flow computer to compensate for the variations in these process conditions.

Thermal mass flow meters are virtually insensitive to variations in temperature or pressure.

Flow Rate Information A crucial aspect of flow meter selection is determining whether flow rate data should be instantaneous or continuous. A flow rate has to do with the quantity of a gas or liquid moving through a pipe or channel within a given or standard period of time. A typical continuous flow measurement system consists of a primary flow device, flow sensor, transmitter, flow recorder, and totalizer.

Desired Accuracy In many production processes, accurate flow measurements can be the difference between on-spec quality and wasted product.

Flow meter accuracy is specified in percentage of actual reading (OR), percentage of calibrated span (CS), or percentage of full-scale (FS) units. It is normally stated at minimum, normal, and maximum flow rates.

A clear understanding of these requirements is needed for a meterâ&#x20AC;&#x2122;s performance to be acceptable over its full range.

Application Environment Flow meters can be employed under a host of varying conditions in a chemical process plant.

For example, users must decide whether the low or high flow range is most important for their metering application. This information will help in sizing the correct instrument for the job. Pressure and temperature conditions are equally important process parameters.

Users should also consider pressure drop (the decrease in pressure from one point in a pipe to another point downstream) in flow measurement devices, especially with high-viscosity fluids. In addition, viscosity and density may fluctuate due to a physical or temperature change in the process fluid.

Fluid Characteristics Users should be cautious that the selected flow meter is compatible with the fluid and conditions they are working with. Many chemical and petrochemical operations involve abrasive or corrosive fluids, which move under aerated, pulsating, swirling or reverse-flow conditions. Thick and compacted materials can clog or damage internal meter components, hindering accuracy and resulting in frequent downtime and repair.

Installation Requirements Planning a flow meter installation starts with knowing the line size, pipe flow direction, material of construction, and flange-pressure rating. Complications due to equipment accessibility, valves, regulators, and available straight pipe run lengths should also be identified. Many types of flow meters must be installed with a run of straight pipe before and after their mounting location. Where this is not possible, a flow conditioner can be used to isolate liquid flow disturbances from the flow meter while minimizing the pressure drop across the conditioner.

Power Availability and Hazardous Areas Pneumatic instrumentation was once used in most hazardous area applications, since there was no power source to cause an explosion. Today’s ATEX installations normally call for intrinsically safe instruments, which are “current limited” by safety barriers to eliminate a potential spark or Explosion proof solutions which feature approved E xd enclosures. Self-powered flow meters offer an advantage in such environments or where a power source is not available. They do not require external power to provide a local rate/ total indicator display for a field application, and instead rely on battery-power for displaying, logging and transmitting data.

Solar-powered systems can also be used in remote areas without power.

Users should closely evaluate their process conditions, including flow rates, pressure and temperature, and operating ranges. Do not be swayed by lower priced alternatives that would be applied outside of their capabilities.

All flow meters are affected to some extent by the flowing medium they are metering and by the way they are installed.

Consequently, their performance in real world conditions will often be different from the reference conditions under which they calibrated.

For the lowest uncertainty of measurement, positive displacement meters are generally the best option.

Electromagnetic meters provide for the some of the widest flow “turn-down” ranges and turbine meters are usually the best choice for the highest short-term repeatability vs price.

bends sometimes suffer from abrasive media wear and blockages. Changes in temperature also affect the internal dimensions of the meter and require compensation.

The need to recalibrate a flow meter depends on how well the instrument fits a particular application. If the application is critical, meter accuracy should be checked at frequent intervals. Otherwise, recalibration may not be necessary for years because the application is non-critical, or there are no factors which will change the meter’s performance.

No matter the chosen flow meter technology, overall system accuracy will not exceed that of equipment used to perform the meter calibration. The most precise flow calibration systems on the market employ a positive displacement design. This type of calibrator, usually directly traceable to National standards, provides total accuracy of at least 0.05 percent.

Necessary Approvals UK firms are obliged to comply with strict standards set by the EU. Approvals for the use of flow measurement equipment in hazardous locations are covered by the ATEX directive. Standards such as the Measuring Instruments Directive (MID) apply to fiscal and custody transfer metering for liquids and gases. In terms of environmental emissions, industrial flow meters must meet the Electromagnetic Compatibility (EMC) Standards EN55011:1992 and EN613261:1997.

Output/Indication Flow meter users must decide whether measurement data is needed locally or remotely. For remote indication, the transmission can be analogue, digital, or shared. The choice of a digital communications protocol such as HART®, FOUNDATION Fieldbus™ or Modbus also figures into this decision. In a large industrial facility, flow readings are typically supplied to an industrial automation and control system or SCADA system for use in process control and optimization strategies.

OTHER IMPORTANT CONSIDERATIONS Companies purchasing flow meters should remember that accurate instruments cost more based on their capabilities. It is better to locate the type of meter suited to a specific application before sacrificing features for cost savings.

Despite their high initial cost, Coriolis meters are ideal for measuring particularly viscous substances and anywhere that the measurement of mass rather than volume is required.

Flow meter users should also take care to examine long-term ownership costs. A flow meter with a low purchase price may be very expensive to maintain. Alternatively, a meter with a high purchase price may require very little service. Lower purchase price does not always represent the best value. Generally speaking, flow meters with few or no moving parts require less attention than more complex instruments. Meters incorporating multiple moving parts can malfunction due to dirt, grit or grime present in the process fluid.

Meters with impulse lines can also plug or corrode, and units with flow dividers and pipe

SUMMARY Choosing the right flow measurement solution can have a major impact on operational and business performance.

For this reason, companies anticipating a flow meter purchase should consult with a knowledgeable instrumentation supplier in the early stages of a project.

The effort spent learning about basic flow measurement techniques, and available meter options, will ensure a successful application once the equipment is installed. www.bellflowsystems.co.uk

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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

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 Issue 40 PECM

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MEASUREMENT & MONITORING

MMS® INSPECTION SERIES FISCHER INSTRUMENTATION

NACE: CORROSION COSTS $2.5 TRILLION ANNUALLY Every year, corrosion causes an economic damage of more than $ 2.5 trillion worldwide. Therefore, the prevention of corrosion, is an issue that plays an im­portant role in many areas. The new MMS® Inspection series that is optimized for corrosion protection reli­ably supports the inspector in assessing corrosion-ex­posed components and in jobs that involve checking of corrosion protection.

Corrosion is the deterioration of a metal as a result of chemical reactions between it and the surrounding en­vironment. This leads to a functional impairment of the metallic component over time. Accordingly, rust forma­tion on a railroad track is not harmful, since the function of the rail is not diminished. However, a pipe which has become leaky due to pitting corrosion is clearly defective, since the safe transport of liquids is no longer guaran­teed. The same applies to the maritime sector, where material surfaces attacked by corrosion on ship walls can quickly become a safety risk.

There are serious con­sequences caused by corrosion in engineering structures such as bridges. If the steel structure corrodes without any control, a bridge can quickly become a threat to those who move on it.

Furthermore, there are economic advantages to implementing proper corrosion prevention methods.

In order to protect metallic materials against environ­mental influences and thus corrosion, in most cases coating with suitable corrosion protection material is sufficient. The expense for this – passive – corrosion pro­tection is relatively low in relation to the costs caused by corrosion such as loss of value, downtime, dismantling, etc. For companies and institutions saving on corrosion protection, it usually becomes expensive to repair the damages afterwards. This is especially so for structures that are very difficult to access after installation, such as offshore wind turbines. Corrosion protection involves regular inspection and checks for proper functioning. This means that inspectors and service personnel need to use targeted measurements to inspect if the quality of the corrosion protection coatings still meet specified standards.

With regard to coating thickness gauges used here, both magnetic induction method and eddy-current testing have established themselves as standards worldwide.

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MMS® Inspection DPM (Dew Point Meter)

MMS® Inspection SPG (Surface Profile Gauge)

1) NACE International, impact.nace.org The MMS series offers a third model, the MMS (2016)Inspection SPG. This gauge measures according to the “Peak to Valley” method,of meeting ASTM D 4417-B Rusting, the formation iron oxides, is a and US Navy NSI 009-32 standards. The surface profile well-known example of electrochemical depth influences the amount of paint needed. If the peak to valley distance is too big, the applied paint layer may corrosion. not be thick enough on the peaks. Additionally, the profile infuences the adhesion of the paint on the surface.

Magnetic induction is the method of choice The MMS series offered as a of set non-magnetic of three to enable for measur­ ing theisthickness better corrosion protection. They are the only device layersonon baseIPmaterials, themagnetic market that meet 65 protectione.g. requirements includeplastic, dust protection and water layerswhich of paint, galvanized orproof. hot-dip galvanized on offers steelone-handed and iron.operation The eddy The MMSlayers Inspection and provides immediate feedbackfor by means of light, vicur­rent method is suitable electrically bration and sound. The auto rotate function allows the non-conductive layers on non-ferrous corrosion inspector to view measurement results at all metals, such as e.g. paint, lacquer or plastic important angles. on aluminium.

Depending on the version, modern gauges such as the newly developed MMS® Inspection series from Helmut Fischer offer both measuring methods.

Helmut Fischer has made every effort to ensure the con­venience of the user. For this reason, international mea­surement standards such as SSPC PA2 (Level 1-5), IMO PSPC, ISO 19840, Australian AS 3894.3-2002 or Swedish IS 1841 60 are firmly integrated as pre-configured batches or measurement specifications via the software. The dew point measuring device MMS® Inspection DPM, which belongs to the same series, measures the dew point before the corrosion protection paint is applied. This helps to ensure that the coating is applied under proper environmental conditions. If the conditions are not suitable, premature corrosion may occur or the paint may peel off as a result of poor adhesion.

MMS® Inspection DFT (Dry Film Thickness)

Inspection SPG. This gauge measures A big advantage of the MMS® Inspection series is the according the “Peak Valley” intuitive usertointerface for allto systems.

Themethod, software guides theASTM user step step through meameeting D by 4417-B and the USindividual Navy NSI suring programs and shows him how to proceed with 009-32 standards.

The surface profile depth each measurement. Thus, the devices can be handled influences amount of paint needed. If the reliably eventhe by untrained personnel. peak to valley distance is too big, the applied Helmut Fischer has designed this series of gauges to paint may not beinspection thick enough on easthe makelayer corrosion protection considerably ier. ThisAdditionally, enables many companies the world tothe peaks. the pro­around file infuences avoid corrosion damage andon thethe resulting loss of value. adhesion of the paint surface.

The MMS series is offered as a set of three to enable better corrosion protection. They are the only device on the market that meet IP 65 protection requirements which include dust protection and water proof.

The MMS Inspection offers one-handed operation and provides immediate feedback by means of light, vi­bration and sound. The auto rotate function allows the corrosion inspector to view measurement results at all important angles.

Intuitive user interface for all systems.

The software guides the user step by step through the individual mea­suring programs and shows him how to proceed with each measurement. Thus, the devices can be handled reliably even by untrained personnel.

Helmut Fischer has designed this series of gauges to make corrosion protection inspection considerably eas­ier. This enables many companies around the world to avoid corrosion damage and the resulting loss of value. www.fischergb.co.uk

Absolutely reliable.

Even under harsh conditions.

THE NEW MMS® INSPECTION SERIES

Corrosion protection starts well before the first coat of paint. The corrosion kit MMS® Inspection comprises three devices that are needed before, during and after surface coating. With the SPG, you can reliably measure the surface profile. The DPM provides all the necessary data for determining the dew point. The powerful DFT is your mobile companion for all coating thickness tasks (ferrous and non-ferrous substrates). www.fischergb.co.uk

MEASUREMENT & MONITORING

INDUSTRY TRENDS SPIRAX SARCO

“NOW IS THE TIME TO OPTIMISE YOUR CONTROL SYSTEM’S POTENTIAL” ADVISE STEAM EXPERTS Process managers could be making improvements to increase efficiency and product quality by paying closer attention to the specification of controls systems used within their facilities – that’s the current message from Spirax Sarco’s National Controls Specialist, Darren Silverthorn.

The latest quarterly Confederation of British Industry (CBI) Industrial Trends Survey suggests that output volumes will be broadly flat in the coming three months (-2%)1. While it is estimated that average unit costs will grow (+31%) in that same period2. As such, Spirax Sarco advocates reviewing control systems as this is one area that could have a positive impact on future budgets. By upskilling staff in controls systems alongside identifying improvements in controls systems technology, manufacturers could reduce costs and improve efficiencies in the absence of increased sales.

Over the coming months, Spirax Sarco will be identifying the key tell-tale signs of inefficient control systems along with significant gains process managers can make to optimise their potential. Ultimately aiming to mitigate the risk of downtime and product spoilage, while also aiding process productivity.

Darren Silverthorn, National Controls and Metering Specialist explains: “A lot of the time, early warning signs related to potential equipment failure can go unnoticed. Control systems ultimately enable safety, stability and accuracy throughout a process. If they are not maintained appropriately, or are not specified correctly prior to initial installation, then any of these things can be jeopardised.”

Darren continues: “Reducing downtime and improving productivity must begin with a more robust specification. When it comes to control systems and control valves in particular, quality issues can arise due to poor specification, either poorly specified or more commonly due to a lack of information being provided during the specification stage.”

the day and that operating a steam system is not always forefront of mind. We are therefore on a journey to help educate those responsible for steam systems on control system strategies that can be put in place, or simply offer additional expertise and resource where it may be limited inhouse.”

Darren concludes: “We know our customers’ roles are becoming more demanding by

Spirax Sarco’s campaign will cover the full spectrum of improvements that can be

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implemented within a steam system to help make the lives of plant managers, process engineers, production managers and the like that little bit easier.

For more information on optimising your control system’s potential, visit: www.spiraxsarco.com/global/uk/ Products/Pages/control-valves.aspx

MEASUREMENT & MONITORING

HELMHOLTZ COIL SYSTEMS BARTINGTON

BARTINGTON INSTRUMENTS ADDS HELMHOLTZ COIL SYSTEMS TO ITS RANGE

Bartington Instruments has now added Helmholtz coil systems to its range. These generate precise magnetic fields ideal for calibration of magnetometers and compasses, and are currently used at Bartington’s own calibration facility.

Helmholtz coils are available in several diameters, from 350mm to 2m. These are supported by a power amplifier and complete control system compatible with every coil in the range. Operating in DC and AC, the three-channel power amplifier delivers up to 29A at DC and frequencies up to 5kHz. Amplitudes and frequencies are coil-dependent, with smaller coils achieving fields exceeding 1mT at DC, and in excess of 100µT at 5kHz.

The control system can be expanded to include a closed-loop control module. This provides active feedback for cancellation of external field variations, making it possible to use the coils in a manufacturing environment. A precise fluxgate sensor is also used as part of the closed-loop system to monitor field disturbances within the coil, achieving field stability of a few nT. The system may be computer controlled via the addition of a National Instruments™ data acquisition card and LabVIEW™ software.

By using source code that we provide, you can adapt the software to your exact requirements, enabling seamless integration into your testing and manufacturing procedures.

These systems benefit from reduced orthogonality errors, which facilitates precise calibration of optical range-finding equipment, magnetic field sensors and compasses inside consumer electronics, and magnetometer packages found in oil and gas industry directional drilling tools. The larger coils in the range are suitable for calibration and testing of satellite subassemblies and CubeSats.

In addition to Helmholtz coil systems, Bartington Instruments also provides equipment for magnetic field surveys of proposed installation sites, in order to achieve the best possible system performance. www.bartington.com/ Issue 40 PECM

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MONITORING HOT SPOTS ADVANCED ENERGY - LUMASENSE

CVM SYSTEM FROM LUMASENSE ALLOWS OPERATORS TO MONITOR THE TEMPERATURE AND INTEGRITY OF CRITICAL ASSETS SAFELY AND ACCURATELY In petrochemical and refining facilities, the monitoring of critical assets such as reformer furnaces and gasification vessels is crucial to maximising efficiency and minimising system downtime and potential safety issues.

The extreme temperatures and pressures involved in these processes can result in high exterior skin temperatures on these assets and their supporting manifolds, piping and joints. Such intense stresses can then lead to damage and failure of the vessels.

Areas of poor combustion mean cooling can be as much of a problem as overheating. If temperatures are too low, condensate can build up between the shell and refractory, leading to corrosion and lower pressure containment capability. Corrosion can also cause the refractory to flake off, allowing sudden burn-through of the shell.

With this in mind, accurate temperature measurement is a vital part of keeping production running. Yet these extreme temperatures and non-uniform gradients mean obtaining accurate data at multiple critical points is a difficult task. Traditionally, thermocouple systems and fibre optic distributed sensing systems have been used for temperature measurement on critical vessels, but these sensors can be unreliable and prohibitively expensive to install and operate.

Typically, they employ wired or fibre optic networks with point sensors which only monitor the temperature of discrete points on the outside of a vessel, often with poor spatial resolution. This can result in inaccurate measurements owing to skin temperature gradients. In addition, the failure of thermocouples or fibre breakage can leave dangerous gaps in entire monitoring systems until they are replaced or repaired.

Instead, innovative thermal imaging systems have demonstrated how radiometric thermography has evolved into a mature and cost-competitive alternative. The non-contact nature of infrared thermal imaging is more robust, more reliable and easier to maintain than wired networks. It also presents a number of technological advantages, such as graphical visual displays,

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historical archiving and trending, hot-spot tracking and easy integration into existing control systems.

THE BIGGER PICTURE

Advanced Energy’s LumaSense ThermalSpection CVM system uses microbolometer-based imagers to collect thermal infrared radiation emitted from monitored components, giving accurate temperature readings at up to 500°C or more.

With multiple imagers placed strategically around the vessel perimeter, a user can build a complete thermal image, with special resolution down to 5cm or less – all without direct contact. Each camera is mounted in a sealed, ATEX- or Class I, Div 2-certified housing. This unit includes internal cooling and a positive pressure purge to prevent flammable gases or dust from entering the enclosure.

With one-second response times, the ThermalSpection CVM system provides continuous coverage with alarm generation functions. Output options include OPC to the plant DSC, Analog and relay outputs. Custom software options build on this platform provide displays of thermal profiles, historical trends which can be compared against baseline performance and developing hot spots can be tracked in real time.

A further benefit of remote monitoring is that the system can be installed, upgraded and serviced in the field, with the vessels remaining in full operation. Each client’s site is custom-modelled, with optics and camera mounting locations chosen to guarantee the best spatial coverage and resolution.

www.lumasenseinc.com

MEASUREMENT & MONITORING

GOT MODBUS? CAPTION DATA

GET INSTANT REMOTE MONITORING & INTERNET OF THINGS! Adding connectivity from your devices to a cloud based IOT portal to manage your assets has never been easier!

Using products and the IOT platform from Caption Data Ltd in Worcester provides an “out of the box” or “plug and play” solution with immediate access..

Watch the video at https://youtu.be/ yUgBKSqXE5A Once their NanoULTRA Edge product is connected to your target device (RS232 or RS485) and powered up, all of the configuration work is then done via the SmartHub. There is no need to connect to the device directly with a PC to configure Modbus communications.

This can all be achieved, securely via any browser using any Smart Device. So no software to buuy or load!

What exactly can you do via the SmartHub in terms of Modbus configuration?

• Quickly chose controllers from a drop down menu • Add new controllers with a list of Modbus registers • Set baud rates, stop bits etc.

• Save Controllers which can be recalled at any point in the future with new NanoULTRA systems • Configure registers for both read and write functions • Add up to four different slave devices to any one NanoULTRA e.g. Power meter, flow meter, environmental sensor all communicating to one NanoULTRA • Configure what Users (as opposed to administrators) can view • Select which registers you wish to monitor at high frequency • Apply bit masks to data strings and associate to alarm messages And what could this mean to your business?

• Improved customer service levels • A helicopter view of your assets with single click drill down to individual units to manage them

• Faster, less onerous commissioning, with less time on site • Better resolution of customer issues • Improved spares & maintenance sales All of which adds up to improved competitive advantage, improved profits and reduced risks!!

Caption Data supply a host of global engineering businesses with their IOT solutions, and provide a one stop shop.

You can contact them on +44 (0)1905 754078 or at solutions@captiondata. com and find lots more information at www.captiondata.com Issue 40 PECM

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FUEL CELLS

BURKERT

CONTROLLING THE ENERGY OF THE FUTURE FLUID CONTROL

Fuel cells have been hailed as the energy source of the future; they can provide a non-polluting supply of power by recombining hydrogen and oxygen to create electricity and water. The chemistry sounds very simple, however creating a reliable, efficient and safe energy source requires considerable expertise, especially in the control of the fluids and gases that are involved in this exciting technology.

The steam generation process required to humidify the gases needs a control loop for ultra-pure water as well as a drain valve for the condensate. Without this, the fuel cell would fill up with water and eventually become inoperable. In some situations, the hydrogen gas may pass through a water quench instead of being mixed with steam. In this case, the level of the water must also be carefully controlled.

Tony Brennan, Field Segment Manager, Gas & Micro, at Bürkert, looks at the process in more detail, what is needed to develop the technology and make it more widely available.

Fuel cell technology has been around since 1839, when electrochemical energy was first produced by combining hydrogen and oxygen, with water as the only by-product.

Since then, the idea has found some niche applications (space exploration for one) but has not been commercialised on a large scale. However, in recent years the market has embraced several different designs and manufacturers are working to fulfil the demand for potential ‘green energy’.

GRASPING THE BASICS

Fuel cells essentially convert electrochemical energy into electricity, heat and water. They make a very good proposition for combined heat and power (CHP) projects then; but, can also be scaled-down for use in mobile applications. Each cell contains two electrodes, the anode and the cathode, as well as the electrolyte which connects the two.

Hydrogen in gaseous form is fed to the anode, while oxygen is supplied to the cathode. The hydrogen fuel travels across the electrolyte, inducing a positive and negative charge, which generates the electrical current. When it is combined with the oxygen, it forms water, which needs to be drained away.

As the fuel, the hydrogen gas needs to be replenished, and there are several ways in which this can be accomplished. Together with the type of electrolyte, these two variations set out the differences between the five main types of fuel cell. Each one has it advantages and its challenges, but

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In addition, the water that is created by the electrochemical reaction also needs to be drained. The main challenge in all these situations is the corrosive nature of ultra-pure water, which means that material specifications for valve components and seals must be carefully considered.

FUEL CELL DEVELOPMENT

all of them require a high degree of control infrastructure to enable them to operate efficiently and reliably.

GAS CONTROL

Accurate gas control is essential for the fuel cell to adapt to changing loads and this depends on understanding the hydrogen source and having a properly calibrated measurement system. Fuel cells that run using hydrogen-rich gas need to have a controlled outlet for the non-hydrogen components, otherwise the production of electricity will stop.

Some types of fuel cell require both the oxygen and the hydrogen to have steam mixed with them to keep the proton exchange membrane humid. The amount of steam required depends on the temperature and load on the fuel cell, which also affects the flow rate of the hydrogen and the oxygen.

In systems that operate with pressurised gases, it is essential for these pressures to be carefully controlled to prevent damage to the internal structures of the fuel cell.

Depending on the type of fuel and the size of the fuel cell, a variety of proportional solenoids, pressure transducers and control valves can be used to adjust and maintain the required pressures within the fuel cell.

Some large-scale and specialist applications for fuel cells have already been established and the technology is advancing at a steady pace. The focus now is on smaller, mobile arrangements along with the creation of a hydrogen fuel station network and the logistics of maintaining it.

Much of the research is carried out on test bench models, where the chemical and physical environments and operational conditions of the real applications can be recreated. This work requires just the same levels of control for the liquids and gases, as well as the ability to record all relevant data for analysis. In fact, it could be argued that the level of control should be more extensive that in the real-world application.

To create gas mixing and metering units, flow control and measurement equipment as well as additional safety shut-off valves, Bürkert draws on decades of experience and expertise. For those developing new hydrogen fuel cell technologies, both large and small, the ability to control and monitor all the parameters in the process accurately and reliably will certainly help to reach the clean energy solutions we are looking for.

Image 1-3: Fuel cells have been hailed as the energy source of the future; providing a nonpolluting supply of power by re-combining hydrogen and oxygen to create electricity and water. www.burkert.co.uk

£ 940

Web: www.youngcalibration. co.uk/calibration Email: ay@youngcalibration. co.uk Tel: 01273 455572

from

The UKAS accredited air flow rig covers 1 cc/min to 1250 l/

sec allowing flowmeters up to 300 mm diameter to be accommodated within the flow calibration rig. The accredited wind tunnels continue to offer world leading measurement uncertainty for UKAS air velocity calibrations on pitot, thermal, vane, cup, omni-spherical and ultrasonic anemometers across 0.05 to 80 m/s.

Also interested in really fast, rugged, light, accurate, customised and inexpensive infrared thermometers and cameras for non-contact measurements between −50 °C to +3000 °C? Visit www.optris.co.uk

The Young Calibration UKAS accredited laboratory (Lab 0604) makes the transition to ISO/ IEC 17025:2017, whilst further continuing to offer world leading flow calibration services. The latest UKAS calibration schedule offers ultra-low flow water infusion and leak calibrations from 1 ml/hour up to a 1000 l/ min up to DN80 flowmeters and traceable water meter calibrations to 4000 l/min on 6” meter sizes.

Thereʼs no two ways about it: our cost-effective Xi series IR cameras with their automatic spot finder function and analog/digital outputs are ideal even for OEM applications.

UKAS ACCREDITED FLOW CALIBRATION SERVICES

On target.

MEASUREMENT & MONITORING

Innovative Infrared Technology

Issue 40 PECM

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STATE-OF-THE-ART KOBOLD

THE WORLD’S SMALLEST DUAL-TUBE CORIOLIS MASS FLOW METER: HIGH PRECISION MEASUREMENTS WITHIN 150 MM Due to the weight influence of sensor coils, for the measurement of very small flowrates it is common practice to use single tube Coriolis flow meters. The sensor coils of dual-tube Coriolis sensors are mounted onto one of the two measuring tubes, thus having, by very small tube diameters, a significant weight influence on the tube on which they are mounted.

Therefore, the influence of the sensor coils on the measurement results increases by decreasing tube diameter. For this reason single tubes are often favoured for the measurement of very small flow‑rates, where the coils are mounted to the chassis and not on the tube. However, with the use of just one measuring tube the influence of external interferences increases dramatically. To reduce this sensitivity and at the same time delivering accurate measurements at very small flow rates, Heinrichs Messtechnik has developed the dual-tube Coriolis principle to a new level.

In this new state-of-the-art technologie, the sensor coils are no longer mounted onto the tubes, but rather between them, thus freeing the measuring tubes from the influence of the coils weight allowing for extremly small tube diameters in dual-tube design.

The result is the world’s smallest dualtube Coriolis Mass flow-meter: The high Performance Coriolis (HPC). With an installation length of just 150 mm it is now possible to achieve high accuracy measurements with deviations of just ± 0.1 percent. Furthermore, the sensor shows insensitivity to temperatures of up to 180 °C, to pressures of up to 600 bar as well as to strong vibrations.

“Market observations have revealed an open gap in the measurement of small flow rates”, explains Frank Schramm, the managing director of Heinrichs Messtechnik GmbH. The current problem is that the state-of-the-art stipulates the use of dual-tube technology, where the magnets are mounted to one tube, the exciter and sensor coils to the other.

However, for very small flow rates this principal has a decisive limit. For example,

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Heinrichs Messtechnik GmbH developed the smallest dual-tubed-Coriolis-Mass-Flowmeter in the world: The High Performance Coriolis (HPC). With an installation length of just 150 mm high accuracy measurements are achieved with deviations of just ± 0.1 percent where extremely small flow rates demands a tube diameter of just 1 mm, the vibrating behavior of the coils weight can influence the measurement results significantly.

“Therefore it is common practice to use one tube systems for these applications, in which the coils are mounted to the chassis of the sensor. This system has the decisive disadvantage in that the second tube, which also serves as a measurement reference, is omitted, requiring that the sensor coils be mounted on to the chassis of the enclosure making the sensor more susceptible to vibrations and other disturbances.

For this reason, Heinrichs Messtechnik GmbH has set as its objective, the development of a high precision, shock

resistant Coriolis Mass Flow Meter.

Emerged is the High Precision Coriolis – short HPC – with its installation length of just 150 mm the smallest Coriolis mass flow meter in dual-tube design.

REDUCING DISTURBANCE INFLUENCES BY POSITIONING THE SENSOR COILS BETWEEN THE MEASURING TUBES “Due to the sensitivity single tube Coriolis sensors, a costly mechanical decoupling is often required, rendering them inappropriate for many applications. Our quest was therefore to find a means of unifying a dual tube design with very small diameter tubes”, explained Schramm.

The whole development phase took a mere 1.5 years. To achieve this short development time Heinrichs Messtechnik utilized the latest simulation technology.

Instead of mounting the coils onto the tubes, the manufacturer chose to mount them onto a PCB situated between the measuring tubes. By simultaneously doubling the number of pickup coils from two to four, the resolution is increased significantly.

Since the fundamental problem lies in the weight of the coils, which when compared with tube diameters of 1.5 mm or less present a significant weight, Heinrichs Messtechnik adopted the following solution: The conventional approach of mounting the coils onto the tubes was abandoned in favour their mounting on a printed circuit board mounted between the tubes. This method also enables the use of four sensor coils instead of two, as is usually the case with dual-tube Coriolis, providing a higher resolution.

On the measuring tubes themselves only very light magnets are mounted, which, with a weight of only 0.08g, have little to no influence on the vibrating behavior of the tubes.

Instead of conventional brazing, the magnet holders are mounted onto the tubes using a special laser-welding technology. Utilizing this method, Heinrichs Messtechnik aims at keeping the production costs of the sensor to an absolute minimum, it not only allows for a stress‑free connection, but also eliminates the time-consuming and elaborate process of brazing in a vacuum oven.

INSENSITIVE TO EXTERNAL INFLUENCES Using the dual-tube design, the new HPC displays extreme insensitivity towards external influences, allowing for precise measurements with a maximum deviation of ± 0.1 Percent of the mean value and a Zero-point stability between 0.001 and 0.005, making a mechanical decoupling in most cases superfluous. Owing to the measuring tubes high working frequency of over 200 Hz, the coupling of installation

vibrations or similar oscillations into the measuring system is prevented and so with avoiding fault signals. A further advantage in mounting the sensor coils on a motionless PCB is the elimination of open wiring within the sensor, as is the case of standard commercially available devices. This wiring often presents a vulnerable weak point, since the wire and its point of connection must vibration continuously with the frequency of the measuring tubes.

With the exception of the laser welded measuring tubes, the HPC consists essentially of a solid drilled and tapped stainless steel block. Furthermore, the HPC has been stripped of a splitter at the inflow of the tubes, instead possessing a reservoir – in which the process pressure distributes the fluid exact into the measuring tubes, hence preventing flow disturbances generally caused by splitters. This technique has the timesaving advantage of one less component to weld as well as one less potential material stress source.

The result is an extremely robust device capable of withstanding temperatures and pressures of up to 180 °C and 600 bar respectively. “In principle, the device may also be ordered with Hastelloy tubes and other alloys”, added Schramm.

VARIABLE ASSEMBLY CONCEPT For flexible installations, different constructive variations of the HPC are available: Besides the traditional Inline Version, which can be inserted directly into the process line, there are three further models available, which are suitable for either wall mounting, by means of wall brackets, or may simply be placed on

a table. “For our Table model there are two available options: either with the measuring pipes pointing downwards below the supply line or pointing upwards above the supply line. For the measurement of gas, upward pointing tubes are recommended to prevent any issues with fluid collecting in the tubes.

The same also goes visa versa for the measurement of fluids”, Schramm remarks.

Collectively, the devices are available in three measuring ranges: 0–20, 0–50 and 0–160 kg/h. On request other adaptations are also available, for example, customer-specific enclosures, connectors or interfaces. In particular for the chemical and semiconductor industry, fully-welded stainless steel enclosures are also available.

RAPID DEVELOPMENT SUCCESS WITH HIGH-END SIMULATION The whole development phase took a mere 1.5 years. To achieve this short development time, Heinrichs Messtechnik utilized a state-of-the-art simulation technology. “By these means the required number of prototypes was drastically reduced, reducing so with development costs significantly”, Schramm says contentedly. Furthermore, with the aid of the simulation technology customerspecific requirements can be captured and individual solutions presented in the shortest of time.

The HPC was presented for the first time on the Hannover trade fair from 23rd to the 27th of April, simultaneously being the official launch of sales. Furthermore, ATEX and IECEx approvals are also planned as well as a patent registration of the technology. Parallel to the launch of sales, Heinrichs Messtechnik is also working on a new miniaturized transmitter with flexible interfaces, specially designed for compatibility with the HPC.

www.kobold.com Issue 40 PECM

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Compact

Compact - high temp

www.kobold.com 01623 427701 info.uk@kobold.com

Quality Engineered Instruments

Compact

Full bore with Compact Electronics

Magnetic Inductive Flowmeters from

Full bore & Insertion - Smart, Hart, ATEX

21/05/2019 Tuesday 21 May 11:03

MEASUREMENT & MONITORING MICRONICS UF AV5500 AREA-VELOCITY FLOW METER

MEASURE FLOW IN OPEN CHANNELS AND PARTIALLY-FILLED PIPES NO FLUME OR WEIR REQUIRED

NEW OPEN CHANNEL OR PARTIALLY-FILLED PIPE FLOW METER Measures Velocity and Level to Calculate Flow n Measure flow in pipes and open channels of any shape n Ideal where flumes or weirs are difficult to install n Works with water level from 25.4 mm (1") to 4.5 m (15 ft.) n Auto-detects field installation of options serial communications and control relays The UF AV5500 Area-Velocity Flow Meter includes a submerged ultrasonic sensor that is installed at the bottom of an open pipe or channel. Exposed materials are stainless steel so the sensor resists fouling and corrosion. It has no moving parts and no orifices, ports or electrodes.

Recommended for: n Wastewater n Industrial Effluent n Stormwater

n Combined Sewers n Natural Streams n Irrigation Water

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For fur ther information call us on

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or email sales@micronicsltd.co.uk w w w.micronicsflowmeters.com Issue 40 PECM

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5-DAY TURNAROUND AVERY WEIGH-TRONIX

AVERY WEIGH-TRONIX OFFERS 5-DAY TURNAROUND ON METROLOGY EQUIPMENT CALIBRATIONS WITH THE OPENING OF NEW CALIBRATION SELECT LABORATORY IN BIRMINGHAM

Avery Weigh-Tronix Calibration Select Laboratory in Birmingham Avery Weigh-Tronix, one of the UK’s leading metrology calibration providers, has opened a dedicated calibration laboratory to offer a 5-day turnaround on the calibration of torque, pressure, temperature and electrical equipment and mass weights.

The Calibration Select Laboratory, located at the company’s Soho Foundry site in Birmingham, features state-of-the-art testing equipment, supported by experienced laboratory technicians and a bespoke, online system which provides direct access to calibration certificates and asset details, and simplifies the customer experience.

Research shows the average turnaround time for metrology calibrations in the UK is between 7-15 days. Often this leads to businesses paying a premium to have items calibrated onsite due to time constraints, or duplicating the number of items needed for a process to use in rotation while others are sent offsite for calibration. While recent changes to the ISO standards for calibrating torque tools will make the process of equipment calibration very difficult to

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achieve when working onsite at customer premises or in a mobile laboratory.

Calibration Select reduces equipment downtime by guaranteeing items are collected, calibrated and returned within 5 days. The expedited turnaround time is made possible thanks to a unique technician collection service, carried out by a network of over 120 Avery Weigh-Tronix service technicians across the UK. While the central location of the Calibration Select Laboratory in Birmingham provides easy access to major UK road networks.

Andrew Fox, Compliance Business Unit Manager at Avery Weigh-Tronix comments, “Based on our customer’s requirements for a single service provider for all types of metrology calibrations, we’ve expanded our offering to benefit our customers whilst developing a unique service model that has not been seen in the market place before.

This enables us to deliver a guaranteed 5-day turnaround and provide our customers with the peace of mind that their equipment will fully conform with quality standards.”

Andrew Fox, Compliance Business Unit Manager, Avery Weigh-Tronix

To find out more, visit calibrationselect.co.uk

MEASUREMENT & MONITORING

TEMPERATURE SENSORS LABFACILITY

TEMPERATURE AND PROCESS TECHNOLOGY

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.

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.

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.

IR INFRARED THERMOMETERS

STAINLESS STEEL BOURDON TUBE PRESSURE GAUGE

Stainless Steel pressure gauges with a large range of pressure ranges to suit your required application. Standard bourdon tubed, glycerine filled and low-pressure industrial capsule versions available.

Commonly used for chemical, petrochemical, power stations, mining, off-shore, environmental technology, machine building and plant construction.

Infrared thermometers are used for measuring the temperature of the object’s surface, which is applicable for various hot, hazardous or hardto-touch objects without contact safely and quickly.

THERMOCOUPLE CABLE / WIRE

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.

CUSTOM BUILT SENSORS & GAUGE CONFIGURATORS

Labfacility are specialists in the design and manufacture of custom-built temperature sensors. Just fill in one of our custom build configurators and you will be contacted by a member of our experienced sales team with a quote.

About Labfacility Labfacility are the UK’s leading manufacturer of Temperature Sensors, Thermocouple Connectors and associated Temperature Instrumentation and stockists of Thermocouple Cables.

In addition to stocked items, 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 For all other sales enquiries please contact us as follows: Email: sales@labfacility.com Tel: +44 (0) 1243 871280 Issue 40 PECM

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WM |MOBILE MEASUREMENT IN THE PRODUCTION ENVIRONMENT Mobile measuring arms from WENZEL are characterized by great flexibility, enabling use in both production and quality assurance processes. By combining a portable 7-axis measuring arm with a high-resolution line scanner, which captures every detail contact-free, the measuring arms represent a useful complement to your established classical coordinate measuring systems. The use of the latest materials makes the measuring arm a lightweight unit that delivers highly accurate and reproducible measurement results in mobile applications. The measuring arm can be used directly on the component - both with optical and tactile sensors - without any warm-up time and without sticking markers to the component. The measurement results obtained can then be transmitted via a WiFi interface for further use. The capacity and low consumption of the integrated battery ensure reliable operation of the measuring arm over a long period of time.

FEATURES ▪ ▪ ▪ ▪ ▪

Freedom of movement due to 7 axes with axis limit detection Automatic button recognition Temperature compensated Stable resting position Internal weight compensation with damping element

WM | MEASUREMENT AT THE SPEED OF LIGHT The Wenzel CORE D is a 5-axis, optical CMM system which is ideal for measurement of small to medium turbine blades, medical implants or any other parts with similar characteristics of polished, reflective surfaces and sharp edges. The characteristics above are measured with a unique, “Double-eye” sensor which ensures good point accessibility and even collects reliable data with the axis of the light beam up to 85ᵒ to the surface normal. The new generation of CORE D has an automatic cover which closes during the measurement cycle ensuring perfect optical, thermal and clean conditions. The CORE D is shop-hardened, designed to be robot loaded and occupies a small footprint. The CORE D can also be calibrated to ISO standards just like a CMM.

BENEFITS •

Specialist Applications, the best machine for the job Turbine blades | Medical parts | Other parts with similar features • Speed, because time is money 5-axis | High scanning speeds | No part preparation or spraying needed • Shop Floor, close to production Small footprint | Protection from environment | Built for automation • Flexibility to get you the solution YOU need Range of sensors and configurations | Internal blade reporting or export in many formats | Measure parts with dull or shiny finish • Reliability of Results, an optical machine you can trust No cosine error | No out-of-plane error | Optical system with known uncertainty (ISO 10360)

WM | CAPTURE YOU PART’S DNA The exaCT U offers a simplified, cost-effective and fully automated workflow for the entire CT analysis process. Due to its high performance combined with a large measuring volume, the exaCT U enables the measurement and testing of large components with higher densities. Due to intuitive user guidance, exact measurement results can be generated after a short training period. The exaCT U thinks along with you: Measurement parameters are automatically optimized by the system. In its performance class, the exaCT U is one of the most compact computer tomographs on the market. It has five independent traversing axes and offers impressive resolution. Hardware and software offer the possibility of automated integration into the production line and deliver market-driven answers to questions about industry 4.0. WENZEL was awarded the Customer Value Leadership Award 2017 from Frost & Sullivan for the exaCT U.

FEATURES Configurable system, to address individual user requirements and automation High power of 300 kV sets new standards for reconstruction speed Large measuring volume of 700 mm in height and 330 mm in diameter High resolution (4000 x 4000 px) for measuring components with tight tolerances and complex structures Five independent travel axes for high speeds and short measuring and testing times

MEASUREMENT & MONITORING

ACEINNA MCX1101 AMR-BASED CURRENT SENSORS ACEINNA MCx1101, 4.8kV Isolated Magnetic Current Sensor, Easy to use Single chip solution Fully integrated Current Sensors for Server Farm and Telecom Power Supplies, IoT applications, Appliances, Inverters and Motor Control, Industrial Robots and Manufacturing Systems, Automotive EV Charging Stations and many other applications.

Their fast response and high bandwidth are ideal for fast switching SiC and GaN based power stages and allow power system designers to make

Tinytag Data Loggers:

use of the higher speeds and smaller components enabled by wide band-gap switches.

These devices deliver a unique combination of high accuracy, 1.5MHz signal bandwidth with industry benchmark phase shift vs. frequency, fast output step response and 4.8kV isolation, making them ideal for current sensing in fast current control loops and protection for high performance power supplies, inverters and motor control applications. www.aceinna.com/currentsensors

Tinytag Plus 2

Energy Logger

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

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

Radio and LAN loggers

Tinytag Ultra 2

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

Manufactured in the UK

• Data downloaded to PC • Cost-effective Accompanying probes are available for monitoring extremes of temperature, and for awkward to reach areas such as pipework.

Automatic data collection Bundles – 3 loggers/receiver/ software from £1000 +VAT

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

»

humidity

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

»

power usage

»

co2

»

count

Indoor temperature & RH From £69 +VAT

»

voltage

»

current

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

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OFFSHORE EUROPE

NEW SESSION AT OFFSHORE EUROPE TO FOCUS ON EXTENDING LIFE OF FIELDS Subsea UK will host a session at this year’s Offshore Europe looking at how underwater operations can extend the life of fields and maximise economic recovery from the UKCS. Neil Gordon, chief executive of Subsea UK, will chair the session which takes place from 10am to 12noon in the Late Life and Decommission Zone Theatre on Friday, 6 September at Offshore Europe. The session will centre on the innovative technology and strategies being developed to manage the late life of subsea systems.

Industry experts will discuss the latest innovations in remote operations and interventions, and smart subsea technology.

Speakers at the session will be, Paul Slorach of EC-OG; Julian Richards of 3D at Depth; Moya Cahill of PanGeo Subsea; Romain Chambault of Baker Hughes GE; Dave Millward of STATS Group; Donald Horsfall of Expro and Jeremy Edwards of Viper Innovations.

Neil Gordon, chief executive of Subsea UK, said: “Decommissioning is the final stage in the life of any offshore production project, and before this takes place it is vital, for companies and the longevity of the UKCS, that the full potential is realised from the field.

“A key part of this is the management of subsea systems in late life, and recent years has seen the emergence of new technology which has the potential to extend the life of fields and maximise reserves from pools which were previously uneconomical.

expanded this year to include late life management. This high level of discussion into how companies can maximise economic recovery is precisely what we were looking to encourage with the growth of this section of the programme.”

“Due to the maturity of North Sea, the UKCS is leading the way globally in life extension and our session at Offshore Europe presents an opportunity to hear from the companies at the forefront of developing innovative technology and operations which have the capacity to extend the life of fields and maximise economic recovery.”

Subsea UK will be at Offshore Europe with its subsea pavilion at Stand 1J50. The stand will feature member companies including; 3D at Depth, Ashford Instrumentation, Malin Marine Consultants, JB Valves, Rotech Subsea, Nippon Gases Offshore and Dockstr.

Simon Marshall, exhibition director for SPE Offshore Europe, said: “Subsea UK’s session is an excellent addition to our Life Extension and Decom Zone Theatre which has been

To book a place on the Late Life of Subsea Systems at Offshore Europe, P&J Live on Friday, 6 September visit www. subseauk.com

API pump applications?

KTR manufacture a range of couplings to meet the special requirements of pump applications in the oil & gas industry, in particular API 610, 671 and 685.

Furthermore, KTR offers ATEX approved products - including jaw couplings, gear couplings, steel laminae couplings and oil/air coolers - for hazardous operating conditions. For more info visit us at SPE Offshore Europe 2019 - stand 3G80

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3-6 SEPT 2019

www.ktr.com

www.ktr.com

NEWS & EVENTS

READY FOR ANY CHALLENGE GRE LTD

A THERMAL ENGINEERING COMPANY KNOWN FOR TAKING ON COMPLEX AND CHALLENGING PROBLEMS GRE launched in 2011 and quickly evolved to specialise in the design and manufacture of bespoke process cooling, ultra-pure water cooling and cryogenics systems. Establishing a global reputation as a thermal engineering company known for taking on complex and challenging problems that few others anywhere in the world are able or willing to handle, GRE are ready for any challenge.

Its engineers create complete cooling solutions that deliver reliable and efficient temperature control for the most demanding applications in the most testing environments. Its customers operate across a vast range of industries and sectors around the globe with products being found in around 50 countries across five continents and directly exporting to South Korea, America, Sweden and other countries in Europe.

GRE’s bespoke systems facilitate critical functions in applications including nuclear fusion, solar panel production, advanced technology for satellite development, and advanced radiotherapy systems for oncology. Having every resource required under one roof to provide a complete solution: • Define Specification • Concept Design • Detailed Design • Manufacture • Software and Integration • Testing & Documentation • Installation, Commissioning & After Sales Support

GRE specialises in the design and manufacture of customised cooling solutions for businesses across the globe in a vast array of sectors and environments. Choosing to focus in are cryogenics, process cooling and ultra-pure water cooling. No matter the application, GRE will be able to tailor the solution for the customer and give them a custom product that perfectly matches their requirements.

Being a one stop-shop sets GRE apart and makes their offering highly attractive in the

international thermal engineering sector.

As an example, software and controls which are the brains of any system - have traditionally been outsourced, but they are one of GRE’s specialities. Positioning themselves as working in true partnership, integrating to become part of the team – which client’s value highly.

GRE’s vision is to be the international go-to engineering firm for complete, bespoke cooling solutions. Specialising in making things happen GRE love to take on the challenges that others can’t handle.

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ENGINEERING MATERIALS LIVE SHOW PREVIEW

MATERIALS EXPERTISE ENGINEERING MATERIALS LIVE

LOOKING TO REPLACE TRADITIONAL MATERIALS FOR LIGHTER, CHEAPER AND SMALLER ALTERNATIVES? Engineering Materials Live is a specialist UK exhibition meeting the needs of engineers tasked with sourcing and specifying plastic mouldings, composites, prototyped parts and advanced engineering materials - and it is all FREE to attend!

Selecting the right material for the right application is crucial to the success of any design project, which means working with suppliers that have the materials expertise and application knowledge - this is why Engineering Materials Live was created.

Looking to replace traditional materials for lighter, cheaper and smaller alternatives?

Want to improve surface preparation processes for better adhesion? Then come and meet our high-quality exhibitor portfolio, which includes some of the UKâ&#x20AC;&#x2122;s leading suppliers in plastics, materials forming, advanced composites, light weighting and rapid prototyping, and find the solutions!

Book now www.engineeringmaterialslive. co.uk/register-to-attend Engineering Materials Live The National Conference Centre, Solihull 19th September 2019

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www.fast-live.co.uk

@fasteninguk ASSOCIATED AND COLOCATED WITH

BOND IT

BOLT IT

TAPE IT

LIGHTWEIGHT IT

VISIT IT

Don’t miss the latest in Fastening & Assembly Solutions and Technology – Live!

REGISTER TODAY!

19 SEPTEMBER 2019

The National Conference Centre, Solihull E! T A D E H SAVE T FREE TO ATTEND: WWW.FASTLIVE.CO.UK

NEWS & EVENTS

HIGH PERFORMANCE CHAIN DONGHUA

CHAIN MANUFACTURER CELEBRATES 10 YEARS IN THE UK

The UK arm of one of the world’s largest chain manufacturers is celebrating its 10th anniversary this month.

Donghua Limited is the UK subsidiary of the Hangzhou Donghua Chain Group which produces in excess of 40 million metres of finished chain per year and designs three new chains per day! Donghua chain had previously been supplied to the European market for 20 years but was sold under more well-known Western brand names.

The UK company was established in August 2009 by Bob Wellsbury, who previously worked for Iwis Drive Systems and Flexon, enabling the chain to be sold direct in the UK under its own brand name.

Located in Wolverhampton, the company moved to larger premises on the same site in 2017 which tripled their warehouse capacity to 25,000 square feet adding space for further technical capabilities to their workshop. Donghua has now become one of the country’s leading

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chain suppliers, offering a range of high performance chain and sprockets sold through a network of suppliers across the UK and Ireland.

made to measure Sprockets as well as the hardness of chain components. The team can also produce 3D models of bespoke chain for customers.

One of the reasons for their success is that they only sell direct to OEMs and Stockists.

Bob explains: “Our ethos is to never sell direct to end-users, but to promote our products via our UK network of suppliers.

Our suppliers value this which is why they chose a chain manufacturer they can trust.”

Bob said: “Our customers have greater choice and reduced delivery times for bespoke Attachment Chain as we can assemble it right here in the UK. There are only a few manufacturers who can boast such innovative technical capabilities direct in the UK and when customers visit they’re always surprised by the facilities we have on site.”

Donghua Limited have enviable technical facilities in their UK workshop with a range of engineering tools and equipment such as a Chain Measuring Machine, Pre-Loading Machine and Hot-Dipped Lubrication facilities enabling the UK production of bespoke Attachment Chain. They have also developed a Laboratory which includes a Component Measuring Machine to accurately measure components and grain structure and test for conformance, concentricity, bore size and parallelism of

Donghua Limited continues to grow from strength to strength and has firmly established itself in the UK market as a chain manufacturer and supplier of affordable, high quality performance chain.

Here’s to the next ten years!

www.donghua.co.uk

The Event for

Design-to-Manufacturing Innovation Registration is now open for TCT Show, a worldleading design-to-manufacturing event delivering business-critical insights on 3D printing, additive manufacturing, CAD/CAE, metrology and inspection as well as conventional manufacturing processes such as moulding, casting and CNC machining.

Over 10,000 professionals from 60 countries and 20 key industries including automotive, aerospace, healthcare, FMCG, defense, consumer products and many more will attend TCT across three show days to find solutions for their design and manufacturing challenges.

Taking place across four dedicated stages split into key themes, including transport, healthcare, materials, design/CAD software, introduction to AM and skills for AM plus many more, the speaker programme will deliver relevant, inspirational content on exciting stages.

TCT Introducing Stage - Weighted towards presentations of new or improved products and services, the TCT Introducing Stage is the ideal stopping point if youâ&#x20AC;&#x2122;re keen to be up-todate with the state-of-the-art across additive manufacturing and 3D printing, inspection, metrology and beyond.

TCT Tech Stage - A diverse range of presentation topics for beginners to additive manufacturing as well as 3D printing experts. The stage acts as a knowledge base, hosting captivating talks on the current issues in the manufacturing world.

TCT Insights Stage - Shines a spotlight on the essentials required to understand the entire spectrum of current and emerging additive manufacturing technologies. It will host a workshop on the fundamentals of AM, delivered

by Graham Tromans, plus the TCT Additive Insight Podcast, presented live by the expert TCT Editorial Team.

The TCT Show will take place in Hall 3 and 3A of the National Exhibition Centre (NEC), Birmingham, UK, from 24-26 September 2019.

24 25 26 SEPTEMBER 2019 NEC, Birmingham, UK

Visitors will benefit not only from the opportunity to connect with cutting-edge exhibitors, displaying the most innovative and dynamic technologies and services available on the market, but also from ground-breaking product launches, exciting showfloor features with LIVE demonstrations and enthralling presentations from a world-leading speaker line up.

TCT Summit - Delivers deep technical knowhow and inspirational application studies across the spectrum of 3D technologies. Speakers from the UK, Europe, USA and Asia will deliver a truly global perspective ensuring your time out of the workplace will be of maximum value.

#TCTShow

Register now www.tctshow.com

SHOW

The Event for

Design-to-Manufacturing Innovation 3d 3d printing printing || additive additive manufacturing manufacturing || inspection inspection machine machine tools tools || cad/cae/cam/plm cad/cae/cam/plm software software || materials materials metrology metrology || moulding moulding and and tooling tooling || post post processing processing

24 25 26 SEPTEMBER 2019 NEC, Birmingham, UK

TCT Show continues to accelerate the adoption of technologies and innovations that play a part in the design-to manufacturing process chain.

In 2019 over 300 exhibitors will come together to present insights, intelligence and inspiration for over 10,000 attendees. If youâ&#x20AC;&#x2122;re looking to reach key buyers and influencers, and offer innovative design-to-manufacturing solutions, then you should have TCT on your show list for 2019.

#TCTShow #TCTShow

Register now Register now www.tctshow.com

SHOW

www.tctshow.com

SHOW

NEWS & EVENTS

Hydramotion celebrates 25 years in Japan In June Hydramotion sent a delegation to the British Embassy in Tokyo to meet with the Director of Trade and Investment, Chris Heffer The primary reason for the visit was to meet with Hydramotion’s Japanese representatives and discuss plans for expansion in 2020. In addition the trip was seen as a celebration to mark 25 years of successful trade with Japan.

Hydramotion has successfully penetrated all sectors of Japanese market including; chemical, petrochem, polymer & resin, oil & gas, pharma, food & beverage. The company specialises in measuring viscosity under harsh process conditions whilst maintaining supreme accuracy. This has placed Hydramotion at the forefront of the industry supplying to most of the leading manufacturers including; Toshiba, Mitsubishi, Hitachi, Kirin Beer, Panasonic, Mitsui amongst many others.

Alloy Heat Treatment

Gas Pressure Reducing Stations

Alloy Heat Treatment is the UK’s only specialist in the heat treatment of aluminium alloys.

With more than 40 years’ experience as a subcontractor, the company is focused solely on heat treating aluminium products, rather than other metals. It offers a range of treatments to change the internal properties and strengthen the aluminium product.

From small, industrial low pressure systems through to high pressure, high volume distribution or power generation biogas or CNG / LNG systems, FT Pipeline Systems can supply a skid-mounted gas pressure reducing station.

An additional choice of safety products ensures a reliable, safe supply of gas for your required environment.

Dudley-based Alloy Heat Treatment works with a diverse range of customers, mainly Tier 2 and 3 companies in the aerospace and automotive industries. The company holds NADCAP, AS 9100 accreditation, and preferred supplier status to many companies such as helicopter manufacturer Leonardo.

Our 3D design service makes it easy to provide the most efficient skid for your needs thereby keeping the footprint of the gas station to a minimum and facilitating its transportation by land, sea or air with minimum installation time.

Please visit our website for more information or call the office if you would like to discuss specific projects.

www.alloyheat.co.uk

For further information: www.ftpipelinesystems.co.uk Tel: +44 (0)1543 416024 enquiries@ftpipelinesystems.co.uk

www.hydramotion.com/en 01653 600294

NEW from Solid Gear – the Onyx Safety Shoes and Boots

Nelson Automotive rebrands as Avistud

Denso Paste & 80mm Tape Control Brunel Bridge Corrosion

Nowadays, good safety footwear is part and parcel of a comfortable day’s work on site.

Combining maximum comfort and protection with a robust and durable design, Solid Gear’s Onyx is available as a shoe or a boot and ideal for different types of on-site work.

This EN-accredited footwear has a modernlooking style that integrates a seamless upper and Cordura reinforcements with a poured polyeurethane midsole, a breathable footbed and strong rubber outsole for maximum grip on slippery and uneven surfaces. Metal-free protection comes from the fiberglass toecap and penetration board for extra personal safety.

What’s more, the unique BOA Closure System distributes the pressure of the fastened shoe evenly across your feet to ensure a glove-like fit all day for maximum comfortable protection.

Global automotive stud welding leader Nelson Automotive has announced a complete rebrand of its business to customers, stakeholders and industry peers. The newly launched brand, AVISTUD, reflects the total separation of the Nelson Automotive business from the brand of its former industrial parent Nelson Stud Welding. Nelson Automotive was initially created as a standalone automotive company following the sale of Nelson Stud Welding from Doncasters to Stanley Black & Decker in April 2018.

Isambard Kingdom Brunels Swing Bridge was constructed of riveted wrought iron plates in 1849 to provide a crossing over the entrance lock for growing vehicular activity in Bristol Docks. It is a rare survivor of Brunels Bristol work and predates the Clifton Suspension Bridge. To hold back corrosion in the early days linseed oil and resin based paint coatings were regularly applied, but after 50 years of neglect the Grade 2 Listed structure has rusted seriously.

To get more information on Solid Gear visit the website at www.solidgearfootwear.com alternatively, call the Hultafors Group UK Helpline on 01484 854788.

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Henning Stams, chief executive of AVISTUD, said: “The automotive industry is demanding more speed and flexibility from its manufacturing processes than ever before.

We have adapted our business to meet the automotive sector’s requirement for more lightweight, high-strength materials, electric vehicles and faster manufacturing processes.” www.avistud.com

Denso paste has been applied to the underside of the ancient bridge’s 4m dia forged iron ring to seal against water entering the deep rust-pits. Then the 3mm thick soft aluminium packers were wrapped with Denso Tape, bedded on to the new 20mm thick steel ring. This was then jacked up to bed on the underside of the old heavilycorroded ring to provide a new track for the bridge to run on. www.denso.net

NEWS & EVENTS

ELECTRIC ARC - UNDERSTAND THE RISKS AND PROTECT YOURSELF! As working clothes on site go, there’s a big difference between conventional electrician’s Workwear and specialist ProtekWork garments from Snickers Workwear, which includes Protective Wear for electricians.

covers exposure to serious risks, which include major hazards such as electric arcs.

It’s therefore important to focus on that category of garments to provide adequate protection.

Over the years, conventional workwear has evolved to make the working day on site more comfortable and efficient, with built-in functionality for tools and fixings, as well as protection against cold, rain and the effects of warm weather.

UNDERSTAND THE RISKS – CHOOSE THE RIGHT LEVEL OF EFFECTIVE PROTECTION

ProtekWork, the new ergonomically designed Protective Wear from Snickers Workwear, has a number of CE (European Conformity) mark across the product range. It has been designed and developed to protect the wearer from serious risks such as heat, flames, electric arcs and hazardous chemicals. In effect, clothing that can mean the difference between life and death for the wearer.

WHAT PROTECTION DO ELECTRICIANS NEED?

To be able to properly identify what protection for electricians, you have to know what risks you, your employees or your workmates face. Category III clothing

Working in high-risk environments involves, as the name implies, high-risk levels.

Arcs due to electrical faults can cause severe injuries and damage. So it’s vital that you choose the right Class III protective wear to ensure your safety.

ProtekWork from Snickers Workwear is the new protective wear solution that will deliver the right level of layered protection to help ensure comfort, safety and wellbeing on site.

For more information on the new ProtecWork products, visit www. snickersworkwear.co.uk alternatively, call the Snickers Workwear Helpline on 01484 854788.

SOURCING CUSTOM PARTS OVERSEAS NEED NOT INVOLVE HUGE QUANTITIES OR HIGH RISK Due to its extensive experience in working with trusted suppliers in the Far East, Blue Diamond Technologies can offer custom parts in low minimum quantities (500 pieces) without the need for high minimum orders that run into thousands of pieces. This allows our customers to source a custom part with very little risk and minimum cost.

“There are many ways we can help our customers get the best outcome from sourcing low cost custom parts. Using our services removes many of the problems and risks associated with sourcing directly from suppliers in the Far East.” explains Mike Doel, Director, Blue Diamond Technologies. “Customers often contact us because they cannot find a standard product to do the required job and they don’t want to compromise on product design or quality. Frequently, they also want to buy low quantities to test the market before daring to commit to the higher volumes often demanded by large overseas manufacturing organisations”.

Further options include the provision of labelling, bar codes and packaging, which can also be incorporated into customer agreements.

For further details, contact Blue Diamond Technologies Ltd, Rolwey House, School Close, Chandlers Ford Industrial Estate, Eastleigh, Hampshire SO53 4BY. Tel: (023) 8025 8966 Fax: (023) 8025 8989 E-mail: bdsales@rolwey.com Website: www.blue-diamond.co.uk

ADAPTABLE AND RELIABLE LED MODULES In recognition of the demand for high-performance reliable LED modules, that do exactly what luminaire manufacturers want, Forge has introduced a custom module to do exactly that. Forge has never been a one size fits all manufacturer and, with the release of this latest customisable module offering, the added-value they bring to product development and manufacturing is evident.

Every luminaire has different LOR, thermal and optical properties, and every luminaire manufacturer wants a USP. Forge has the technical expertise to ensure manufacturers get only the very best modules in their fittings.

How? With the ability to: lengthen and shorten heatsinks, choose connectors and wire lengths, pick heatsink colours, add logos, and even incorporate specific fixing and mounting methods. All whilst giving manufacturers the peace of mind that their module will perform thermally, optically and reliably to pre-determined L70 expectations, through in-house testing.

Forge has also recently developed a <10⁰ optic to suit the module

perfectly, fulfilling that demand for a tight crisp beam pattern to complement the medium and wide offering. With Forge’s optic design and manufacturing capability, you can also create your own bespoke beam pattern and achieve specific light distribution.

All of this is before you even consider your light CCT and CRI requirements - you really can put light where you want it!

Forge is on hand to deliver what you really want and will do all the hard work and even test the solution in your fitting for complete peace of mind. So, don’t make do with something off the shelf – choose Forge.

For more details on Forge’s latest product developments visit forge.co.uk or call our sales team today +44(0)1229 580000.

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NEWS & EVENTS

A COMPETITIVE EDGE IOSH

INSPIRING REAL, LASTING CHANGE IN YOUR BUSINESS

Managing Safely sets standards globally and is the market-leading safety and health course for businesses large and small.

Here’s why: • It’s business focused. IOSH works with business leaders in the development of flexible courses to ensure they deliver the insights and efficiencies you need to gain a competitive edge.

• It’s cutting-edge. IOSH works tirelessly to ensure that the course content is at the forefront of current best-practice.

• It’s unique. Managing Safely combines practical step-by-step guidance with an engaging and inspirational approach that will make your managers think afresh about how safety and health can positively impact the whole business.

• It’s contextualised. The content of the course and the scenarios that are explored will directly reflect your sector, workplace and even factors relating to your geography or business demographic. So, it’s easy to put everything they’ve learned into practice.

• It’s world-class. IOSH is the Chartered body for safety and health professionals and the quality of the training and the content of the course reflects that.

WHO SHOULD ATTEND? This course is for anyone who manages or supervises people, in any industry sector or environment. They’ll learn to:

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• assess risks • control risks • understand responsibilities • understand hazards • investigate incidents • measure performance Successful delegates are awarded an internationally-recognised IOSH Managing Safely certificate. It’s a vital achievement and demonstrates that they have the knowledge to be more efficient, productive and safe in the workplace – to the benefit of all.

WHAT WILL MANAGING SAFELY DELIVER FOR YOUR BUSINESS? The most successful organisations recognise that a focus on the safety and wellbeing of their people has a direct and measurable impact on business performance.

They’ll learn about the ‘why’ as well as the ‘how’. Why should we look out for our colleagues? Why should we continue to innovate? How can I make a difference?

Organisations that manage on-going risk more effectively can focus on the more significant risks, meaning they can become more productive.

You’ll benefit from: • greater productivity – stronger focus on significant risks means fewer days lost through sickness and accidents • increased efficiency – it is business focused and practical in its approach with no unnecessary ‘frills’. Your managers will learn techniques to drive more efficient working

• reduced costs – lowered recruitment costs and greater retention levels and a reduction in insurance premiums and legal costs • reputational advantage – your customers, suppliers and stakeholders will recognise that you are an innovative organisation that makes sound ethical choices. People will want to do business with you.

• a safer workplace – fewer accidents and lower levels of sickness mean a happier workforce. And happy staff will deliver more for your business.

WHY IOSH? Here’s why: • Our track record. Managing Safely from IOSH is the market leader in safety and health and we’ve trained 172,000 delegates on 23,000 training courses in 76 countries.

• Our vision. We can help you prepare for tomorrow. The world of work is transforming at a rapid pace and we want to ensure that you are ready to embrace those changes and profit from them rather than being left behind.

• Our status. We are a global organisation with 47,000 members in 130 countries, many of whom are business owners themselves, and we represent their views to governments and regulatory bodies to make sure business can continue to drive the positive change we all need and deserve. www.iosh.com

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IOSH Managing Safely means many more employees who are much safer at work Tell them about IOSH Managing Safely www.iosh.com/pems

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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

THE HOME OF VISCOUS PUMPING SOLUTIONS

Kecol have over 25 years of experience in handling all types of viscous products in the food, pharmaceutical and cosmetics markets, as well as general industrial applications.

A sample of products we already pump… ✓Honey ✓Petroleum Jelly ✓Mascara ✓Sauces ✓Lanolin ✓Lip Gloss ✓Essences ✓Eye Ointment ✓Meat Paste ✓Paraffin Wax

T: +44 (0)1746 764311 E: sales@kecol.co.uk W: www.kecol.co.uk

✓Face Scrub ✓Teething Gel ✓Tomato Puree ✓Medical Adhesives ✓Veterinary Creams ✓Fruit Paste ✓Toothpaste ✓Malt ✓Jam ✓Wax

Stand: H30

PROCESS TECHNOLOGIES

INCREASED DEMAND FOR VERSATILE, PORTABLE AND PRACTICAL CONTAINERISED SYSTEMS Axium Process is experiencing an increased demand for “standalone” containerised systems which are quickly becoming a mainstream option for many types of applications across all industry sectors.

Installations have ranged from clean room systems, water processing and filtration applications to digestate, leachate and effluent treatment. The benefits of a quick to install, self-contained process, requiring minimal infrastructure and civil engineering, is an increasingly preferred option for capital investments The advantages of a secure, portable asset include ease of transportation or re-location (even to remote destinations), absolute control of quality during construction and the ability to conduct pre-delivery preparation and commissioning procedures.

Axium’s customers are also benefitting from, reduced installation time on-site, minimal civil engineering and

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often freedom from planning permission, which together, translates into considerable time and cost savings.

Axium Process is one of the UK’s leading hygienic process system manufacturers and specialises in the design and build of bespoke containerised systems to suit specific site parameters and conditions. The systems require minimal intervention and can be designed as either manual or fully automatic in operation using state of the art PLC control with live data logging and remote access options. www.axiumprocess.com

PROCESS TECHNOLOGIES

ONE TRUE BRAND Since the first SEPURA™ oil/water separator was developed over fourteen years ago, others have attempted to imitate its success - producing units that might look similar to the untrained eye.

Bowman Stor’s owner and managing director, Richard Potts, is keen to stress that buyers should beware of inferior products designed to look like SEPURA equipment - sometimes using the same colour finish.

“Just because it’s blue it doesn’t mean its a SEPURA separator,” says Richard. “If there’s no SEPURA badge on the front, it isn’t a genuine SEPURA product.”

And only SEPURA-branded separators, manufactured exclusively by global filtration specialists Bowman Stor, contain the revolutionary, SILEXA™ - the internationallypatented media which set the new standard in condensate treatment, providing industry with a cleaner, lighter, more adsorbent media.

Above left, The Bowman Stor team, headed by Managing Director Richard Potts (third from right) were delighted to receive the Nachural International / Enterprise of the Year Award.

Above right, SEPURA’s groundbreaking SEP60 condensate cleaner. largest range of medium and high capacity separators on the market.

Bowman’s ongoing drive for quality and improvement is also receiving recognition from some of the most influential voices in industry. The Walsall-based firm was SEPURA’s flagship unit, the SEP60, was the the proud winner of the International / world’s first fully disposable separator - a Enterprise of the Year Award at this year’s single-use, compact, quick-fit unit which prestigious Nachural Summer Business Ball out-performs equipment more than twice and Awards - a programme which highlights its size. Since then the firm has continued Sepura True blue ad 132x180L.qxp_IPE 19/07/2019 11:11 Page 1 to grow the range and now produces the the achievements of individuals and

companies from across the West Midlands region.

Against significant competition, the filtration specialist received acknowledgement for its continuing research, innovation, growth and performance. The awarding body also took into consideration glowing endorsements from a selection of Bowman’s customers. sepura-technologies.com

the art of oil/water filtration

True Blue

There are many oil/water condensate solutions on the market, many of them blue.

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Only Sepura separators contain the superior Silexa™ filtration media that makes all of this happen.

Genuine Sepura™ products can only be purchased from our sole UK distributor

t: 01978 855995 e: sales@mfeuk.co.uk Issue 40 PECM

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SOFTWARE & SYSTEMS

COMPREHENSIVE ERP SYSTEM SAPMAN

IF YOU MAKE STUFF WE’LL HELP YOU MAKE IT IF YOU HAVE A WARHOUSE WE’LL HELP YOU MANAGE IT IF YOU HOLD STOCK WE’LL HELP YOU CONTROL IT

Buying an ERP system used to be a major capital expense, potentially running to tens of thousands of pounds for an up and running system. The cost of the software purchase and associated consultancy made it a hugely considered financial outlay.

For manufactures looking for a rapid Return On Investment – this was a major obstacle for many businesses : together with the desire to spend their CapEx budgets on modern machinery and increased manufacturing capacity rather than software!

For companies that want the software “out of the tin” - and do not require any bespoke programming – a system install and set-up, including training and data conversion would be arounf £2,950. Our licencing is £50-£75 per month (depending on user numbers) with no minimum contract obligation. Additional users can be added as required and, indeed, reduced.

A key market for us is Sage users. Sapphire Manufacturing Systems Ltd. The developer of Sapmanv12 has been an Authorised Sage Developer for over 20 years. So most of our users run on Sage50 and Sage200, and we

still have some clients on Sage Line 100 yet to upgrade.

One of the great advantages of Sapmanv12 for Sage users is that users can benefit from multi depot stock and full Serial Number and Batch Traceability without the need to upgrade their accounting engine from Sage50 to Sage200. This is an additional cost saving benefit We can demo the software remotely via Team Viewer or organise a visit to your premises or you can visit our Bristol Demo Suite : call us on 0333 456 12 12 to have a chat

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At its core Sapman v12 is a sophisticated Manufacturing, Warehousing and Stock Control solution. This modular product provides extensive facilities for Stock Control, Sales and Purchase Order Processing, Warehouse Management, Bill of Materials, Works Order Processing, Engineering Control, MRP and CRP. With the Microsoft SQL database engine at its core this product provides a leading edge business management solution.

Our highly skilled team has 20 years of experience resolving our customers’ Assembly, Manufacturing Control and ERP requirements, their Stock Control and Warehouse Management needs using our advanced, effective and efficient software solution.

Sapman v12 fully integrates with Sage’s Accounting solutions: Sage 50 and Sage 200. It also provides an upgrade path from Sage 100.

disposable BBQs our customers rely on Sapman v12 to run their businesses.

Sapman v12 is highly customisable to operate with virtually any business model. With successful installations in a huge range of industry types from manufacturers of medical products to

Sponsored development of specific functionality is possible where customers require some modification to allow the software to exactly map their business’s operational model.

SAPMAN V12 AND SAGE 50 IT ALL STARTS WITH A SALES ENQUIRY! SELL IT

with collapsible/expandable nodes

Quotations: Quote ( including price breaks)& Drawings & Pricing : v12 can attach drawings to the Quote

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

SoP : The Sales Order Processing gets underway

WiP With Shop Floor Data Capture SFDC v12 knows :

MAKE IT

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

Stock : Stock Enquiry : Check material Needs : Make to Order or Ex Stock?

If not it may generate a Purchase Order for more Stock If the Sale item is Make To Order (MTO) then the Works Order Processing routine kicks in v12 is suitable for Batch Manufacturing, Make to Stock, make to Order, Kanban & service works Stock values from v12 update Sage50 Nominal Ledger PoP Purchase Order Raised Purchase Invoice received & Sage 50 updated for Nominal Codes, Purchase Ledger and VAT WoP The confirmed order has to be manufactured & v12 produces the works order BOM V12 produces the BoM : tree-view

Every stock issue is linked to an original GRN - ensuring full Serial Number and Batch Traceability

WHAT THEY SAY “We really like the Shop Floor Data Capture system which enables us to see the current status of any Works Order live and onscreen.”

Alan Saitch, Managing Director, Lada Engineering Services Ltd

“V12 offers us greater productivity, improved communications with third parties and the interconnectivity between the various menus and our Sage Accounting software makes operating our company infinitely easier.”

Colin Mallard, Finance Director, Lakeland Laboratories Limited

Stock Finished item is booked into Stock v12 knows where it is; it covers multiple sock locations and stock with Sub Contractors Stock values per client defined categories can be up dated to Sage50 Nominal at client defined times

“V12 was a complete transformation for our business back in 2014, with the added bespoke service and repair package designed by the SMS team the customer input and traceability became seamless.”

Mike Perkins, Managing Director, Encoders UK Ltd

SEND IT Stock Stock records updated, Despatch note raised; Certificates of conformity produced Sales Invoice raised & Sage 50 updated

For more information on SAPMAN v12 please visit our website at Sapmanv12.co.uk Email us on info@sapmanv12.co.uk Or please telephone us on : 0333 456 12 12

for Nominal Codes, Sales Ledger & VAT Issue 40 PECM

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SOFTWARE & SYSTEMS

IT & OT CONVERGENCE COPADATA

DO PEOPLE, PLACES AND PROFIT HOLD THE KEY?

THREE ADVANTAGES OF IT/OT CONVERGENCE

Engineers and academics have been extolling the benefits of IT and OT convergence as far back as the early Eighties, but many businesses are still reluctant to adopt platforms that combine the two. Here, Martyn Williams, managing director of industrial software provider COPA-DATA UK, explains the advantages of IT and OT convergence.

In a 1982 paper published by the US National Institute of Standards and Technology (NIST), the authors proposed a new control system architecture for use in an Automated Manufacturing Research Facility (AMRF).

In a diagram reminiscent of a castle, the shapes that make up the control system appear to create two fortified tower-like structures joined by a flat wall-like section in the centre. The tower on the right depicts a hierarchical database that contains the control programs that define how to manufacture parts — think of this as the operational technology (OT) of today.

The tower on the left makes up the hierarchical database that contains the management information system and data on the state of the parts — think of this as information technology (IT).

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Finally, the wall in the middle is made up of I/O lines and feedback control loops connected to boxes that represent robotic workstations and machine tools.

The convergence of IT and OT not only benefits from the resource sharing of connected devices, but it also promises to boost productivity.

While these structures were symptomatic of their time, they have historically separated IT and OT teams both figuratively and literally, with staff often working in different departments or even different facilities.

Better scheduling, production planning, material allocation, product tracking and real-time access to process data are quick and easy with the two realms working in sync.

In contrast, today’s control architectures have broken down the rigid structures, replacing them with highly integrated and free-flowing systems that are flexible and easy to change based on business needs.

However, without an effective digital platform running at the heart of the system, businesses will continue to face issues with complexity, compatibility and cost.

Advantage one: Profit Whether you call it digital transformation, the Internet of Things (IoT) or Industry 4.0, the primary driver for businesses seeking automation improvements is to bolster the bottom line.

At a time when political uncertainty is driving up the cost of doing business, many organisations are looking inward, searching for those all-important marginal gains.

This is why COPA-DATA developed zenon, a manufacturing and automation software platform that provides a single, integrated environment, combining data recording, machine operation and business intelligence.

Using zenon, manufacturers can eliminate the redundancy and cost associated with running two separate overlapping IT and OT systems, delivering better performance and productivity.

Advantage two: People The second major benefit of combining IT and OT is to allow staff on both sides to overcome their differences. Cybersecurity, decision-making, scalability and downtime are just some areas that can put IT and OT staff at odds with each other.

Take downtime, for example. In mission critical applications such as food and beverage production, where unexpected downtime could result in spoiled produce, OT staff may be responsible for getting the line back up and running as quickly as possible. IT staff, on the other hand, may be responsible for ensuring data integrity for traceability purposes and will therefore prioritise this task.

In this situation, a software platform such as zenon can help IT and OT staff collectively solve their problems. zenon’s network technology features seamless and circular redundancy and high availability, so that downtime is eliminated. For engineers, it also offers post-event fault analysis and allows operators to reload modified functions without having to restart the system.

Similarly, data archiving allows IT staff to immediately retrieve and store traceability data.

Advantage three: Place Business theory dictates that if you want to make it difficult for your competitors to enter your market, you need to put up barriers to entry. This includes technological, regulatory or economical hurdles that you’ve spent years overcoming, and ones that make it unattractive for new entrants to replicate.

But what if these same hurdles prevent you growing as a business? This is often the case in “places” such as sugar refining, dairy processing, and pharmaceutical manufacturing. Businesses in these industry sectors have spent decades developing finely tuned proprietary processes that are not only difficult to automate, they’re difficult to scale.

Take sugar refining for example. Because the harvesting window for sugar cane is so narrow — typically three months from December to March — manufacturers are under pressure to ensure that they can quickly setup the plant for seasonal production.

What’s more, the process of turning raw sugar cane into the processed sugar we’re familiar with is a complex one. This involves many steps including shredding, milling, juice extraction, clarification, evaporation, syrup production, crystallisation, centrifugation, drying and packaging.

All these processes need to be carefully coordinated as any downtime can be critical to the success of the final product. If the refining process doesn’t align perfectly with the harvesting window manufacturers may suffer from perished crops and lost revenue.

Here, the integration of IT and OT is essential in democratising automation, levelling the playing field and facilitating business growth.

To allow customers to achieve this, we’ve ensured zenon supports open standards such as OPC UA, as well as being built with over 300 open interfaces and native drivers.

The platform runs on common industrial clients and operating systems and offers visualisation using standard HTML5 web technology.

Take advantage now As the industry breaks down the rigid barriers of traditional engineering structures, we’re seeing how powerful digital platforms can be in underpinning the sustainable convergence of IT and OT. The advantages are clear, it’s time for businesses to act. Maybe in another forty years, engineers will look back and wonder why industry was so reluctant to topple the figurative IT and OT castles.

www.copadata.com Issue 40 PECM

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QUALITY 3D PROCUCTS 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.

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HELPFUL VISUALIZATION TOOLS FOR DESIGNERS 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 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 webdesign 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.

WHAT´S NEW?

DOSCH VIZ-IMAGES

Innovative, “ready to use” 3D-scenes for manufacturing or automotive design

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 Viz-Images are compatible with most 2D- and 3D-applications, and the AlphaChannel 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.

This year we introduced a new product line – 3D scenes - which is a significant work relief and time and money saver for designers. Currently the following, completely textured 3D-scenes are released: Different versions of Car Scenes, Factories, Lofts and Office Scenes. Each of these product is available in two versions.

The “light version” contains the pure environment, the “extended version” also contains people or vehicles.

Curious to know more? Then download our free samples 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!

www.doschdesign.com Issue 40 PECM

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SOFTWARE & SYSTEMS

CYBER ATTACKS NTT SECURITY

UK MANUFACTURING DROPS TO SECOND PLACE IN LEAGUE TABLE OF MOST ATTACKED INDUSTRY SECTORS – 2019 GLOBAL THREAT INTELLIGENCE REPORT REVEALS

UK Manufacturing and Technology sectors continue to battle it out for first and second place in the table of most targeted industry sectors by cyber attackers, according to the 2019 Global Threat Intelligence Report (GTIR) from NTT Security, the is the specialised security company and the center of excellence in security for NTT Group.

While Manufacturing took top billing in the 2018 GTIR, with almost half (46 per cent) of all cyber attacks in the UK, this year’s report shows a significant fall to second place with a fifth (20 per cent) of attacks. However, the Tech sector, which attracted less than a quarter (23 per cent) last year, jumps to top spot with 47 per cent of attacks in the UK. The annual GTIR is the result of NTT Security summarising data from trillions of logs and millions of attacks, and analysing threat trends based on log, event, attack, incident and vulnerability data from NTT Group operating companies. In the latest report, NTT Security analyses of attacks against 18 industry sectors.

David Gray, Senior Manager – Cyber Security Consulting, NTT Security, says: “While manufacturing may have dropped down a position, the fact that it is still attracting a fifth of all attacks against UK organisations is a major concern. The critical national infrastructure sectors

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tend to grab the headlines, such as the attacks on the Ukrainian national grid in 2016, or the Wannacry attack on the NHS in 2017. However, the recent attacks on Norsk Hydro demonstrate the impact that cyber attacks can have on other sectors, such as manufacturing, and highlight the importance of effective incident response.”

David Gray adds: “The lines between traditional and digital manufacturing are blurring, where high value manufacturing and advanced technologies are key for global competitiveness and there is greater convergence of IT with Operational Technology (OT), which brings with it greater complexity and risk. The problem is that OT has traditionally been something of a ‘dark art’ for IT and security teams who lack the knowledge and skills to effectively map their OT risk landscape and implement practical plans and processes.”

NTT Security advises manufacturing organisations to focus on four key areas when it comes to cybersecurity: 1. Get the basics right: without the right fundamentals in place, attacks do not need to be advanced to succeed. People are often a manufacturer’s greatest threat, so invest in staff awareness and training, and highlight the importance of collective responsibility.

2. Take an intelligence-driven approach to security. IT and security should avoid

working in silos and having a ’not in my backyard’ mentality by developing robust holistic processes and procedures.

3. Develop threat intelligence capabilities.

There is no such thing as an isolated incident and there is a need to manage the whole incident by developing threat intelligence – pervasive visibility is essential.

4. Manufacturers are still failing to prepare. There is still an element of ‘head in the sand’, where they do not think it is going to happen to them. Having effective incident response capabilities that are tested regularly is key and enables organisations to respond quickly in order to mitigate the threat and identify the cause.

China tops source of attacks table Once again China is the number one source of attacks by country against UK organisations (20 per cent) followed by the US (16 per cent) and France (10 per cent).

Apart from Sweden, the UK is the only country to see most attacks coming from China. Across EMEA, China is second (13 per cent) just behind the US (16 per cent) while at a global level again the US is top attack source on 22 per cent followed by China on 13 per cent. www.nttsecurity.com

Pinnula

P P

UNIPLAN ERP ACCELERATES YOUR GROWTH Enquiry Manager CRM/Prospect/Task Manager Stock Management Plan Capacity/Scheduling Resource Management Bill of Materials Production Control Job Costings Process Management Packing & Shipping Serial Numbering Barcoding & Labelling Shop Floor Job & Time Tracking Full Batch Traceability Procurement/Sales Full Accounts/Payroll/HR Bank Integration Dashboard Analytics

Plus much more!

Flexible System Add and remove modules as your business evolves

Uniplan ERP is a modular, scalable and flexible Manufacturing System designed to suit your business as it evolves and grows.

Add functionality and users as the business develops.

We provide functionality rich software which can be configured to best match your business processes.

We have years of experience in implementing systems and can manage a full implementation from start to end.

Uniplan ERP will deliver both greater efficiency and control to your business.

Experience Savings We have been building ERP Reduce costs through systems for over 40 years critical process management

www.pinnula.co.uk | sales@pinnula.co.uk | 01709 839933

SOFTWARE & SYSTEMS

DIGITAL TECHNOLOGY RELAYR

DIAMOND PROCESSING INDUSTRY GOES DIGITAL • Thanks to a partnership with relayr, Coborn is adding new digital services to their diamond grinding machines which will improve product performance and therefore increase asset utilisation for the customer.

• The long-term strategic alliance will also add an innovative pay per use model which will make financing Coborn grinding machines easier for UK and European customers.

Romford based Coborn Engineering Company Limited, a global provider of engineered solutions for the diamond industry, and Berlin located relayr, a specialist for industrial solutions in the field of Internet of Things (IoT), have formed a strategic alliance. The purpose of this longterm partnership is to develop Coborn’s diamond grinding machines into smart equipment by installing digital services in their products.

Thanks to anomaly detection through relayr’s AI-based analytics, data collected from Coborn’s machines will allow them to determine and resolve failures in advance. Delivering pre-emptive service to each diamond customer will enable Coborn to offer machines with guaranteed performance and availability targets. Each machine will also come with an insurance policy to support these guarantees.

As an additional feature, Coborn will be offering a pay per use business model for its equipment, also known as an Equipment as a Service (EaaS) model. EaaS is an innovative business model in which Coborn‘s diamond grinding machines are not sold but made available for a usage fee. Coborn will remain responsible for maintenance, service, repairs and spare parts. This model makes Coborn’s products easier to finance for companies in the diamond industry, especially in emerging markets.

Partnering with relayr will enable Coborn to deliver business solutions to their customers through a unique blend of technology, finance, and insurance offerings. This unrivaled approach will provide a distinct level of tailored customer support and services whilst guaranteeing the uptime of Coborn’s Intelligent Machines. In turn, Coborn customers will be able to increase their productivity and receive exactly the services they need.

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For Coborn, cooperation with relayr is decisive for the further expansion of the company: “Coborn is the only global company that is totally focused on grinding and polishing all types of diamonds. Our company is a vital part of the diamond industries value chain. The partnership with relayr is a unique opportunity to provide engineered solutions, both technical and commercial, to support the continued growth of the industry by predictive maintenance, controlled machine downtime and ultimately, process optimisation. It will enable our customers to realise the full potential value from our machines,” explains Steve Westlake, Managing Director at Coborn.

“OPEX Revenue models like EaaS are fundamental to the successful digitisation of any industry. We are proud to help Coborn grow through our intelligent technology, supply expertise, insurance products,

and financing options. Our goal is to be a strategic partner to Coborn and ensure their success across the board and ensure that we bring the power of relayr’s technology, and coupled with the financial tools and strength of Munich Re Group, for Coborn and their customers. Coborn are set out to disrupt their market, and as relayr we will be by their side to help.” adds Josef Brunner, CEO of relayr.

Digital transformation is one of the greatest opportunities for the global diamond industry. Digital technologies, especially the Internet of Things, will affect not only diamond processing but all parts of the value chain of the diamond industry and will have a huge impact on increasing efficiency and productivity. The partnership between Coborn and relayr will make a significant contribution to further advancing this development. www.relayr.io/coborn/

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Cloud.

No No more more need need for for intermediate intermediate Gateway Gateway devices! devices!

Verborn Verborn Systems Systems Limited Limited Hawthorne Hawthorne Cottage, Cottage, Lower Lower Whitley, Whitley, Cheshire, Cheshire, WA4 WA4 4JF 4JF Company Company No.: No.: 09472226, 09472226, VAT VAT No.: No.: 208994079 208994079

Skype: Skype: xlogic.vsl xlogic.vsl

www.xlogic-relay.co.uk www.xlogic-relay.co.uk

Tel: Tel: +44 +44 (0)7757222660 (0)7757222660

Email: Email: support@xlogic-relay.co.uk support@xlogic-relay.co.uk

STORAGE, HANDLING AND DISTRIBUTION

ADDING GENUINE VALUE CROCODILE

DESIGNING BESPOKE PACKAGING SOLUTIONS TO PERFECTLY FULFIL CLIENTS’ NEEDS Crocodile began as a family company back in 1991 in response to a growing demand for innovative and versatile industrial packaging solutions. To this day Crocodile remains entirely family owned and run and the goal of providing high quality sophisticated packaging solutions that add genuine value to clients has not changed.

Crocodile has a truly global outreach, with manufacturing partners in China, Germany and the USA. But the key to Crocodile’s success is it’s commitment to quality, which is why all aspects of the business from design to manufacturing, right through to delivery of the product is managed under the same roof in Swindon.

By controlling every aspect of the business Crocodile ensures that only the best product and customer service is delivered.

Crocodile does not sell from a catalogue, but custom designs bespoke packaging solutions to perfectly fulfil clients’ needs.

We visit prospective customers and listen to them in order to ascertain as much information as we can about exactly what they want and need from their packaging.

Our team of CAD Engineers will then design a packaging solution based around these needs, which we will then present to clients for approval or feedback.

Crocodile’s unique clip system means that packaging can be flat packed and reused, which dramatically cuts customers’ total costs and provides a sustainable, environmentally friendly way to ship goods.

In 2006 Crocodile opened a Timber Frame Division in order to provide economical timber products to the growing timber frames industry in the UK. For the last 12 years Crocodile Timber Frames has been manufacturing high quality products for use in schools and homes across the UK.

Our aim is to win customers by delivering a first class but cost effective solution and performance. We then passionately wish from then onwards to continue supplying the customer every time they need packaging. This only happens if service is of the highest quality. We aim to provide

180

PECM Issue 40

this as a minimum requirement, every time and to never lose a customer. This can only happen if a company is made up of individuals that share this goal. Crocodile is very proud to have such staff.

www.crocodile.uk.com 01793821555

ISPM 15 COMPLIANT

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CALL US ON: 01793 821 555

www.crocodile.uk.com Unit 62, South Marston, Swindon Wiltshire, SN3 4TA Email: quentin@crocodile.uk.com

STORAGE, HANDLING & DISTRIBUTION

SEVEN STORMS SOLUTIONÂ Â Â Â Â Â Â Â Â Â Â Â

Working for a major online retailer, Hart Door Systems has installed seven of its successful Speedor Storm doors at a highvolume distribution facility. Â All Speedor Storms, five of which measure 5m x 5m and two 3m x 3m, were installed to the despatch building on busy door openings. The Speedor Storms allow quick and easy access to the openings where sectional overhead doors were being left open enabling heat loss and an unpleasant working environment. Â Hart provided expert design advice, specification and installation. A Hart spokesman says: â&#x20AC;&#x153;Speedor Storm is being

increasingly used in high traffic situations where exceptional wind resistance is required. The energy-saving potential of this door is also particularly high. Â â&#x20AC;&#x153;We find the Storm is used predominately as an external rolling door with a unique guide system offering wind resistance up to class 5 as defined by DIN EN 12424, on larger openings up to 8m x 8m. â&#x20AC;&#x153;Capable of withstanding winds up to 90 mph when closed, the Storm is a robust and reliable system.â&#x20AC;? www.hartdoors.com

Storage, Handling & Distribution

MAGNETEK

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Magnetek is the premier provider of innovative power control and delivery systems and solutions. With hundreds of thousands of Ć&#x152;Ä&#x201A;Ä&#x161;Ć?Ĺ&#x161;Ä&#x201A;Ç ĹŻÄ&#x17E;Ä?Ć&#x161;Ć&#x152;Ĺ?Ä? sÄ&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E;Ć? Ĺ&#x161;Ä&#x201A;Ć? Ć&#x161;Ĺ&#x161;Ä&#x17E; Ć&#x152;Ä&#x201A;ĹśĹ?Ä&#x17E; Ä&#x201A;ĹśÄ&#x161; Ä&#x17E;Ç&#x2020;Ć&#x2030;Ä&#x17E;Ć&#x152;Ć&#x;Ć?Ä&#x17E; Ć&#x161;Ĺ˝ adjustable frequency drives, radio remote controls, pendant stations, Ä&#x161;Ä&#x17E;ĹŻĹ?Ç&#x20AC;Ä&#x17E;Ć&#x152; Ć&#x161;Ĺ&#x161;Ä&#x17E; Ć?ŽůƾĆ&#x;ŽŜĆ? Ç&#x2021;Žƾ ĹśÄ&#x17E;Ä&#x17E;Ä&#x161; Ͳ ĨĆ&#x152;Žž Ć&#x161;Ĺ&#x161;Ä&#x17E; Ĺ&#x161;Ä&#x201A;ĹśÄ&#x161;ĹŻĹ?ĹśĹ? ŽĨ and brakes working in the field, we have a proven track record in a Ä&#x17E;Ć&#x2039;ĆľĹ?Ć&#x2030;ĹľÄ&#x17E;ĹśĆ&#x161; Ä&#x201A;ĹśÄ&#x161; Ĺ?ŽŽÄ&#x161;Ć? ŽĨ Ä&#x201A;ĹŻĹŻ Ć?Ĺ&#x161;Ä&#x201A;Ć&#x2030;Ä&#x17E;Ć? Ä&#x201A;ĹśÄ&#x161; Ć?Ĺ?Ç&#x152;Ä&#x17E;Ć?Í&#x2022; variety of industries.

Ć&#x161;Ĺ˝ Ć&#x161;Ĺ&#x161;Ä&#x17E; žŽÇ&#x20AC;Ä&#x17E;ĹľÄ&#x17E;ĹśĆ&#x161; ŽĨ Ç Ä&#x201A;Ć?Ć&#x161;Ä&#x17E; Ä&#x201A;ĹśÄ&#x161; Ć&#x2030;Ä&#x17E;Ć&#x152;Ć?ŽŜŜÄ&#x17E;ĹŻÍ&#x2DC;

We employ some of the top development and application engineers KĆľĆ&#x152; Ć&#x2030;Ć&#x152;Ĺ˝Ä&#x161;ĆľÄ?Ć&#x161; Ć&#x152;Ä&#x201A;ĹśĹ?Ä&#x17E; Ĺ?ĹśÄ?ĹŻĆľÄ&#x161;Ä&#x17E;Ć? Ć&#x152;Ĺ?Ä&#x161;Ä&#x17E; ŽŜ Ä&#x201A;ĹśÄ&#x161; Ć&#x2030;Ä&#x17E;Ä&#x161;Ä&#x17E;Ć?Ć&#x161;Ć&#x152;Ĺ?Ä&#x201A;Ĺś Ä?ŽŜĆ&#x161;Ć&#x152;ŽůůÄ&#x17E;Ä&#x161; Ć&#x161;Ĺ˝Ç who design and implement cost effective control solutions that meet and Ć&#x161;Ć&#x152;Ä&#x201A;Ä?Ć&#x161;Ĺ˝Ć&#x152;Ć?Í&#x2022; ĹŻĹ˝Ä&#x201A;Ä&#x161; Ä?Ä&#x201A;Ć&#x152;Ć&#x152;Ĺ?Ä&#x17E;Ć&#x152;Ć?Í&#x2022; ĆľĆ&#x;ĹŻĹ?Ć&#x161;Ç&#x2021; Ç&#x20AC;Ä&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E;Ć?Í&#x2022; Ć&#x2030;Ä&#x17E;Ć&#x152;Ć?ŽŜŜÄ&#x17E;ĹŻ Ä?Ä&#x201A;Ć&#x152;Ć&#x152;Ĺ?Ä&#x17E;Ć&#x152;Ć? Ä&#x201A;ĹśÄ&#x161; ŽƾĆ&#x152; ĹśÄ&#x17E;Ç exceed your expectations. ĨƾůůÇ&#x2021; EĎ­ Ĺ&#x161;ŽžŽůŽĹ?Ä&#x201A;Ć&#x161;Ä&#x17E;Ä&#x161; Ä&#x17E;ĹŻÄ&#x17E;Ä?Ć&#x161;Ć&#x152;Ĺ?Ä? Ć&#x152;Ĺ˝Ä&#x201A;Ä&#x161; Ç&#x20AC;Ä&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E;Ć?Í&#x2DC;

As part of Columbus McKinnonâ&#x20AC;&#x2122;s Crane Solutions Group, our mission is KĆľĆ&#x152; Ä&#x17E;Ç&#x2020;Ć&#x2030;Ä&#x17E;Ć&#x152;Ć&#x161; Ć&#x161;Ä&#x17E;Ä&#x201A;Ĺľ Ä&#x201A;ĹŻĆ?Ĺ˝ Ä&#x161;Ä&#x17E;Ć?Ĺ?Ĺ?ĹśĆ? Ä&#x201A;ĹśÄ&#x161; ĹľÄ&#x201A;ŜƾĨÄ&#x201A;Ä?Ć&#x161;ĆľĆ&#x152;Ä&#x17E;Ć? Ä?Ä&#x17E;Ć?Ć&#x2030;ŽŏÄ&#x17E; Ä&#x17E;Ć&#x2039;ĆľĹ?Ć&#x2030;ĹľÄ&#x17E;ĹśĆ&#x161;Í&#x2DC;

to be your Partner in Motion Control, providing you with the highest hĆ?Ä&#x17E;Ä&#x161; Ç&#x20AC;Ä&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E;Ć? Ä&#x201A;ĹśÄ&#x161; Ç&#x20AC;Ä&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E; Ć&#x152;Ä&#x17E;ĹśĆ&#x161;Ä&#x201A;ĹŻ Ĺ˝Ć&#x2030;Ć&#x;ŽŜĆ? Ä&#x201A;ĹŻĆ?Ĺ˝ Ä&#x201A;Ç&#x20AC;Ä&#x201A;Ĺ?ĹŻÄ&#x201A;Ä?ĹŻÄ&#x17E;Í&#x2DC; quality, most advanced lifting and motion control products in the

industry.

dÄ&#x201A;ĹŹÄ&#x17E; Ä&#x201A; Ä?ĹŻĹ˝Ć?Ä&#x17E;Ć&#x152; ůŽŽŏ Ä&#x201A;Ć&#x161; ŽƾĆ&#x152; Ĩƾůů Ć&#x2030;Ć&#x152;Ĺ˝Ä&#x161;ĆľÄ?Ć&#x161; Ć&#x152;Ä&#x201A;ĹśĹ?Ä&#x17E; ŽŜ ŽƾĆ&#x152; Ç Ä&#x17E;Ä?Ć?Ĺ?Ć&#x161;Ä&#x17E;Í&#x2DC;

Phone: +44 (0) 1234 349191 Ä&#x17E;ĹśĆ&#x2039;ĆľĹ?Ć&#x152;Ĺ?Ä&#x17E;Ć?Î&#x203A;Ä?Ć&#x152;Ä&#x201A;Ä&#x161;Ć?Ĺ&#x161;Ä&#x201A;Ç Ä&#x17E;ĹŻÄ&#x17E;Ä?Ć&#x161;Ć&#x152;Ĺ?Ä?Ç&#x20AC;Ä&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E;Ć?Í&#x2DC;Ä?Ĺ˝Í&#x2DC;ƾŏ Ç Ç Ç Í&#x2DC;Ä?Ć&#x152;Ä&#x201A;Ä&#x161;Ć?Ĺ&#x161;Ä&#x201A;Ç Ä&#x17E;ĹŻÄ&#x17E;Ä?Ć&#x161;Ć&#x152;Ĺ?Ä?Ç&#x20AC;Ä&#x17E;Ĺ&#x161;Ĺ?Ä?ĹŻÄ&#x17E;Ć?Í&#x2DC;Ä?Ĺ˝Í&#x2DC;ƾŏ

Email: eurosales@magnetek.com

182

PECM Issue 40

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Training & Recruitment

TRAINING & RECRUITMENT

TRAINING FACILITY MGTS

MGTS OFFICIALLY OPENS NEW TRAINING FACILITY FOR FOOD INDUSTRY

Leading engineering training provider, MGTS (Midland Group Training Services) had its brand new, purpose-built facility for engineering food maintenance and food process manufacturing at its Redditch training centre officially this summer by Rachel Maclean MP. This doubles its capacity to train apprentices in the food industry sector from 50 to 100.

Rachel Maclean MP said: "It was a real honour to open MGTS' new centre today. I was inspired by the apprentices I spoke to who are a real credit to MGTS. They are our future workforce and it's fantastic to see young people in Redditch being trained locally, giving local businesses a highly skilled, high quality pool of talent to choose from."

The company specialise in engineering training, with three sites across the Midlands.

The investment in the Redditch training facility has seen an area of 355 sq m (3,821 sq ft) devoted to apprenticeship training for the food industry, refurbishing and equipping this space with industry standard equipment.

Food industry engineering training was until now only provided at its Reasheath College site.

David Bridgens, MGTS chief executive said: “This investment follows discussions with our food industry partners. The UK needs skilled engineers so we’re developing the necessary skills and supporting industry to recruit a trained workforce. For apprentices, it really is a fantastic time to pursue a career in food process manufacturing, with plenty of exciting opportunities. It’s a win-win for everyone involved.”

MGTS train apprentices for some of the country’s leading food manufacturers, such as Müller, Arla, Ferrero, Dairy Crest, Morrisons and Heineken. This expansion will help the whole of the food and drink industry to recruit much needed, highly skilled engineers.

James Cubbin, Senior Manufacturing Manager at Morrisons said; “Morrisons are excited to be the first company to send apprentices to the new MGTS Redditch facility where they will deliver the fantastic Food and Drink Engineering apprenticeship scheme.

We are also looking forward to working closely with MGTS in setting up the new Morrisons training academy where all engineer training and development courses will take place. The proactive support from David Bridgens (chief executive) and Steve Palmer (operations manager) is hugely appreciated and I'm sure this will lead to a

successful partnership moving forward.

Joseph Clark, an apprentice from Pilkington Automotive, based in Kings Norton said: “Coming here straight from GCSEs was a challenging step up, but the support provided by MGTS has been fantastic. The actual training facilities here are excellent, we get hands-on experience with industry standard machines which means it’s not such a massive jump when I return to the company.”

MGTS already train 800 apprentices at any one time across the whole of the engineering industry.

The company have been helping to create ‘Engineers of the Future’ for more than 50 years, working in partnership with a diverse range of local, regional and national engineering companies, from the automotive, aerospace, medical, food and drink, and manufacturing sectors.

MGTS is now delivering the new standards apprenticeships for the engineering and manufacturing sector, as well as the new engineering technician standard, in product design and development, mechatronics, toolmaking and machining.

www.mgts.co.uk Issue 40 PECM

183

RELIABILITY TRAINING & CERTIFICATION

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We We will will support support you you in in recruiting recruiting the the right right talent talent for for your your business business and and provide provide essential essential apprenticeship apprenticeship funding funding advice. advice.

The The role role of of the the MTC MTC is is to to train train the the next next generation generation of of young young engineers engineers and and then then deploy deploy them them into into businesses businesses to to support support the the future future of of UK UK manufacturing. manufacturing.

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t 02476 701774

MEASUREMENT & MONITORING

SAFE ELECTRICAL SWITCHING PYROPRESS

EXPERTS IN HAZARDOUS AREA INSTRUMENTATION Established more than 60 years, Pyropress is a leading UK based designer and manufacturer of weatherproof and ATEX/IECEx certified switches and transmitters for measuring pressure, differential pressure, vacuum, temperature, level and flow.

Its quality, reliable and durable products incorporate proven design techniques and technology to provide safe and reliable electrical switching of alarm or control circuits within flameproof (Exd), Intrinsically safe (Exia), marine or industrial areas and are available with SIL2 certification to customers worldwide.

All ranges are available with SIL2 approval and have a documented failure rate of 1 failure per million hours of operation. They have also been certified both IP66 and IP67 in line with the latest standards.

DEVELOPMENTS FOR ATEX AND IECEX SWITCHES

Pyropress has added new features to its Perseus range of ATEX and IECEx switches for use in hazardous areas which is now available with a stainless steel housing for the first time.

“We have added an adjustable differential setting capability to the Perseus range of Exd flameproof switches and Exia intrinsically safe switches. It allows fine tuning of compressor cycling in air conditioning and HVAC applications for example and has other uses where hysteresis control is required,” says Stephen Burns, Managing Director Pyropress Limited. “The same module allows two switches with separate settings. There is also the option of a second M20 electrical entry.

The Perseus range has been available with only black anodised aluminium for 10 years so introducing the stainless steel housing completes the entire offering.

Pyropress are able to offer custom switches and transmitters to suit different applications across all industries and we hold sufficient stock to manufacture millions of combinations to suit specific applications.

The Perseus range of switches is available in pressure, temperature, level and flow variants and is fully certified to the European ATEX 2014/34/EU and International IECEx for explosion proof (Ex d) and intrinsically safe (Ex ia).

188

PECM Issue 40

They are available for operating pressures starting at 0.4 mBar, for ultra low pressure, vacuum and differential pressure and reaching 800 Bar on the high pressure range. Pyropress offers many options and variants for applications where gas, vapour, powder and dust are present. For further details contact us or your nearest Pyropress distributor.

NEED IT FAST?

We offer an Express Manufacturing Service for our switches which can mean having a bespoke sensor delivered within 48 hours of

order placement. We can also offer products that are customised to your application.

We have full onsite design, machine shop, manufacturing, and calibration facilities, enabling a fast response, and all backed with our highly commended customer service.

Between 11th – 14th November 2019, Pyropress will exhibit at ADIPEC in Abu Dhabi, an exhibition devoted to the oil and gas sector. www.pyropress.com

PERSEUS PRESSURE SWITCH Exd or Exia ATEX/IECEx certification | Stainless steel or black anodised aluminium housing to IP66 & IP67 standards | 316 Stainless steel wetted parts | M20 x 1.5 ISO electrical connection | Other threads available via adaptors | Select housing material, certification, pressure range and process connection |

a

ATEX / IECEx AS STANDARD

SPDT MICROSWITCH

a

a

EXD (FLAMEPROOF) OR EXIA (INTRINSICALLY SAFE) AVAILABLE

316 STAINLESS STEEL WETTED PARTS

a

a

BLACK ANODISED ALUMINIUM OR 316 STAINLESS STEEL BODY

VITON DIAPHRAGM

a

a

RANGES BETWEEN 0.1 BAR AND 800 BAR

ADJUSTABLE SETPOINT WHILST OPERATIONAL

a

a

M20 X 1.5 (F) ELECTRICAL ENTRY

STAINLESS STEEL

ULTRA LOW, LOW AND DIFFERENTIAL PRESSURE RANGES ALSO AVAILABLE

BODY OPTION PICTURED

a

PRESSURE RANGES & PRICING PRICE

CODE

RANGE

MAXIMUM PRESSURE

ALUM

A

0.1 - 1.5 bar

12 bar

£250

B

1.2 - 4.2 bar

12 bar

C

0.2 - 3.0 bar

D

3.0 - 9.0 bar

E

0.4 - 6.0 bar

PRICE

CODE

RANGE

MAXIMUM PRESSURE

ALUM

£315

J

30 - 180 bar

500 bar

£280

£345

£250

£315

K

70 - 420 bar

500 bar

£280

£345

25 bar

£250

£315

L

4.0 - 14 bar

700 bar

£315

£380

25 bar

£250

£315

M

10 - 36 bar

700 bar

£315

£380

50 bar

£250

£315

N

28 - 108 bar

700 bar

£315

£380

ST.ST.

ST.ST.

F

6.0 - 18 bar

50 bar

£250

£315

P

50 - 200 bar

700 bar

£315

£380

G

8.0 - 34 bar

50 bar

£250

£315

Q

115 - 455 bar

700 bar

£315

£380

H

15 - 90 bar

500 bar

£280

£345

R

200 - 800 bar

1000 bar

£315

£380

The design features a simple form of adjustment. The switch is factory set and shipped at a mid-range falling and adjusted upon receipt. The set point can even be safely adjusted whilst the switch is electrically connected and in the hazardous area.

PART NUMBER BREAKDOWN PF61

S

B

/

Bespoke variants are available.

F

2

Contact sales@pyropress.com

HOUSING

PROCESS CONNECTION

S = 316 STAINLESS STEEL

1 = 1/4” BSP.P FEMALE

A = BLACK ANODISED ALUMINIUM

2 = 1/4” NPT FEMALE

CERTIFICATION B = Exd ATEX / IECEx FLAMEPROOF

to discuss alternative microswitch, diaphragm, process connection, range and electrical entry options.

RANGE CODE

O = Exia ATEX / IECEx INTRINSICALLY SAFE

T: +44 (0)1752 333933 | sales@pyropress.com www.pyropress.com

VALVES & FLOW CONTROL

STEAM EQUIPMENT EXPERTS VALSTEAM

A STRONG PASSION FOR DEVELOPING EQUIPMENT AND FOR SOLVING PROBLEMS Focused on providing groundbreaking products for industrial steam and fluid systems, 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.

GIVING NEW WORLDS TO THE WORLD 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 area 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 90 people that together drive the 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!

A “ONE STOP SHOP” 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

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• Special construction equipment • 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.

PRODUCING LOCALLY, SUPPLYING GLOBALLY 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 more information and to check the latest news, visit www.valsteam.com

VALVES & FLOW CONTROL

DIXON EXTENDS RANGE OF VALVES Dixon announces the extension of its wide range of hygienic process valves with the addition of the Dixon Rieger range of Mix Proof and Double Seat valves both hygienic and aseptic. The range includes Mix-Proof valves, double seat valves which are an economical alternative to mix proof valves, hygienic pressure resistance valves, hygienic overflow valves, tank bottom, pigging (product recovery) valves and regulating valves.

Applications Food and beverage, dairy, bio-processing, pharmaceutical, and cosmetics where aseptic and hygienic conditions are required and clean ability is paramount.

This new range offers Dixon customers a full range of hygienic process valves which now includes ball, butterfly, seat, check, sample, and of course the mix proof valves.

and electro polishes are available. Solid housings manufactured from solid 316L bar and exotic materials such as Hastelloy are available.

Certified to EHEDG and 3A.

Thanks to a modular block design, changing over to an aseptic design is possible for the single seat valves. Dixon Rieger valves are completely drainable and have a dead space free design. All valves come with Ra 0.8µm. Higher specification polishes

•

The opening mode of the pneumatic actuator may be changed by a simple device modification from “air open – spring close” to “spring open – air close” and vice versa.

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Screwed pneumatic actuators for easy maintenance

Innovative Design Dixon Rieger valves offer a market leading hygienic design;

Features

maintenance and optimized spare parts holding.

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Simple and quick assembly without any special tools.

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Less seals in comparison to other similar products ensuring less failure and reduced costs associated with

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

HYGIENIC PROCESS VALVES Hygienic & Aseptic Range

Features

• • • • • • •

• • • • • • •

Single seat, Double seat (Mix-Proof) Hygienic pressure resistance Hygienic overflow Tank bottom Product recovery Regulating Sample

Leak free change over Modular block design Manufactured from solid 316L bar (exotics available) Fewer product contacting seals for ease of maintenance No special tools required Fully balanced & drainable Certified to EHEDG and 3A

For further information please contact us now:

01772 323 529

01772 323 529 • dixoneurope.co.uk • sales@dixoneurope.co.uk

©2019 Dixon Group Europe Limited

• C U S TO M E R S E RV I C E • I N N O VAT I O N • M A N U FA C T U R I N G • Q U A L I T Y • T E C H N I C A L E X P E RT I S E • U N C O M M O N E X C E L L E N C E • D E S I G N • C U S TO M E R S E RV I C E • I N N O VAT I O N •

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VALVES & FLOW CONTROL

3M, the science-based technology company, has added a 10” filter cartridge and housing (referred to collectively as a filter system) to its High Flow Filter System range, extending its capability to lower process flow applications, including modular water treatment systems and filling lines. The new High Flow 10” Filter Cartridge from 3M uses the same proprietary high efficiency polypropylene microfibre filter media as the existing 40” and 60” length versions. The compound radial pleat structure and large diameter core offers the same significant advantages: high flow rates per filter cartridge in a compact design, allowing fast and easy filter change-outs.

Bonut Engineering Ltd Bonut Engineering Ltd was established in 1966 and is a leading UK manufacturer and supplier to the fastener and general engineering industry. We specialise in the UK manufacture of engineer’s studs, shaft collars, precision turned parts and valves in stainless steel, high grade alloy and non-ferrous metals.

Bonut has also acquired the Dereve Safety and Water Valve business as well as the fusible plug business which is now consolidated under the Dereve brand. Our experience of both the fastener and valve manufacturing businesses enables us to support our customers over a wide sector of Industry. www.bonut.co.uk

The flow rate capability (up to 19.3m3/hr) and very com

Process Valves & Instrumentation Ltd 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.

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

For further details on this product range, visit 3M.co.uk/highflow or 3Mireland.ie/highflow

COMPONENTS FOR BULK SOLIDS HANDLING

3M High Flow Filter System range extended for lower process flow applications

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

www.dmnwestinghouse.co.uk Issue 40 PECM

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PRECISE MONITORING BURKERT

FAST, CONVENIENT WATER QUALITY MONITORING COULD HOLD THE KEY Water is used in so many ways throughout the food and beverage industry, even as the final product, which means the quality of that water needs to be carefully monitored. With such an influence on the finished product, precise water quality monitoring can provide the key to consistent quality output, so is it time to look at the next generation of compact continuous analysis solutions?

Greg Wainhouse, UK Water Segment Manager for Bürkert, looks at water usage within the food and beverage sector, and the best practical method of continuous monitoring for various aspects of water quality as it enters the process.

Water is an essential element in the manufacture of food and drink, from washing produce to being the main ingredient, each application has different water quality requirements. Having access to reliable, upto-date data on water quality parameters is an important step in improving productivity as well as the quality of the final food products.

SOURCE MONITORING

In most cases, water will be supplied by the local water authority, which has the responsibility to provide a service within certain parameters. However, demands on the treatment plants, seasonal changes and the age of the network can have a big influence, and this means variability in the quality of mains-supplied water.

It is possible for the local authority to be unaware of an ‘out-of-consent’ incident until it is reported by consumers, but for some industrial customers, this notification will have come far too late. Furthermore, water authorities are required to add sufficient levels of chlorine to reach the furthest points of the network. This means that those closest to the water treatment works may receive some free-chlorine, which can damage sensitive equipment such as reverse osmosis membranes for example.

The alternative is a bore hole, usually on or near the manufacturing site, but this source can be affected by temperature, rainfall and local agricultural activities, which means it needs to be tested for quality at least every month, preferably more frequently. On-site

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treatment should be looking to remove sediment, dissolved iron, nitrates and bacteria.

FILTRATION SYSTEMS

Whichever source is used, manufacturers will employ a range of water treatment processes, depending on their application. Carbon filters can remove chlorine, biological contaminants and flavours, while a sand filter will remove iron. Ion-exchange processes are used to soften the water and both pH and conductivity monitoring can take place at this point.

Finally, filtration is used to remove unwanted particles, organic matter and bacteria.

Depending on the quality of water required, manufacturers may use ultra-filtration, nanofiltration or reverse osmosis and each process can be equipped with sensors for turbidity, chlorine and pH to provide feedback on water quality.

CAPTURING VITAL DATA

To resolve this situation, manufacturers need an accurate but flexible system that can be built around their application and connect directly into their control infrastructure. Some will only need pH and turbidity, while others require a more comprehensive solution that includes iron, chlorine, conductivity and oxidation reduction potential (ORP).

However, capturing the data is just the first step, validating it for accuracy and using the data for positive process control also need to be considered. To this end, calibration of the sensors is an important step that may require a certain amount of downtime and additional expense.

MODULAR, FLEXIBLE SOLUTIONS

There is an opportunity for food and beverage manufacturers to use the latest in sensing technology that has a proven track-record in accuracy and simplicity. As a compact and modular design, Bürkert’s Type 8905 Online Analysis System, offers a range of benefits that make it cost-effective and reliable for this purpose.

The Type 8905 offers a multi-channel, multifunction unit capable of measuring pH, ORP, conductivity, free chlorine and turbidity, chlorine dioxide and iron. Several of the measurements are conducted by compact plug-in sensor cubes, offering ease of use and convenience. The introduction of a chlorine monitor is an important addition due to its popularity in the disinfection process as an effective microbicide, disinfectant and sanitiser.

Bürkert has also developed an auto-cleaning process for the sensor cubes that uses a solution of clean, filtered water and mild citric acid, primarily to flush the turbidity sensor cube. The accuracy of the water analysis equipment can be maintained using a hand-held cleaning and calibration module that connects to the Type 8905. This enables operators to follow simple step-by-step maintenance instructions and procedures for using calibration fluids. All the while, the base unit is constantly monitoring the process and recording the necessary data. www.burkert.co.uk/en

An extensive range of explosion protection equipment.

From supply to full turn-key solutions Visit our new website

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

* www.stuvexuk.com * Earthing Control

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

Gas Gas Version Version

·· Single and multipoint injection suppressors capable of

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

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

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

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

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

Explosion Venting StuvEx supplies a range of explosion venting devices.

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

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

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

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